2008 Prius Muffler Hanger Rusted Away

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.

 

If you weld, don't do it poorly like I did.

 

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.

 

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.

 

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.

 

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.