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240 exhaust replacement 200 1989

posted by  Stanley89 on  Wed Sep 28 13:10 CST 2016
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Hi there, recently have been working on replacing parts of the exhaust on my 89 244, the header pipe, cat converter, ox sensor, and manifold. Everything is so far working out fine, all except for this. There is a length difference between the old and new catalytic converter, which is too short. The old one looks to be the original and the new one is a walker i got off rock auto for a decent price. I was wondering if there is some way to adapt the one i bought so it will fit, or if i need to hunt down and get a new one? i'm looking around online and don't see anything much different than the one i bought. Any suggestions?








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    240 exhaust replacement 200 1989

    posted by  Volvo From Heck on  Wed Sep 28 14:09 CST 2016
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    last visit: Mon Oct 13 20:56 CST 2014
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    It'll cost you a few bucks but any competent muffler shop could weld an extension to your new cat. Are all the new parts from the same manufacturer? Sometimes mixing and matching brands can lead to this sort of problem. I replaced the cat and some pipes for a client's 240 a while back and remember how careful I had to be in ordering parts, what with differences in flange connections, O2 sensor location, etc. -- Dave








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      240 exhaust replacement 200 1989

      posted by  Stanley89 on  Wed Sep 28 16:55 CST 2016
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      I got both the header pipe and cat converter from walker. My old cat con is 36 3/4 and new ones 36 1/2 not much difference. O2 sensor in on the cat converter not having a problem there. There may be some size difference with the pipe, and may be the problem. Trying to find a longer one but I am having a hard time finding any differences, not sure if i should try another brand or not. The flange connections seem fine. I got my manifold from salvage yard, no problem there. I checked and double checked all product fittings and recommended brands.








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        240 exhaust replacement 200 1981

        posted by  81242DLB21FCA on  Fri Sep 30 20:48 CST 2016
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        last visit: Thu Oct 23 22:26 CST 2014
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        So if you bolt up the pipe to the end of the cat, the other end of this pipe is to short to reach the first muffler? If so, you can buy short lengths of slip-on pieces at an auto parts store.








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          240 exhaust replacement 200 1981

          uid 33936's pic
          posted by  TheBrickTank on  Sat Oct 1 19:10 CST 2016
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          last visit: Thu Oct 23 17:54 CST 2014
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          There is no way a 1/4" is going to make a difference as that pipe sits inside the muffler.

          Once you put the clamp in place and tighten the clamp, its not going to move, thus the reason for my comment earlier.

          Now if you had say a couple of inches, then you need an extension.

          I removed the first muffler from my set up and I needed a 20" pipe that I had made to make up the difference from the end of the cat pipe to the exhaust pipe.

          A 1/4" is nothing in the whole length of that setup. Things can me moved to make up that difference.

          Matt







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