Replacing exhaust donut on 3S-FE (hard or easy?)

[hairball]

I searched the entire Gen 1 & 2 threads for the answer all the way back to 2005 but found nothing.

I've replaced tons of donuts in my days but they were mostly on domestic cars. Many are super easy but a lot are a nightmare. Never done one on a 90 DX 2.0L and the last thing I want is to snap a stud or something. I do have penetrating oil to prepare for the task.

So, I'm wondering, has anyone run into any issues replacing their exhaust donut? Like having trouble getting to the nuts? Breaking studs? Or worse? Or is it a fairly simple task? Replacing the donuts are usually a piece of cake (no pun intended)... it's getting the nuts loose than can be difficult sometimes! I know some cars are relatively easy, especially straight 6's in American cars. If the Camry donut can be a difficult job, I'll just have my favorite local muffler shop get it over and done.


Thanks.

[hairball]

I'll pick up the donut on Tuesday and tackle it. My car is starting to sound like crap up front and from the sides. Guess I'll figure out hard easy or hard it is when I cross that bridge.

[hairball]

What happened to everyone? Rough weekend?

[89Camry89]

Are you referring to a gasket located between the catalytic converter and the exhaust pipe?

I didn't actually change mine, but I did have that unbolted recently.

In order to reach it, I had to remove the structural thing that runs from the front to the back of the car. This is the curved piece that accepts some of the engine mounts to prevent engine rotation. Naturally to get that off, I first had to remove the large cross piece that runs left/right beneath the car.

There were 3 studs with nuts on them. They were super tight. For all I know they have been on there for 21 years. I hit them with an impact wrench. One of them came out, two of them broke off.

I was able to remove the broken ones using an extractor, but the threads of the holes were damaged on the way out. I presume this was because of rust on the threads of the studs.

I bought a tap of the correct size and used it to "fix" the holes. I was lucky that I was able to get it started straight and aligned with the existing threads. This way it more or less deburred the threads so that a bolt/stud could be put in its place. Because the studs are kind of hard to reach (sort of recessed in that engine area), I had to put an extension on the end of my tap, which meant I had to spent about $20 bucks in sockets/adapters to fit onto my 3/8" drive ratchet.

The best thing to do would be to order new studs from Toyota, or at least to get high grade or heat rated bolts. I was trying to get it back together that day, so I bought the only thing the hardware store had, which ended up being regular metric bolts. I forget the length, it was around 1.5"

I have the imagination that I will replace those bolts before they rust so bad that it is ridiculous, but there is a distinct reality that may never actually happen.

[hairball]

Thanks. I appreciate your input! But after reading all of that, you make me want to just let the muffler shop tackle it! Sounds like a hassle. Yes, that's the one I'm talking about. Between the pipe and the cat. So you say it's more of a "gasket" than a donut? Hmm. I guess I'll see it when it's in my hand.

I appreciate your input. That's just what I wanted to know. I don't know that I have the patience for all that, considering my steering rack leaks so badly and the underside is dripping.

To the muffler shop I ride!...

[sayers74]

I had to use 2 autozone donuts. they had 2 part #s for my camry, so i got em both. put 1 in , still leaked a bit. put both in siamese style,. good to go.

Guess thats why they have 2 slightly different gaskets for the same joint...

[hairball]

Thanks! I'll see if AutoZone has 2 different part numbers and donuts. Now you have me worried.

[sayers74]

youre probably supposed to use 1 or the oyher but i had to use both. that was 2 years & 40000 miles ago, still holdin up. Dont be scared..its not that hard. worse case is your bolts are rusted on there. exhaust systems front to back have a rust problem more so than other areas youll be wrenching on. you can definetaly do this your self. save the cash for the beer and band aids..lol

[sayers74]

I said scared, you said worried. Dont be worried!