2008 Prius Muffler Hanger Rusted Away

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Mike Axsom, Feb 10, 2026.

  1. Mike Axsom

    Mike Axsom Junior Member

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    Hello. I've searched and found options for when the hanger on the muffler itself is broken, but I'm missing the one that should be on the actual frame of the car. Are there replacement hooks out there or affordable options for the DIY'er? I'd rather not have to go to a muffler shop to get something welded on but will if that's the only option. Thank you all so much for any help.
     
    #1 Mike Axsom, Feb 10, 2026
  2. Mendel Leisk

    Mendel Leisk MMX GEN III

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    The missing hanger was presumably welded to the car body? Can you weld? If so, I'd get some comparable round bar, bend to suit,, debur the end, weld it in. Putting it in position in the rubber connector would likely help to position it for the weld.

    I've never welded (apart from an abysmal attempt in high school shop, muffler shop would be my approach. :)
     
    #2 Mendel Leisk, Feb 11, 2026
  3. hurricos

    hurricos Junior Member

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    If you weld, don't do it poorly like I did.
    PXL_20260123_053005572.jpg PXL_20260123_061533778.jpg PXL_20260123_063917056.jpg
     
    #3 hurricos, Feb 11, 2026
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  4. hurricos

    hurricos Junior Member

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    To complete my thought:

    I used 1/2" steel bar stock, cut into the metal and then heated it with a torch to get it to bend (since I don't have a brake press or anything like that). I got very lucky with the shape; I'm nearly certain that I'd have messed it up on second try.

    I used TIG, 3/16" electrode and pedal, ~50-110A, 1/8" filler rod. I used wayyyyy too much current, and the new stock was way too thick for how thin the sheet metal of the car is.

    This is my third time welding, ever, and the first time doing it to a car.

    If you can clean the area up and remove the muffler for a shop, they will have a very easy time welding in a hook for you from stock they have on hand -- the cleanup and staging part is most of their work.
     
    #4 hurricos, Feb 11, 2026
  5. Mike Axsom

    Mike Axsom Junior Member

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    Alas, I cannot weld. I was hopeful someone would point out a bolt-on hook option that I've been unable to locate on my own. Seems like maybe I should just pull the muffler, which is hanging on by imagination, and take it to the shop.
     
    #5 Mike Axsom, Feb 11, 2026
  6. hurricos

    hurricos Junior Member

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    Yeah, pulling the muffler and heat-shield (which I doubt is still present) will earn you some points with the shop you bring it to.
     
    #6 hurricos, Feb 11, 2026
  7. Mendel Leisk

    Mendel Leisk MMX GEN III

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    If it's not dragging, I'd just bring it in as-is. And if it is dragging, wire it up a bit. It's just needs a hanger, why break loose the flanged connections, you're just asking for leaks.
     
    #7 Mendel Leisk, Feb 11, 2026
  8. hurricos

    hurricos Junior Member

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    The shop will need the space to do the new weld justice (working in that crevice is a pain with the muffler there; doable with MIG). The real value: if the muffler has been hanging on for a while my experience that exhaust joint is already leaking and the donut needs replaced.
     
    #8 hurricos, Feb 11, 2026
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  9. Mike Axsom

    Mike Axsom Junior Member

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    It's beyond dragging although I do have it suspended with galvanized pipe tape. The inlet pipe is rusted completely free from the muffler body.
     
    #9 Mike Axsom, Feb 11, 2026
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  10. Mike Axsom

    Mike Axsom Junior Member

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    Thank you for the pictures. I wasn't sure where the hook had been until I saw yours. Doesn't look like a bad weld job as long as it holds.
     
    #10 Mike Axsom, Feb 11, 2026
  11. Mike Axsom

    Mike Axsom Junior Member

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    While I'm attempting to find a shop that will weld (none within 30 minutes will do it), I have purchased a Walker 54560 replacement muffler. Everything says it's a direct replacement, but those hangers look very different. Anyone had any issues using this muffler?
     
    #11 Mike Axsom, Feb 12, 2026
  12. hurricos

    hurricos Junior Member

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    I have bought and used the OPMMT5014, which is one other RockAuto alternative.

    I'm sure both parts will fit just fine.

    In my experience, Walker just doesn't flare the hangers, and it's not a problem. Consider what kind of dynamics might lead to the hanger coming off - if the exhaust gets hooked by something (wire) enough to pull it off the hanger, it's probably getting bent by said snag anyways.
     
    #12 hurricos, Feb 15, 2026 at 8:05 AM
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