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The exhaust pipe going into my rear muffler has rusted through and the rear muffler is now hanging and swinging on the hanger brackets. A well-respected local independent Volvo shop provided a preliminary estimate - they haven't had a chance to look at the car yet - of $250 to replace the connecting pipe and rear muffler. They estimated $350 to replace both front and rear mufflers. My question is whether it is foolish to only replace the rear muffler and more cost effective to do both at the same time. I do not really have time to try to do this project myself.
Any advice or perspective would be appreciated. And should I try to track down a stainless exhaust for this project? The car only has 43K miles on it.
Thanks,
Markus
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'85 240 DL with 39K miles, '94 940 with 192K
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This is a car that sounds like it has a long life ahead of it. I think it might be a candidate for the full cat back 304 stainless outfit, and it would be good forever. I think about $350. on EBay. If you spread the cost over the life of the car and it's potential for several exhaust systems, it think it would pay back well. It would also be a big selling point if you decide to sell. I know it would impress me.
There's stainless and there's stainless. Walker makes mufflers out of Grade 410, 12% Chromium, Quiet Flow, that fit 240's. This grade is good, lasts around 10 years in the East, and 410 what all stainless auto exhausts are made with.
The trouble with this is that I don't think you can get the connecting pipe without having it custom made, and taking them apart to replace the pipe is very hard on mufflers, so you lose some of the advantage
This system that's being sold on EBay, Swedish auto parts I think, is made in Europe from Grade 304, 18% Chromium and 8% nickel, and that will last forever, maybe longer until there's nothing left except the exhaust and the bronze brake lines. For what it is I think this is a great deal and it includes the stainless clamps which are a must. Installation wouldn't be any more than what you're looking at now. Have a look.
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Upon further thought, I think it may be that you don't need to replace either muffler. My experience involves 2 240's, an 80 and an 87, that I salvaged. Both cars had their original mufflers , and these were constructed of stainless steel double wrapped in a galvanized shell. The galvanized looked ragged and I only discovered their construction when trying to cut off a nipple with a torch.
Why they would build them that way I can't say, but all 4 of those salvaged mufflers are still being used today in the north east. Their galvanized shells are long gone. The way to tell is by looking at the end plates, or the mountings. A little Scotch Bright will help.
If you have the original exhaust on your car, it may very well have these stainless mufflers. My feeling is that they are well worth the extra effort required to remove and refit them to new pipes, however your installer may not share my enthusiasm.
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Do you really think Volvo is making exhaust systems for 240s? They havent made the downpipe or cat in at least a decade. Its either Bosal or Starla/Walker.In other words same aftermarket system/kit you can buy anywhere.
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joekidd wrote--"Do you really think Volvo is making exhaust systems for 240s? They havent made the downpipe or cat in at least a decade. Its either Bosal or Starla/Walker.In other words same aftermarket system/kit you can buy anywhere." While it's true that Volvo probably doesn't make exhaust for the cars--manufacture farmed out as it is in the case of many components---the difference (if there is) would be in the specs of the product. Volvo mufflers had welded joints where the aftermarket has folded seams. That's where I'd look to see if there's really a difference. When I worked in a Volvos only repair shop we installed factory kits. Now I'm on my own and every penny counts--have replaced the exhaust--cat-back on both my '80 245DL and '84 245Ti in the past two years--both times with aftermarket - either Starla or Walker - the last ones (for the '84) had a Starla sticker pasted right over a Walker sticker - or maybe it was the other way around.
When my son had his Mini-Cooper/ BMW repair shop he used Borla products and was happy with them.
Whatever the OP decides -- he should use the factory original full circle clamps - some of the mail order stores list them. -- Dave
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If all the old exhaust system is the same age I'd just replace it now and be done with it. What is the condition of the mufflers? If one muffler is rusted through the other can't be far behind.
Dan
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My wife's car is a 1990 240 with 46K miles and all original exhaust. The axle pipe has a big crack right before it goes into the rear muffler. I had the same question for my indy. He had me stop by and looked underneath and said the mufflers are still good. He wants to just replace the axle pipe only, and keep the Volvo mufflers. He believes these are better than anything aftermarket. This is a large indy shop. I trust his experience.
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240 exhausts from a Volvo main dealer can often be well priced. They will also be better or at least similar quality to the Walker / Bosal systems found elsewhere. You can also get a good guarantee with them at the dealers. The place you have the rust is unfortunately pretty common and seems to a bad design at that point. At least shop around a few dealers and ask for best price before going aftermarket. SS systems are expensive and often don't fit well, but it's your choice.
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I will also add, don't let them weld it together.
Dan
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Something satisfying replacing the entire exhaust, from header, cat, all the way back.
Derek, you mention Bosal / Walker. What of Starla brand? I thought Starla was good. (I don't recall right now.)
Markus, indeed, we can replace the entire exhaust system on a RWD drive Volvo.
You'd need to use axle stands or chassis braces on the axle point. Extra points for redundant axle stands, lift, or chassis braces.
Failing exhaust removal is very dirty and can be incredibly difficult. Installation is easier. You may need to use cutting tools to remove it if the rust is bad.
There is a bracket that secures to several bell housing bolts on the North America passeneger side.
To that bracket, an L-shaped bracket secure between the bracket on the bell housing bolts and the end of the header pipe just before the cat converter inlet. You utterly MUST secure the end of the header pipe. It is a rather critical union that must be sealed. At least inspect it.
You'll want to at least verify the integrity of the piping from the cat converter forward. Verify the three header pipe to exhaust manifold nuts are tight and that the union does not leak. These nuts sometimes come loose as they do not have lock washers sometimes.
Also, the hardware that secures the header pipe output to the cat converter input is a rather small diameter hardware from the factory. If the union is loose, or the hardware rusty, and frail, yet the cat converter housing, pipes, and internal honeycomb substrate are good, reuse it.
I took my cat converter to a machinist, who presses out what remained of the thee studs on the 1991 240 sedan cat converter. I went one or two sizes larger in diameter using quality since-plate carbon steel. I dunno if you can find quality stainless for high heat, somewhat high torque applications.
Questions?
Hope that helps.
Happy Friday, everybody! Or, Happy Sat-Your-Day eve!
cheers,
Duffy's Tavern. 337 Main Street. Chico, CA.
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KGV /King George V
I just pulled those two brands out of the air, wasn't meant to be a recommendation. I'm in the UK so although all three makes may be available, if you go to a quickie exhaust place you're at the mercy of whatever they get from their suppliers. Going to Volvo, you at least should get something that they approve of.
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Hi Derek.
I understand and thank you.
I dunno who makes OEM exhaust for Volvo now or back in the day. Anyone?
Bosal / Walker / Starla are brands not installed by the Midas / Meineke tire and brake store chains in the states, unless that as changed. Independent shops may be better on selection. Maybe one can buy the parts and have the exhaust shop install it? (Unlikely, huh?)
One could look at iPd USA and FCP Groton's sites for what they offer.
I have the larger cat back diameter Turbo Exhaust on a 1992 240 GL. So, I have a single resonator / muffler. Loud, and awful and annoying and makes the whole car shake. A baffle or more may be broken inside. I mean to replace it.
Thank you,
Carrot Cake and Earl Grey Tea.
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