MagnaFlow Overland Series Cat-Back Performance Exhaust Install on 5th Gen 4Runner

MagnaFlow Toyota 4Runner Overland Series Cat-Back Performance Exhaust System #19546 4.0L V6 (2003-2021) With No Drone Technology (NDT)

I wasn’t looking to install a new exhaust system on my 2019 TRD ORP but I was kind of forced into it after a trip to Arizona, somewhere along one of the many trails between Superstition Mountain, Sedona, or the Grand Canyon I crushed my tailpipe and started looking into the different exhaust systems, I could have cut a section off and installed a new tip but I would have crushed that as well and I wanted something with more clearance.

Sound Clips, Review and Overview

Why I purchased the MagnaFlow Overland Series:

1. I liked the higher clearance profile that sits closer to the body than stock
2. Single high-clearance no-tip, passenger-side rear exhaust exit allows for significantly improved ground clearance and departure angles
3. Exhaust exit allows for decrease exhaust smell problems common with the 4Runner
4. The No Drone Technology (NDT) cancels out the natural droning frequencies of the 4Runner V6 at cruising speeds. This allows for a quiet ride on the highway while retaining the character of your 4Runner’s exhaust tone/note
5. CNC precision robotic manufacturing enables perfect fitment and 100% hassle-free bolt-on installation
6. 100% stainless steel construction and is covered by MagnaFlow’s limited lifetime construction warranty.

This thing looks almost too pretty to install under your 4Runner.

This is one of three ways to configure the new MagnaFlow system using the No Drone Technology

Find it online: 

• MagnaFlow Website: Check Price

Tools & Materials:

• WD40
• Penetrating oil
• 13M socket
• Mechanics creeper
• Jack stands
• Medium screwdriver or Exhaust Hanger Removal Pliers
• And just in case a Reciprocating Saw
• Safety goggles or glasses

Install Overview

To ease removal of existing exhaust components (especially on older vehicles) spray penetrating lubricant (WD40) on all five (5) hangers/insulators that will be loosened or removed and let soak before disassembly.

Use penetrating oil on the four bolts to be removed (if needed).

Remove spare tire if it’s mounted underneath your 4Runner.

I’m able to crawl under my 4Runner that is lifted with plenty of room to spare, you can jack up the rear and use jack stands, or if you have a buddy with a lift even better.

Step 1. Uninstall Exhaust OEM Bolts

Working front to rear remove the OEM exhaust system by unbolting but do not remove the two 14M spring fasteners at the muffler flange Y joint junction, leave the bolts lightly loosened until the next steps.

Step 2. Remove Bolts Near Spare Tire

Using a 13M socket remove the two bolts that hold the spare tire heat shield in place in the rear section. By removing this heat shield you will have much more room to pull the entire exhaust system out.

Step 3. Loosen 13M bolts on Upper Bent Heat Shield

That’s why you don’t remove the first two bolts in the front so you can get some leverage to loosen these two.

I let these two bolts soak in penetrating oil for a long time but I wasn’t able to bust them loose and I started to strip them. My guess was that all that high heat makes them soft, so I did the next best thing and used my reciprocating saw and cut the piping above the axel area.

One cut and I was able to remove the larger muffler section altogether.

Step 4. Work Front to Rear

Remove the bolts and save the spring bolts from the Y-pipe section; you will need these two to install the new MagnaFlow Cat-Back Exhaust. Then you can disengage all five (5) welded hangers from the rubber insulators and remove the system.

(Do not damage the rubber insulators) they should just stay in place; they will be needed to mount the new system.

This is the bill of materials photo that is on the front page of the install instructions

Note: the new version of this kit does not have the hanger bracket; I called MagnaFlow since it was missing from the install kit and was told they did away with this and extended the hanger arms longer to fit into the OE rubber insulator/hangers in the rear tailpipe section.

Install MagnaFlow Exhaust

• Step 1. Attach the Inlet Pipe (1) (96-00) using the two OE spring bolts to the catalytic converter outlet Y joint junction.
• Step 2. Loosely attach the Oval Muffler (2) to the Inlet Pipe (1) (96-00) with the supplied 2.50″ clamp. Insert the two hanger arms into the rubber insulators.

This system is configured to allow the user to tune the sound in three different ways.

For a more moderate exhaust sound install the U-pipe assembly and the 4.00″ NDT Chamber (as shown) using the supplied 2.50″ clamps.

For more aggressive sound, use the U-Pipe and the MF block-off cap.

For an even more aggressive sound, skip the U-pipe and just clamp the MF block-off cap to the muffler. Not sure what to do with the cap but I’ll keep it.

Step 3. Loosely clamp the rear tailpipe section using the 2.50” clamp and slip the hanger arm into the rubber insulator once a final position has been chosen for the new exhaust system. Then, evenly tighten all clamps from front to rear using the torque specifications on page one of the included instructions (40 -45 ft-lb for band clamps) and inspect all fasteners after 25-50 miles of operation and re-tighten if necessary.

Step 4. Reinstall the spare tire heat shield.

That’s it!

All in, it would have taken me under two hours (stopping to take pictures and deciding to use my reciprocating saw added more time). It would be helpful to have a friend help you but a couple of jack stands worked perfectly fine for me.

I took a test run of about 25 miles and got on it on the highway and felt and sounded great with my TRD Cold Air intake, once back in the garage, I logged into Torque and no error fault codes were reported and I let it cool down and inspected all the fasteners.

Final Thoughts

A couple of days later I drove down to southern California and back (roughly 900 miles round trip) and I really like the sound inside and out, it’s a little louder inside but nothing I can’t hide by turning up the music.

I know there are other systems to choose from, but I think this was the right choice for me since I like to spend a lot of time on and off-road as this is my daily driver.

Not to mention, the No Drone Technology (NDT) (which isn’t available from the other brands that I know of) is a huge plus and you can not beat it being made in the USA.

For more detailed pictures you can check out Brenan’s install of the MagnaFlow 15145 MFSeries Performance Cat-Back Exhaust System.

Enjoy the ride!!