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TRD dual exhaust - detailed installation

Discussion in 'Performance and Tuning' started by Netmonkey, Mar 18, 2017.

  1. Mar 18, 2017 at 4:29 PM
    #1
    Netmonkey

    Netmonkey [OP] Don't be a Dumbass

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    Icon stage 2 lift, 295 60 20 nitto ridge grapplers, fuel kranks, TRD dual exhaust, TRD rear sway bar
    Hey guys,

    For some time, I had been considering upgrading to the TRD dual exhaust. I had debated whether or not to install it myself or have Toyota install it. I searched online for detailed instructions so that I would know what I might be getting into. I did find the PDF instructions on Toyotas website and it seemed pretty easy, but I couldn't find any detailed threads from Tundra owners. In any case, I took the plunge and ordered the exhaust (4 weeks on back order :( ) and I installed it today.

    I am making this thread for the next guy who might be on the fence about installing the exhaust himself. Seriously.... it is so easy.... just do it yourself.

    First off, you will need to print out Toyotas instructions and familiarize yourself with what is involved:
    https://spad.external.toyota.com/ArorImages/InstallInstructions/DIO/MY09 Tundra TRD Dual Exhaust IssD.pdf

    The exhaust arrives in 2 boxes. The smaller box contains the muffler and the larger box contains a part box and the two tail pipes.
    [​IMG]

    Here are the pipes. Be sure to leave the bubble wrap on the tail pipes. You want to protect the tips while you are installing the pipes.
    [​IMG]

    The parts box contains a new heat shield, a hanger kit for the drivers side tail pipe, and a gasket kit for the muffler/tail pipes.
    [​IMG]

    My truck is not a 4x4 or lifted and it has steps. This makes it impossible for me to slide under the truck. So, I had to jack up the passenger side a few inches.
    [​IMG]

    The first step in the installation is to remove the tail pipe. On the back of the muffler, there is a clamp with a single bolt. Remove the bolt and slide the clamp towards the rear of the truck.
    [​IMG]

    With the clamp slid back, the tail pipe easily separates from the muffler.
    [​IMG]

    Since I was doing this work myself, I didn't want the exhaust to come crashing down when I slid the pipe off the muffler. So, I hung the tail pipe from the frame.
    [​IMG]

    Spraying a little bit of WD-40 on the rubber hangers makes it easy to remove them. For the original tailpipe, keep the rubber hanger attached to it and remove the rubber hanger from the truck.
    [​IMG]

    Once the tail pipe is removed, it is easy to remove the rubber hanger. Remove it and save it for the new tail pipe.
    [​IMG]

    The next step is to remove the muffler. There are 4 bolts; 2 on each pipe going to the catalytic converters. Remove these bolts and save them. For me, these bolts were a pain to loosen. They were torqued way above spec.
    [​IMG]

    Again, I didn't want muffler to come crashing down when I removed the bolts. So I tied it to the frame.
    [​IMG]

    [​IMG]

    After the 4 bolts from the catalytic converters are removed, then (from the back of the muffler) pull off the rubber hanger from the truck.
    [​IMG]

    Next, pull the muffler away from the 2 front rubber hangers. The muffler will now drop.
    [​IMG]

    Be sure to leave the gaskets on the pipes leading to the catalytic converters.
    [​IMG]

    Old and new muffler. Be sure to remove and save the rubber hanger from the old muffler.
    [​IMG]

    Next, replace the old heat shield with the new heat shield. This heat shield is located above and just behind the rear axle.
    [​IMG]

    [​IMG]

    The new heat shield is much more durable than the old heat shield.
    [​IMG]

    The next step is to install the hanger bracket on the drivers side. This will hold the divers side tail pipe. Near the spare tire, there is a single hole in the frame that a bolt will go through to secure the bracket.
    [​IMG]

    The bracket has a notch that will hook into the spare tire carrier.
    [​IMG]

    Bracket installed. The arrow is pointing to the notch that hooks into the carrier.
    [​IMG]

    Install the new rubber hanger from the kit onto the bracket.
    [​IMG]

    Install the rubber hanger from the old muffler onto the new muffler.
    [​IMG]

    Next, it is time for the new muffler to go in. With a single person, it is impossible to hold the muffler up while installing it. So, I slinged the muffler to the frame.
    [​IMG]

    [​IMG]

    [​IMG]

    With the muffler held up, you can now push the muffler up a little and slide on the rear rubber hanger.
    [​IMG]

    Next, slide the muffler into the 2 front rubber hangers.
    [​IMG]

    Then, using the original 4 bolts, attach the new muffler pipes to the catalytic converters.
    Muffler all in place....
    [​IMG]

    The next step is to install the tail pipes. There is a gasket kit for the muffler to tail pipe connection. The kit also comes with the nuts and bolts to attach them. Install the 2 gaskets on the rear of the muffler.
    [​IMG]

