Once again I'm indebted to the FAQ for helping me through my first exhaust job. Thought I would post the results in case useful to others.

Both mufflers, the pipe joining them and the tailpipe needed replacement. Pressed for time (emissions inspection due tomorrow), I got a Midas estimate: $462. That's over $300 in parts, $130 in labor and the rest in the usual trimmings.

No thanks. I went to Advance and got the parts for $180 on a one-day order. They are Walker parts, made in USA and Canada, lifetime muffler warranty (from what I read in faq, I'll be using that).

-Backed the car up the wheel ramps, which gave enough access.
-Dremel with cutting wheel made quick work of the forward clamp, then split the overlaying muffler pipe horizontally in two places and peeled it back like a banana, as in faq.* That freed the parts needing replacement.
-New parts fit together well except pipe would not slip over one muffler collar. Some quick, careful work with the belt sander on the collar and I was in business.
-Everything else came together nicely. The rear muffler was not marked for air flow direction, unlike the one that came off, and both ends seemed the same. I hope it doesn't matter which end goes which way.
-Reused the rubber hangers.
-Returned the $26 pipe-cutting tool unopened, since Dremel did all the hard work, and took son for pizza instead.

Done in less than an hour and all seems tight and quiet. I know some recommend higher end parts but this seemed like the right quick fix, with no time to order from the usual places. Thanks Brickboard.


*Technically, my son did this.

I used Walker parts back in 96 on our 89 244, perfect fit, no problems. It worked great without rust of failure until 2000 when the car was destroyed. The exhaust however survived and I transplanted it to a 90 244 and got 3 more years out of it. Yes, the head pipe was restrictive, but it worked well.

jorrell
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92 245 250K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!

Thanks, good to see you again. I do have one question...I can feel exhaust leaking from forward-most connection. Not much, but it's obviously at idle. This is the muffler collar over the old pipe that goes into the cat. Can I really come on to those clamp nuts? I've got them real snug already. I could try repositioning clamp closer to the end.

The 'old' pipe is slightly out of round from the previous clamping. I usually try to put the new clamp on the same position as the old one so the new, overlapping pipe bends up the same as the previous.

The job really is quick, just getting that one pipe off can get dicey.

I have acetylene torches and it's a dream. You can easily cut the outer pipe without hurting the inside pipe.
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'75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me http://home.no.net/ebrox/Tony's%20cars.htm

if memory serves the pipe in front of the muffler which allows the cat pipe to slide into it has slots.

if that is the case the cat pipe may not be inserted enough into the muffler to well clear those slots.

a tool i find i do not use much but is great when you need it and is not really expensive at harborfreight or advanceautoparts is a tail pipe expander.

if you insert it into the front of the slotted muffler pipe which the cat pipe fits into you can easily open up that pipe enough to get an excellent fit and likely stop your leak.