8.0
pretty badTypical Repair Cost:
$392.00
Average Mileage:
43,944 miles
Total Complaints:
12 complaints
Most common solutions:
- not sure (7 reports)
- replace with an aftermarket stainless steel muffler (2 reports)
- midas cut the tailpipe after the catalytic converter (1 reports)
- muffler & catalytic converter replaced (1 reports)
- stainless steel patch (1 reports)
This problem may be covered under warranty. Ask your Toyota dealer.
2011Jun 14
RAV4 V6
- Automatic transmission
- 75,807 miles
I just can't believe all the parts that are failing on this vehicle.
I'm not going back to Toyota for my next vehicle!
2011Jul 01
RAV4 Sport V6
- Automatic transmission
- 35,000 miles
06 Rav4 Sport V6 and the exhaust is rusted through, middle section of it, crazy for it to already be rusted through. Hoping Toyota will cover under emissions wty as muffler is part of a piece that included the cat converter but we'll see...
Update from Jul 17, 2011: Toyota dealer and Toyota Canada say the muffler is not part of the emissions system and thus not covered under the emissions warranty. 4 years old, low mileage, poor quality.
2011Jun 25
RAV4
- Automatic transmission
- 40,000 miles
I had a similar prob to the the others with the rusted exhaust system. The dealer wanted $1700 to repair it but thanks to this web site I pushed the dealer and finally they conceded that it was covered under the 8 year 80000 mile warranty. Thanks so much to the site!!!!!!!
2011May 22
RAV4 LTD 3.5L V6
- Automatic transmission
- 46,000 miles
click to see larger images
Premature Exhaust System Failure: My 2007 RAV4 muffler has a hole in the top rear passenger side after only 4 years and 46K miles. This has not happened before for other Toyota or Subaru vehicles that I had with SS exhaust systems. Based on other comments this is not an isolated incident. I agree with those that this is a manufacture's defect by Toyota's supplier(s). Poor stainless steel material seems to be the problem. There has not been any recall or negotiated settlement with customers from what I have seen so far.
Has there been a class action started for this issue? SS exhaust systems should last well over 100K or 10 years. Tomorrow I plan to discuss with the service manager at our local Toyota dealer. I suspect I will not get a satisfactory response but this would be my first attempt to see if Toyota will help rectify the problem. They deserve at least that from me.
Update from Oct 14, 2011: My premature muffler failure has been resolved by Toyota; but, before I say any more I want to take you back to the beginning of my dilemma. Bear with me through this saga because it is worthwhile noting the results and how I got there:
Initial Complaint: Premature Exhaust System Failure: My 2007 RAV4 muffler has a hole in the top rear passenger side after only 4 years and 46K miles. This has not happened before for other Toyota or Subaru vehicles that I had with SS exhaust systems. Based on other comments this is not an isolated incident. I agree with those that this is a manufacture's defect by Toyota's supplier(s). Poor stainless steel material seems to be the problem. There has not been any recall or negotiated settlement with customers from what I have seen so far. Has there been a class action started for this issue? SS exhaust systems should last well over 100K or 10 years. Tomorrow I plan to discuss with the service manager at our local Toyota dealer. I suspect I will not get a satisfactory response but this would be my first attempt to see if Toyota will help rectify the problem. They deserve at least that from me.
Initial Result: I took it in to my local dealer who did the inspection. They said, sorry, but this vehicle is out of warranty and you will have to pay $1,679 plus tax for us to replace it! That did not seem right to me so I took the holy gapping rusty muffler with me for latter action by me. I could not drive it this way because tickets cost too much, so I had to go to Midas to replace it – just the muffler, not the rest of the rusting but not yet holy exhaust system - for an unreasonable $400 but what could I do?
First Action Taken: Upon receiving my Midas muffler repair that rattled after installation when I took left turns, I called the USA Toyota main office in Torrance, California to ask what can be done about poor materials and premature failure for their RAV4 stainless steel mufflers. They said nothing could be done since my car is out of warranty, they suggested I call the dealer customer service to see what they could do. I did as they said and the customer service manager verify that they really could not do anything for me even after he had done the same thing I had by calling the Torrance, CA. So that is it…you’re stuck… but no, continue on:
Second Action Taken: It took a while to get my ducks in order, but the next step was to write a letter to 3 different identities with color photos showing my failed muffler:
• Dealership Owner
• President USA Toyota, Torrance, CA
• President Toyota Manufacturing Corp, Tokyo, Japan
Resolution: About a month later I got a call from the Torrance office. They said they were very sorry for the mix-up, but that this failure is supposed to have been covered under the emission control warranty since the muffler is directly connected to the catalytic converter without any flange between. The emission control warranty continues for 8 years or 80,000 miles. They said they would reimburse me for the Midas muffler and provide me with a new exhaust system at no charge. Today, after much consternation, time and effort this problem has been completely resolved…almost. The new system has identical construction (weld seams, etc.) as the old one. The muffler, pipe and catalytic converter are strongly attracted to my magnetic – certain stainless steels are attracted to magnets, so I have no way to verify that it is truly stainless steel or quality stainless steel. This may happen all over again 47,000 miles or 4 years from now if this “stainless steel” exhaust system fails in the same manner; but, this time with an expired emission control warranty it will be on my tab at $1,679 plus tax, plus escalation! I wish Toyota can assure me that I do not have the same materials I had previously; but, if this unfortunate saga happens again I will need to pursue another resolution based on an extended warranty as another premature failure should definitely not occur after receiving a new stainless steel system at (now) 49,000 miles.