    Attach the rubber hanger from the old passenger side tail pipe to the new passenger side tail pipe.
    [​IMG]

    Getting the tail pipes in the correct location will take a bit of finagling.
    [​IMG]

    Work the passenger side tail pipe into position and slide on the rubber hanger and bolt it to the muffler.
    [​IMG]

    The drivers side tail pipe is a bit more challenging. Be patient.... it will go into place.
    [​IMG]

    Be sure to route the drivers side tail pipe over the brake lines. On my first try, I ran the pipe in between the brake lines and the differential.... and it didn't fit right :)
    [​IMG]

    For the drivers side pipe, slide it onto the rubber hanger and bolt it to the muffler.
    [​IMG]

    Finally, carefully remove the bubble wrap from around the tips. Be careful not to scratch them or get finger prints on them. If you do, then you will need to use window cleaner or mild soap and water to get them off. The instructions say that when the tips are first heated up, any finger prints will stain them.

    Here is the finished installation. For me, the tips were almost level to each other. The passenger side is about 1/2 inch lower than the drivers side. I tried playing with the hangers a bit, but I could not get them any closer.
    [​IMG]

    When I started the truck up for the first time, my wife came running out into the garage. She heard it from inside the house. She was pleasantly surprised :)

    Here is a video of the exhaust at startup.
    https://www.youtube.com/watch?v=cHeSljINdGY

    Here is a video of some accelerations.
    https://www.youtube.com/watch?v=G15sOQGWNkY

    In the videos, the exhaust sounds much louder due to the back window being open. Under normal driving, the exhaust is tempered, but when you step on it, you can really hear it.

    The installation took me about 2 hours, but I was taking my time and also taking pictures.

    The exhaust sounds awesome :) I love it :)
     
    Last edited: Jun 24, 2021
  2. Mar 18, 2017 at 4:42 PM
    #2
    glg20

    glg20 New Member

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    Thanks for the great write up. I have access to a left and should even be easier.
     
  3. Mar 18, 2017 at 5:49 PM
    #3
    TheBeast

    TheBeast The Beach

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    excellent write up !

    now install a remote start for when you wanna hear that growl :)
     
    AJGallo41, Ellis_McPickle and SuaveRC like this.
  4. Mar 19, 2017 at 2:17 AM
    #4
    Netmonkey

    Netmonkey [OP] Don't be a Dumbass

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    Icon stage 2 lift, 295 60 20 nitto ridge grapplers, fuel kranks, TRD dual exhaust, TRD rear sway bar
    thanks :)


    heh.. the truck came with a remote start :)
     
    NewImprovedRon likes this.
  5. Mar 19, 2017 at 3:36 AM
    #5
    Puud

    Puud Graveyarder

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    Great write up makes me want the TRD exhaust that much more.
     
    StrayCat4x2 likes this.
  6. Mar 19, 2017 at 3:55 AM
    #6
    RLHOK

    RLHOK Keeper of the smoke.

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    Oklahoma, just like the musical, but no singing
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    Still rolling stock baby....
    Awesome details. I have had my TRD exhaust for almost a year, you think it sounds good now, give it some time, it gets better...
     
  7. Mar 19, 2017 at 5:45 AM
    #7
    Andy Vu

    Andy Vu New Member

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    Great job Buddy
     
    iglenner likes this.
  8. Mar 19, 2017 at 7:24 AM
    #8
    Kyle100

    Kyle100 New Member

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    Nice work
     
  9. Mar 19, 2017 at 7:56 AM
    #9
    T-Rex266

    T-Rex266 Sushi, and Teslas Staff Member

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    Added to DIY OP
     
    Netmonkey [OP] likes this.
  10. Mar 19, 2017 at 11:54 AM
    #10
    RLHOK

    RLHOK Keeper of the smoke.

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    Oklahoma, just like the musical, but no singing
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    Still rolling stock baby....
    You really should, just saying.....no pressure or anything like that.....
     
    NewImprovedRon and T-Rex266 like this.
  11. Mar 19, 2017 at 1:23 PM
    #11
    T-Rex266

    T-Rex266 Sushi, and Teslas Staff Member

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    The exhaust will sound even better over time. Especially with a SC :burnrubber:
     
    RLHOK likes this.
  12. Mar 19, 2017 at 8:10 PM
    #12
    Peck1631

    Peck1631 New Member

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    Trd dual exhaust, cold air intake
    Great post.
     
  13. Mar 20, 2017 at 3:37 AM
    #13
    Patriot

    Patriot Member

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    Nice write up!
     
  14. Mar 20, 2017 at 4:21 AM
    #14
    Netmonkey

    Netmonkey [OP] Don't be a Dumbass

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    Icon stage 2 lift, 295 60 20 nitto ridge grapplers, fuel kranks, TRD dual exhaust, TRD rear sway bar
    how does it get better over time?
     
