Hi folks,

I need a decent used exhaust for any year NA 240; my 245 needs to soldier on for another year or more until it succumbs to rust and I would like to avoid the cost of new bits if possible. My manifold is cool but all the other bits are more welding wire than original steel at this point and it's time to swap out the old Swiss cheese setup for something that will pass inspection. I'm in Boston and would pay cash, naturally. Please let me know if you can help; I have email notifications on this message so shoot me a note and I'll respond fast. Thanks!

~Sam

I got a new exhaust front to back from advance auto for around $160.00 two muflers,catalitic converter, all hardwear included. nice!

WHOA! Really? Can you post a link please?

rockauto has a walker cat back for $93 shipped cant beat that, plus its better quality than starla imho

Wish I could help, but I'm currently turning my own exhaust into "more welding wire than original steel." If you must buy new, avoid the OE Volvo cat-back system, and note that Volvo has a new part for the catalytic converter: 8551606. Tasca has that cat for a little over $100, eEuroparts.com has it for $128. Make sure to match the flanges on that and the header pipe. eEuroparts.com also has the best price on a cat-back system at $165 for the Starla parts. Still not a cheap endeavor, but...

Did you try your local boneyards? I'm in MA too. In the Cape area try Robertson's in Wareham or Handler's in Harwich. In Freetown there is a Volvo independant mechanic who used to keep a fleet of 240's and other Volvo's out back. His name is Chuck Gurney. Definitely give him a call.

Chuck's Import Village
22 Gurney Rd.
East Freetown, MA 02717
(508) 763-2248

Thanks for the tip - I will keep that contact info handy. There really aren't any good local boneyards near me, at least not that I am aware of. The good ones where I used to live got absorbed by Greenleaf long ago, so those are totally useless. I also have to balance the value of my time... I'll suck it up and buy a new exhaust if I have to, I was just hoping someone close by had a full line wasting space in their garage and wanted to make a quick hundred or two cleaning up their space, or had a parts car they didn't need the line from.

You may want to consider Tasca as you are close to their location. Dunno about Volvo OEM.

I bought a cat back from iPD in 2010 as a kit for a 1991 240. Starla (big pieces and piping) and Walker and Bosal parts. Fits like socks on a rooster. The aftermarket rubber hangars deteriorated in under two years.

I've not yet grounded the exhaust to the chassis like at the tail pipe hangar. Grounding the exhaust to the chassis greatly slows corrosion. Use braided stainless. The tinned braided copper conductor is not so durable to the turbulence and heat under the car. A poorly grounded exhaust system can limit O2 sensor effectiveness and corrode prematurely (faster in salty and frozen places).

Be certain the head pipe in put flange is well secured at the exhaust manifold output flange. The three retainer nuts can loosen overtime shortening the exhaust gasket duty cycle. You may want to closely inspect the four gaskets between the cylinder head exhaust output and the exhaust manifold input. If they appear rusty and flaky, the four gaskets may require replacement sometime soon. I have to replace mine.

Be certain the hangar assembly securing the center the head pipe to two lower right bell housing bolts is secure. This connection is also a good ground point for 02 sensor operation. On one car, the upper plate with embedded nut fastener was gone, having rusted off. I had a spare bracket that would secure to the now missing nut in that plate. A discount muffler place welded the bracket bottom to the head pipe and secure it, using the two screw and single plate assembly, to the bracket secure to the two bell housing bolts. The head pipe is old yet sound. Use anti-seize compound. Molybdenum-based anti-seize compound may be better than lead-based.

Finally, you'll also want to be very certain the flanged connection between the head pipe output to the catalytic converter input is solid and does not leak. This exhaust connection is very critical and should be checked on occasion. Or have it all welded together, yet supported.

Maybe check 02 sensor and inspect the catalytic converter?

I found a catalytic converter-back section as won welded job in the yunkyard a few months ago. So, for 20$ for this catback section and one hour's labor labor welding. I brought extra Volvo rubber hangars since the after market ones deteriorate so quickly. Exhausts sounds like it should. Welding is cool.

Hope that helps.

cheers,

dud.

FWIW - This goes back about 5 years, but I bought a cat-back system for my 90 from Boston Volvo for @ $150.

Hi,

The kit from Tasca about 2 years ago was $160. A Bosal cat. converter from Partsgeek.com was about $80 last year and a header pipe from Tasca 4 years ago was $150. If you needed to buy new your best bet is probably FCPGroton, FCPEuro (sometimes their prices differ), eEuroparts for kit & header pipe (free ship from all three places) & Partsgeek for a converter (don't know if they offer free ship). You could also tranfer your exhaust parts to another 240 after you need to get rid of your current one.

Travis