My 92 740 turbo wagon exaust system needs replacemet. Can I do this myself... limmited experience working on cars or should I take this to the professionals. If I do it, can I replace with used from junk yard or buy new?
Thanks.

Hey Tom,


I totally agree with Javalion about getting a new exhaust system. Once they've been on for any time at all, its just about impossible to take apart in a non-destructive way. Its not worth it. If you can get the tools that were mentioned before, its very possible to do it yourself. It will be dirty, however. Safety glasses are a must. If you have a die grinder, its even better with a cutoff wheel than a drill. For the exhaust parts, if you want to go aftermarket, FCP Groton, (www.fcpgroton.com) has what you need for a reasonable price. For original parts, Tasca Volvo (www.tascavolvoparts.com) has OEM parts at employee prices and ships to your door.


Regards, Jon 'Uncle Olaf'

Just got my OE Volvo system from Tasca. It's a 1992 940. The price was $169.64 delivered to my door. All OE parts, it fit perfectly. Be sure to notice that there are 4 clamps supplied, but one clamp is a smaller diamter, it fits the header pipe. I didn't discover this until the system was all installed, so it took me about 20 minutes extra to switch the clamps around.

That's not a bad price. Is that the entire system aft of the cat?

I remember making the same mistake with the clamps when I replaced mine a few years back. There's such a slight difference in diameter that they should label them.

Yes, entire system back of the cat. Can't beat the price and the system fit perfectly.

Actually, the clamps are stamped with the diameter, I just missed it when I put it together.

"...For original parts, Tasca Volvo (www.tascavolvoparts.com) has OEM parts at employee prices and ships to your door..."

Plus, Volvo will give you a lifetime warranty on the mufflers - at least they used to. If you go that route, get the hanger kit also. It gives you all the rubber straps etc needed for a true plug-and-play installation. It's probably a little more expensive to go this way than with some of the aftermarket systems, but you know they'll fit correctly with minimal hassle. The build quality is also predictable.

Here are the tools to remove less a wrench or two. The cut off wheel is attached to a nut and bolt, chucked on an electric drill. PB plaster, a chisel, hammer, crowbar, gloves and vice grips. It is mostly leverage, a little cutting and safety glasses. The soap was used to install the rubber hangers during installation.

Replace with new parts. It is almost impossible to remove old rusty exhaust parts without destroying it.