  15. Mar 20, 2017 at 5:12 AM
    #15
    louscrw

    louscrw all jacked up on Mt. Dew

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    nice write up
     
  16. Mar 20, 2017 at 5:32 AM
    #16
    Crewmax Chris

    Crewmax Chris Paper Airplane Enthusiast

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    AWESOME write up, man! Looks great and sounds even better! Thanks for writing that up!
     
  17. Mar 20, 2017 at 6:49 AM
    #17
    MotoTundra

    MotoTundra The Ocho

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    -TRS Mini D2S Retrofit on TRD Pro Headlights (Apollo 2.0 Shrouds, 35w XB Ballasts, 5500k Bulbs) -Baja Designs Squadron R Sport Aux lights. -TRD Pro Grill -TRD Rear Sway Bar -BakFlip VP Tonneau w/BakBox -Dipped wheels & bumpers -Iron Cross HD steps -Undercover Swingcase -SunTek Paint Protection film -Tinted glass -Bedmat -OEM Towing Mirrors
    Awesome DIY! Great job.
     
  18. Mar 20, 2017 at 7:17 AM
    #18
    COMiamiFan

    COMiamiFan SSEM #3. Don't forget to try the search bar. #PSL

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    Excellent!
     
  19. Mar 20, 2017 at 7:22 AM
    #19
    T-Rex266

    T-Rex266 Sushi, and Teslas Staff Member

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    Not sure, but sound improved. You'll see the same too..I think.
     
  20. Aug 14, 2017 at 9:02 AM
    #20
    edwin729

    edwin729 Tundra Life

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    @Netmonkey do you know the size bolts that came with system? Or the parts list? thanks!
     
  21. Aug 14, 2017 at 9:09 AM
    #21
    BlueBottle

    BlueBottle not a PRO

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    See fine print
    Does anyone know what size clamp is needed for here? The factory clamp sucks and I want a better one.
    IMG_2559.jpg
     
  22. Aug 14, 2017 at 9:17 AM
    #22
    Netmonkey

    Netmonkey [OP] Don't be a Dumbass

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  23. Sep 7, 2017 at 1:09 PM
    #23
    BayRunner

    BayRunner I’m here, except when I’m not

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    Was going to have the dealer install the dual exhaust, but after reading @Netmonkey detailed posting, I decided to do it myself. Took me about 2 hours, but turned out well. Not too obnoxious, but a pleasant low pitch. Great write up @Netmonkey!
     
  24. Sep 7, 2017 at 1:15 PM
    #24
    OBXTundra

    OBXTundra Member

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    Does the TRD system have any type of X or H pipe incorporated into the system?
     
  25. Sep 7, 2017 at 2:59 PM
    #25
    Netmonkey

    Netmonkey [OP] Don't be a Dumbass

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    Icon stage 2 lift, 295 60 20 nitto ridge grapplers, fuel kranks, TRD dual exhaust, TRD rear sway bar
    Awesome. Easy install, huh?
     
    mjgonz1 likes this.
  26. Sep 7, 2017 at 4:44 PM
    #26
    BayRunner

    BayRunner I’m here, except when I’m not

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    Yes, very easy. Actually, the Toyota instructions were pretty good. So after reading this thread and the instructions, it was a piece of cake. The most time consuming issue for me was installing the driver side hanger bracket. I'm left handed, so the angle reach to hold the back wrench on the bolt head and the second nut wrench was awkward for me. Also, I made 2 attempts to even the passenger side tail pipe. It still is is about 1/2" lower, but you have to look close to really tell.
     
  27. Sep 7, 2017 at 5:19 PM
    #27
    Netmonkey

    Netmonkey [OP] Don't be a Dumbass

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    Icon stage 2 lift, 295 60 20 nitto ridge grapplers, fuel kranks, TRD dual exhaust, TRD rear sway bar
    Yeah I noticed that too. I tried to make it perfectly even as well, but I was unsuccessful.
     
  28. Sep 7, 2017 at 6:12 PM
    #28
    be77solo

    be77solo New Member

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    Sounds great in the videos and thanks for the pictures! Still happy with it? Do you tow at all?

    Thanks!
     
    Netmonkey [OP] likes this.
  29. Sep 8, 2017 at 4:20 AM
    #29
    Netmonkey

    Netmonkey [OP] Don't be a Dumbass

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    Icon stage 2 lift, 295 60 20 nitto ridge grapplers, fuel kranks, TRD dual exhaust, TRD rear sway bar
    thanks :) I am absolutely still happy with it :) I tow infrequently.
     
  30. Sep 12, 2017 at 9:52 PM
    #30
    2XFly

    2XFly New Member

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    Thank you kindly. Just installed my TRD exhaust. New versions don't come with any instructions. There is some blurb about seeing your service advisor for a printout. Anyway, I didn't, and this was most helpful. Thank you.
     

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