Hello,

The exhaust pipe on my '97 850 N/A broke off right behind the catalytic converter. Otherwise, the corrosion doesn't look too bad. For now I am using some wire to hold the cat up, in order to reduce the stress on the other joints and to keep it from falling down...

Has this happened to others' 850s? I am kinda hoping this can just be welded back together?


I'd appreciate any comments on how to handle this. Just want to make sure I am not sold a bigger repair than it really needs.

Thanks.


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'97 850 n/a Wagon, 170K mi ... '98 V70R AWD 106K mi

I had the same thing happen to my 96 850, at about 120K, about a year and a half ago. I opted to replace the rest of the exhaust system as well as the catalyst at that time, but I'm not sure I would do that again. Welding it might be the better option. My thinking was that I only wanted to deal with the exhaust system once and I doubted that I could get the pieces apart without damaging the joints, especially the flex joint upstream of the catalyst. This didn't turn out as well as I had hoped.

I ran into problems with the replacement parts or installation. The aftermarket muffler unit (Bosal, I think) is very noisy compared to the stock unit; I am thinking about replacing it just due to that. I'd definitely go with the Volvo part instead. Then, this winter I got a MIL and trouble code for the catalyst (efficiency below threshold or something similar). I am still trying to diagnose the source of the DTC; it may not be the aftermarket catalyst, but it may be. (That is still under warranty luckily.) And my final problem was that I broke an exhaust manifold stud installing a new manifold (which wasn't the fault of the parts, of course). By the time I paid for all the parts and a garage bill to get the broken stud out plus towing, the total was over $1000.

Hopefully, you may be able to fix your problem by welding. If not, be careful in buying your parts and good luck.

Gregg Downing
96 850 GLT wagon, NA, manual

To all, thanks for sharing your experiences.

My mechanic ended up using a short piece of pipe to bridge the break, and welded the break.

He also hand-made a new hanger for the tailpipe (I didn't realize it was bad, but now realize this may have caused additional strain and flex and contributed to the broken pipe. There are no hangers from the manifold/flex hose all the way back to the muffler..).

Parts: $ 7.50
Labor: 2.5 hours @ $75/hour

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'97 850 n/a Wagon, 170K mi ... '98 V70R AWD 106K mi

Two years ago that happened to our 1995 850 turbo sedan. I had the end (long) part replaced at Midas for about $500 (only ~ 80 labor). The part has a lifetime warranty. I hope this helps.

It really seems like messing around with manifold bolts is tricky business. I think if you're going to take the exhaust manifold off you should plan on breaking a couple of studs and possibly have to extract in some exotic way, and also I think you should plan on using new studs from the dealer (I've had very bad luck using common bolts in volvo exhaust setups. Specifically I'm talking about turbo mounting studs on a 86 760, but nonetheless... assume the studs are special and likely expensive).


I'm sorry I don't really have any advice for the orig poster and his exhaust problem. Exhaust guys can do some pretty magical things when their fabrication skills are called upon. They can also gum things up a lot.