Hi,
I’ve heard replacing the down pipe/ catalytic converter is a real pain. So getting at that 02 sensor doesn’t look fun either.
My questions are:
1). How rusted in do those bolts get, are they a nightmare or by any luck anti-seized at the factory? ((119,000 miles on car)
2). How long do the stock cats last? I have to replace the back of the exhaust and would rather do the whole thing than have to revisit it in a year or two. (Of course I’d rather just do the back if the cats last 250,000+)
3). Any other things I should be aware of?

Thank you!

Thanks guys,
Autozones code reader said it was the cat, but maybe the 02 sensor is throwing things off?
I’ll take a look at it over the weekend and see how hard it is to get to. I have a 4 post lift. If I can just do the back and maybe an 02 sensor I’ll try to get away with that.
The code reader also said the fuel rail pressure sensor, so that might be throwing off the code reader on the cat? I’ll replace that this weekend first.
Thanks again.

Different model, but the cat and downpipe were still going on my 95 850 at 250k when I sold it. In fact, the entire exhaust was original except for the muffler hangers. Never had an exhaust last so long on a car. Amazing!! My recently sold 2002 VW Passat wagon was also all original (except for the flex pipe) at 242k. Believe the Passat and Audis of that era also had SS exhausts like Volvo. This was driving on the snowy, salty roads of New England.

Examine the front pipe's and cat's condition. If good, consider doing just the back. The cats for these cars are pretty pricy....
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Will I buy another Volvo??? We'll see....

There is no reason the down pipe and cat would fail before 250K. Unless the front O2 sensor dies and the error message is ignored for 5-10K miles.

My 1995 exhaust is still on the car after 185K miles. Says a lot for stainless steel!

The front O2 sensor should easily last to 120K, the rear is probably 200K or more depending on how rich the engine runs.

The tail pipe bolts have no anti seize, they will need penetrating oil. Same for the clamp bolts.

Getting at the front O2 sensor is not as bad as it looks. Most auto parts stores rent for free a 7/8 wrench tool to get the sensor off. You just need to have the car on jack stands.
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Keeping it running is better than buying new