The exhaust in my 1985 BJ60 had been on the truck since before I bought it 4 years ago, and was getting progressively worse. According to the journal the previous owner had kept, he had the exhaust pipe/muffler replaced in January of 2005. The truck had 223,536 km. When I bought the truck, the exhaust was already not in great shape; it seemed to have a slight exhaust leak near the passenger door, but I kept it running while it still worked.
Then one fateful afternoon on the way home from school, I floored the accelerator as usual to get up a large hill, and suddenly realized the truck was a lot louder than it should have been. Once I could pull over, I checked for the source, and felt a blast of air on my hand just after the exhaust pipe bends down from the manifold. I then decided I’d try to make it the rest of the way home before examining what was wrong. After making it another kilometer, it kept getting worse, and fearing a flurry of noise complaints, I pulled over on the side of the road, admitting defeat. This was 255,100KM on the odometer.
Not wanting to give in completely and have to take the bus all week, I decided I’d head down to Calgary Muffler Carline and ask about getting the exhaust patched up. Upon arriving, they put my truck up on the lift and I was able to see just how bad the exhaust was. The exhaust pipe was completely severed in half, with black soot coating the underside of the passenger floorpan, framerails, and everything else nearby. There was also more soot on the exhaust hangar, about 6 inches further down.
After examining the condition of the rest of my exhaust pipe, I decided to ask how much it would cost to replace everything back from the good metal at the very front. I was told it would be about $570, before tax. I figured I may as well replace this while I could, instead of waiting for something else to fail in another month. Having work in about 4 hours from then, I asked how soon it could be done. “2 hours or so” was the response, and I gratefully accepted.
1 hour and 50 minutes later, I took a look at the truck, with a new shiny exhaust system of 2.5″ pipe, a new muffler, and a side exit exhaust. It was awesome. I paid the $594, and drove home. It was rather loud, but I could live with it for then. After all, I hadn’t really clarified what amount of sound reduction I wanted. A week later, I drove back, and timidly inquired as to how much it would cost to get a quieter muffler. Al, the helpful owner, was very kind in offering a quieter muffler, free of charge. After a half hour had passed, the truck had a new muffler, and sounded as good as new. Better, in fact. They even properly routed the exhaust around the shocks and spring hangars; the previous exhaust system from 2005 was constantly rattling against the spring hangar and shock whenever it was at cold idle. When I replaced the rear shocks, the old one was dented where the old exhaust system ran. So this was a major improvement.
I’ve now been driving the truck for a few weeks, and the exhaust is great. Al was wonderful in understanding how to route the exhaust exactly as I hoped, and they handled the whole experience really well. I’m quite thoroughly impressed. Though, I’m also rather impressed that the previous exhaust managed to hold up for 14 years and 32,564KM of Canadian winters.