Getting ready to replace the exhaust on my 242 from the cat back. Using the original Volvo pieces. I've done this before and it's pretty straightforward. However, I always seem to have some difficulty getting the rubber donuts on the mounting ears on the first muffler. A lot of grunting and groaning, and it seems I can never find a good angle to wedge them on. What are your tricks for doing his a bit easier ? I do warm them up before installing so they will be a bit more pliable. Thanks.

Mike

Art's idea is great! Another idea: I've found that it is always easier to fuss with the upper (chassis) mount. So, hook the rubber first on the lower (muffler) mount, put soapy water on the rubber, use your knees to push up on the muffler, and then slide the slippery rubber over the upper mount.

I've always had good luck: 1) installing the inner one; 2) prying w/ a 2x4 towards the outside of the car against the driveshaft; 3) rolling the 2nd rubber on w/ a large screwdriver.
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240s: 2 drivers and some parts cars

I've found a large philips screwdriver #3 works. Slip screwdriver between rubber and "hook", lever it on, slide out screwdriver.
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1980 245 Canadian B21A with SU carb but electronic ignition and M46 trans in Brampton, Ont.

what i do is put the exhaust system together outside the car and then put the whole thing on at once. works good! i give a final tighten down after install. i've done it even with the header pipe.
saves on the back pain pills!

i have not tried warming them up, because I learned in a physics experiment that heating a rubber band causes it to shrink rather than to lengthen -- something to do with the bonds among long polymer molecules.

On the other hand, when I bought new solid tires for a push lawnmower, the dealer said that the way to proceed was to cut the old tires off the wheels, then heat the new ties in boiling water before stretching them onto the wheels. It worked.

So maybe the tires are not rubber. Ditto for the donuts.
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jds

Hi Mike,

I've put so many of those on, I got tired of the grunting, groaning, and prying against nothing. Use a good sized zip tie as a come along.




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Art Benstein near Baltimore

We childproofed our homes, but they are still getting in.

Absolutely brilliant, Art, and thanks. Your phrase "prying against nothing" is exactly the problem. When pushing the muffler to a position where it was close enough to get the donut on, I always seemed to be one hand short to get the muffler in position and fiddle the donut over the ears. I knew there just had to be a better way lurking in the combined experience and brilliance of the Bricksters out there !!

Mike

INTERESTING...(AND INFORMATIVE AS USUAL.......)

BUT DO YOU LEAVE THE ZIP ON???? (AS EXTRA 'INSURANCE'????)

OR SNIP IT???
--CARLOS

No, I snip it. Probably wouldn't hurt though and not transmit noise, but I bet it would fall apart in a few months.

The extra practice begins when you get it hooked in and realize you forgot to put the clamp on.


--
Art Benstein near Baltimore

Accept that some days you're the pigeon, and some days you're the statue.

Gee, I certainly wouldn't know ANYTHING about shooting myself in the foot like THAT! Oh no, not ME! (Yeah, uh-huh, sure..) "the hurrier I go, the behinder I get." Thanks for another great tip as well as another "too true" picture, Art!

Something tells me that Art may just have a photograph for everything!

Fear not! Even the professionals forget to put the clamps on. :-)

-Ryan
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Athens, Ohio
1987 245 DL 324k, Dog-mobile, E-codes
1990 245 DL 137k M47, E-codes, GT Sway Bars, GT Braces, Dracos
1990 744GLE 189K 16-valve project
1991 745 GL 304k, Regina, 23/21mm Turbo Sway Bars

ART--

YOU ARE A TREASURE, INSTRUCTION AND MIRTH IN THE SAME THREAD.........

I GUESS YOU JUST HAVE TO LOOK AT THE 'PICTURE' AS A PHOTO OP, TO BETTER SHOW THE WHOLE CLAMP.....RIGHT?????
--CARLOS

Art
Brilliant, I love it.
Dan

Two good flat head screwdrivers. Put one donut on one side for muffler and car. I save the one toward the middle of the car for last. Put this donut on the muffler, and then use one screwdriver to pry it up towards the "ear" on the car. Use the other screwdriver to get it up and over the lip. Keep alternating 'til you get the donut all the way around.

Also, I use some good rope to do kind of a trucker's hitch to stretch the muffler towards the ear on the car. Makes it a lot easier. Put the rope through the donut before tightening it up.

After figuring these two tricks out (and getting a sawzall to "encourage" the old stuff to come off!), I don't fear this job anymore.

-Ryan
--

Athens, Ohio
1987 245 DL 324k, Dog-mobile, E-codes
1990 245 DL 137k M47, E-codes, GT Sway Bars, GT Braces, Dracos
1990 744GLE 189K 16-valve project
1991 745 GL 304k, Regina, 23/21mm Turbo Sway Bars

I remember replacing an exhaust system and finding a screw driver wedged in the doughnut to be removed.

The only thing I use ArmorAll on anymore is rubber pieces that I want to lubricate. I use it on the exhaust donuts.

I leave everything loose. I do not tighten any of the clamps until everything else is in place. That seems to allow a bit more flexability in getting the hangers in place.

I slip the donut onto the shaft of a screwdriver and position it on the hanger so I can stretch the donut and then slide it onto the hanger with my other hand. A little lube on the shaft of the screwdriver helps.

The muffler has one side that is easier to get on than the other in my experience but I can't remember which side that is...

Finally I grunt and groan like everyone else until I have them all in place and tighten the clamps. I don't tighten them enough to deform the pipes so that when I need to replace a single component I can get the system apart (relatively) easily.

As an aside I will throw out the fact that years ago I learned (the hard way) that any time you are working under a car looking up it is wise to wear safety glasses. Having someone with a medical degree remove iron oxide from your eye cancels the cost savings of replacing the exhaust system yourself.

Randy

A great reminder here on the safety glasses. Those precision mechanisms don't like contaminants falling into them!

Those precision mechanisms don't like contaminants falling into them!

The replacement costs are out of sight.....

I've never really been able to see eye to eye with my optometrist..

Thanks, Randy,

Seem like I am doing it "right" after all. I heat the donuts a bit and then spray them with something like silicone or Armor-all and use the screwdriver as a wedge. I think last time I did this I hung the front muffler first, before attaching pipes, so I had maximum wiggle room to move it around to get a better angle. Supported it with a jack or block of wood, too. Still a bit clumsy, and as I remember, the outer donut is a bit easier than the inner one. Ditto on the safety glasses. Rust is not good for the eyes, and, as an aside, doesn't taste real good either.

Mike