D1 Exhaust Replacement

eXtraDutyDisco

Well-known member
Dec 6, 2011
209
11
Oregon
I have the cats from AB and exhaust kit from RN (links below). Looking for some install instructions or tips. I crawled under my XD, and it looks like I'll need to cut the pipe (possibly in 2 places) to get it out without removing my rear axle. Does anyone have experience with these kits? The Cats look pretty straight forward. But the exhaust system may need some welding (?) or do just the pressure fit ends with clamps work fine enough?

any source of info or help would be appreciated.

 
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Tugela

Well-known member
May 21, 2007
4,137
89
Seattle
I went through this on my D1 a few months ago. Bought a clamp-together kit. The instructions in RAVE describe a way to remove the cat-back exhaust in one piece by rotating it a certain way and backing it out over the rear axle. It probably works with some patience, but I just took an angle grinder to it and in a couple minutes had it in 2 pieces. I wasn't going to reuse it so I didn't need to keep it intact.

Having a second person helps with installing the new kit. I started at the Y-pipe juncture, working my way back, installing piece by piece and keeping all the hardware loose until I had all the hangers reconnected. It's handy to have as much play in the system as you can so you can position the hardware. I ended up removing the rearmost exhaust hanger bracket from the body, connecting it to the new pipe, then finagling the hanger back onto the body. Grease the inside of the rubber hanger to ease installation. Here's where it's helpful to have one person hold everything in position while the other works the hardware back into place. It's not a difficult job, just a bit awkward.

I have a new Y-pipe sitting in my garage I'm waiting to install. This could go either really smoothly if my O2 sensors all come out easily and I can free the hardware on the manifold flanges without trouble. Or it could be total headache. We'll see. Please post up what your experience is on that.
 

4Runner

Well-known member
May 24, 2007
381
9
Boise Idaho
Not familiar with those exact parts but when I did the exhaust on my 96, I already had the frame on jack stands so I released the bottom of my rear shocks with jack under the rear axle. Lowered the rear end down while making sure the brake line doesn’t get damaged. Gave me a lot of room to move
 

eXtraDutyDisco

Well-known member
Dec 6, 2011
209
11
Oregon
I went through this on my D1 a few months ago. Bought a clamp-together kit. The instructions in RAVE describe a way to remove the cat-back exhaust in one piece by rotating it a certain way and backing it out over the rear axle. It probably works with some patience, but I just took an angle grinder to it and in a couple minutes had it in 2 pieces. I wasn't going to reuse it so I didn't need to keep it intact.

Having a second person helps with installing the new kit. I started at the Y-pipe juncture, working my way back, installing piece by piece and keeping all the hardware loose until I had all the hangers reconnected. It's handy to have as much play in the system as you can so you can position the hardware. I ended up removing the rearmost exhaust hanger bracket from the body, connecting it to the new pipe, then finagling the hanger back onto the body. Grease the inside of the rubber hanger to ease installation. Here's where it's helpful to have one person hold everything in position while the other works the hardware back into place. It's not a difficult job, just a bit awkward.

I have a new Y-pipe sitting in my garage I'm waiting to install. This could go either really smoothly if my O2 sensors all come out easily and I can free the hardware on the manifold flanges without trouble. Or it could be total headache. We'll see. Please post up what your experience is on that.
Thanks! That makes sense, now I just gotta find the mojo to get in there and do it.