Engine Exhaust System problems of the 2007 Toyota Yaris

Exhaust is extremely loud on Yaris during acceleration and causes the interior cabin to smell. I had a friend look at the exhaust for a leak and all he could find is a shredded gasket. The exhaust was in excellent shape and showed no damage or corrosion. Internet searches have revealed that the gasket on the 07 Yaris is poorly designed and several people are affected by this.

Experienced failure of exhaust system due to poor connection joint and gasket design. Internet search reveled other failures of exhaust gasket material but no TSB was found. Engine operation results in movement of exhaust joint which wears at the gasket material. This operational wear and exhaust heat breaks down the gasket material developing an exhaust leak producing an audible noise and in-cabin smell complaint. The noise is most audible during acceleration but the in-cabin exhaust smell is more constant. Repair requires a new exhaust gasket ($30), new bolts ($5), new tension springs ($5), plus 0. 5hr of labor charges. Parts replaced and test drive confirmed complete repair. None of the parts are updated from original so it is expected that this failure will return in time. There is concern that the leaking exhaust gases are entering the cabin which could be a contaminate risk for the driver and occupants. Failure of this simple component is irritating to the consumer and irresponsible of the manufacturer. Customer has already noted that this event will affect (negatively) future vehicle purchase decisions. Note: this failure does not illuminate the check engine lamp (cel).