98 Hilux Exhaust Problems

[98hilux]

Hi
I have a 1998 Hilux 3.0 Litre Diesel Dual Cab 4wd. My problem is the exhaust. The original lasted for 223,000km, I have just gone thruogh 4 more in 2,000km including another one today. The exhaust box that is being fitted is about half the size of the original and the pipe is about quater of a inch smaller. The exhaust dealer thought it was a manufacturing fault so a different brand was put on early this week, it lasted 400km. The exhaust box is getting very very hot and looks like a oxy has been used to burn the outside. The constant heat then cooling is causing the baffles to come loose and make a hell of a noise. The dealer says I have a problem with my motor and will not fit another box until I find the problem. My motor is very well maintained, my mechanic even says it's very well looked after. any help on this will be great.
Thanks
Robert

[mav]

Hi
I have a 1998 Hilux 3.0 Litre Diesel Dual Cab 4wd. My problem is the exhaust. The original lasted for 223,000km, I have just gone thruogh 4 more in 2,000km including another one today. The exhaust box that is being fitted is about half the size of the original and the pipe is about quater of a inch smaller. The exhaust dealer thought it was a manufacturing fault so a different brand was put on early this week, it lasted 400km. The exhaust box is getting very very hot and looks like a oxy has been used to burn the outside. The constant heat then cooling is causing the baffles to come loose and make a hell of a noise. The dealer says I have a problem with my motor and will not fit another box until I find the problem. My motor is very well maintained, my mechanic even says it's very well looked after. any help on this will be great.
Thanks
Robert


what does the dealer say about the smaller exhaust system, a restriction could cause some problems is the car using more or less fuel than usual or is the car down on power since the new exhaust has been fitted ??? ??? ???

[98hilux]

The dealer says I should only fit a genuine part, they were not much help. The car seems to be a bit down on power and is using more fuel. One mechanic told me today it could be the fuel pump, using more diesel than it should and the next guy tells me its the fuel I'm using. I had the fuel pump and injectors overhauled at 150,000km and have been using the same fuel supplier for the past 8 years. I measured the exhaust pipe next to the joint which is on the engine side of the muffler and it is 1 3/4 inches, maybe that might have something to do with it.
Thanks
Rob

[baby_troupe]

It is better to be oversize than undersize.
If it breathes better, more power & less fuel.
If it can't get rid of the exhaust gasses properly, engine has to work harder, which will use more fuel & that will produce more heat.