Exhaust Gasket - Rear

Replace the rear exhaust gasket between the catalytic converter and rear exhaust section on a 2018-2024 Toyota Camry 2.5L I4 engine.

Warnings

Tools required

Parts

• Rear exhaust flange gasket × 1 — Use OEM Toyota gasket or equivalent donut gasket
• Exhaust flange bolts (if corroded) × 2 — M10x1.25 bolts, replace if damaged

Preparation

1. Ensure exhaust system is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Place wheel chocks behind rear wheels
4. Raise front of vehicle and support securely on jack stands at manufacturer lift points
5. Spray all exhaust flange bolts with penetrating oil and allow to soak for 15-30 minutes
6. Visually inspect exhaust system for additional damage or leaks

Procedure

1. 1

   Locate rear exhaust flange connection
   Position yourself under the vehicle and locate the flange connection between the catalytic converter outlet and the rear exhaust pipe inlet. This is typically located just behind the catalytic converter, approximately mid-vehicle. Identify the two flange bolts that secure this connection.
2. 2

   Support rear exhaust section
   Have an assistant support the rear exhaust section or use a floor jack with a block of wood to gently support the rear muffler assembly. This prevents stress on the connection when bolts are removed and aids in alignment during reassembly.
3. 3

   Remove flange bolts
   Using a 14mm socket and ratchet, carefully loosen and remove both exhaust flange bolts. Apply steady pressure and avoid stripping bolt heads. If bolts are seized, apply additional penetrating oil and allow more soak time. Work bolts back and forth if necessary to break corrosion bond.
4. 4

   Separate exhaust flange connection
   With bolts removed, carefully separate the flange connection by pulling the rear exhaust section backward. The connection may be stuck due to carbon buildup. Use a rubber mallet to gently tap the flange if needed. Do not pry with screwdrivers as this can damage sealing surfaces.
5. 5

   Remove old gasket and inspect
   Remove and discard the old exhaust gasket from the flange. Inspect both flange surfaces for damage, warping, or excessive corrosion. Check that flanges are flat and undamaged. Inspect bolts for thread damage or excessive corrosion and replace if necessary.
6. 6

   Clean flange surfaces
   Use a wire brush and gasket scraper to thoroughly clean both exhaust flange mating surfaces. Remove all carbon deposits, old gasket material, and corrosion. Surfaces must be clean and smooth for proper sealing. Wipe clean with shop towels.
7. 7

   Install new gasket
   Position the new exhaust gasket onto the catalytic converter outlet flange. Ensure the gasket is properly centered and oriented. Most donut-style gaskets have a specific directional orientation with the tapered side facing the correct direction per gasket packaging instructions.
8. 8

   Align and connect exhaust sections
   Carefully slide the rear exhaust pipe forward to engage with the catalytic converter flange. Align bolt holes while keeping the gasket in position. This may require slight adjustment of the rear exhaust support position. Ensure gasket remains properly seated during alignment.
9. 9

   Install and torque flange bolts
   Apply a thin coat of anti-seize compound to the threads of both flange bolts. Insert bolts through the flange and thread by hand to ensure proper alignment. Using a torque wrench, tighten bolts in an alternating pattern to the specified torque value. This ensures even compression of the gasket.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Check exhaust alignment and hangers
    Verify that the exhaust system hangs properly with adequate clearance from the underbody, fuel lines, and suspension components. Check that rubber exhaust hangers are properly seated and not damaged. Adjust hanger positions if necessary to achieve proper alignment.
11. 11

    Remove supports and lower vehicle
    Remove the support from under the rear exhaust section or lower the jack. Carefully lower the vehicle from jack stands and remove all tools from under the vehicle. Remove wheel chocks.

Reassembly

1. No disassembly of additional components was required for this procedure
2. Ensure all exhaust hangers remain properly engaged during test drive

Verification

• Start engine and allow to reach operating temperature while listening for exhaust leaks at the repair location
• Perform visual inspection under vehicle while engine is running to check for exhaust gas escaping from flange connection
• Take vehicle for short test drive and re-inspect flange connection for leaks after thermal cycling
• Verify no exhaust rattle or contact noise with underbody components
• After 50-100 miles of driving, re-check flange bolt torque as gasket may settle slightly

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