2011Jun 15
RAV4 3.5L V6
- Automatic transmission
- 56,263 miles
2007 Toyota Rav4 base model V6 engine.
Three and a half years and my stainless steel exhaust system is rotted out. Vehicle is too new to get aftermarket parts.Midas,Monroe and Meinike can't get the part except from a toyota dealer. Dealer quoted parts cost: Muffler - $1,230.00. Gasket - $39.15. Gasket - 69.60. That's $1,386.38 including CT sales tax. Labor not included.
That is way too much to replace a three and a half year old muffler. I switched from owning Jeeps to Toyota because Consumer Reports rated the quality and longevity very high. What a mistake. Also, 3 out of 4 air pressure sensors have had to be replaced. My wife needs a car this year - guess what? We are comming back to owning Jeeps made in America & Canada.
2011Jun 03
RAV4 Sport 3.5L
- Automatic transmission
- 49,710 miles
Hole on top of muffler. Had to patch it.Replacement too $$$. Will see how it lasts!
Update from Jun 29, 2011: I had emailed my complait to Toyota as well as how angry I was at having to replace the Muffler at 80,000km.(Seam on top of muffler blown open). Three days later I got a call from dealer that they would replace it and the Catalytic Converter (both on same assembly #17403A) no charge. The unit is covered under the 130,000 emissions warranty.That's great but why don't they offer that right away.Many people may just pay the $1244 + tax they want for the repair to what is a faulty part
Update from Apr 28, 2012: Update- Don't accept paying $1200 + for a new muffler if your dealer refuses to do the work under warranty. If you are still within the 130,000 km emission warranty push Toyota Canada (the muffler and catalyst are all one welded section) and they will cover it. If you go to a muffler shop to cut and install an aftermarket it may not work properly (back pressure?) and may effect resale value. I traded in my '07 with 98,00 km on it for more than half of the original price. Not too many vehicles retain their value like a Like Toyota. I now have a 2012 Highlander V6 and love it
2011Feb 23
RAV4 V6
- Automatic transmission
- 43,700 miles
I purchased this vehicle new and the exhaust issue is the latest problem for this vehicle. Estimated cost of repairs was listed @ $1,440. I am reserving any final comment as the dealership is working with Toyota to see if they will reslove this problem. This site while confirming just 2 issues thus far validates my concern for potential quality issues. I was told there was no aftermarket muffler available. I will follow through on the suggestions from this board if the Manufacturer refuses to replace. With these vehicles no entering their 4 & 5th year it will be interesting to see if there is an increase in instances with this issue.
2011Apr 13
RAV4 LX V6
- Automatic transmission
- 60,000 miles
I was told that the stainless steel muffler on the RAV4 would last for at least 10 years .... but it didn't!!
The Midas outlet I took it to was very good and very surprised but could not source a muffler from Toyota only the whole exhaust system for $1100. Add on the labour cost and to say the least, I am not happy. I really don't want to increase Toyota's profits, so I will have a non Toyota muffler installed like the other RAV4 drivers who have been caught .
I really don't understand why Toyota does not stand behind their claims on the exhaust system or even sell a replacement muffler... just too greedy I think!!
2011Feb 15
RAV4 V6
- Automatic transmission
- 20,000 miles
If the muffler and catalitic converter are a single component then the muffler failure is covered under the 8 year 80000 mile emissions warranty. Dealer replaced mine last week. If your dealer didn't know this you should contact Toyota and ask for compensation.
2010Dec 22
RAV4 2.4L
- Automatic transmission
- 38,000 miles
I have a 2007 Toyota Rav4 with 38,000 miles and the muffler rusted through on the top very close to the back of the muffler. This appears to be a very strange area to rust through. The rest of the exhaust system is in good shape and is not rusted. This is either an engineering problem or a defective part that is going to cost $1200 because some Toyota engineer decided to put the catalytic converter in the defective muffler. I have a 36 month (36,000 mile) bumper to bumper warranty and a 60,000 mile drive train warranty. I bought the car new in December of 2006 and I have owned it for 48 months, so no warranty covers this. It would have been covered a year earlier. This is my fifth Toyota and the first problem I have had with a Toyota. I consider this an engineering problem and I am extremely upset about it costing me $1200. I bet it will happen again at 76,000.
Update from Jan 16, 2011: I took the 2007 Rav 4 to Midas, The final cost was $471,71 as Midas cut the tailpipe after the catalytic converter and used an after market muffler, I also have a lifetime guarantee if it happens in another 38,000 miles.
Update from Jan 16, 2011: I took the 2007 Rav 4 to Midas, The final cost was $471.71 as Midas cut the tailpipe after the catalytic converter and used an after market muffler, I also have a lifetime guarantee if it happens in another 38,000 miles.
2010Jun 07
RAV4 Limited V6
- Automatic transmission
- 22,465 miles
My Rav4 has just over 20,000 miles and the center muffler completely rusted and blew open. my warranty expired in April 2010 as its 36 months and Toyota wanted nothing to do with me. This is a second issue with this car, back in February they replaced the leaking water pump and this luckily was under warranty. The dealer wanted $1200 for the part alone as it comes with the catalytic converter. In the end I took the car to Speedy who custom fitted a stainless steel muffler with a lifetime warranty for $312 dollars including labor and taxes!!!
I am beyond desapointed in the shoddy workmaship and parts quality of Toyota nowdays and will make sure this is my last Toyota for a long time to come.
2012Feb 23
RAV4 V6
Only a total idiot puts the catalytic converter and muffler on the same piece of pipe. This
is a great way for Toyota to circumvent the 8 yr warranty on the converter. By having the
muffler go after 3 to 4 years, you replace the converter at the same time and get a new
converter, but your warranty on the converter is still only good for 4 to 5 years.
Jim T.
Milton, ON, canada
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