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Hey folks,
I replaced the exhaust manifold on my 940 Turbo three years ago with a genuine Volvo part.
Over the past couple of weeks, I started hearing that all-too-familiar engine sound: tic, tic, tic.
I thought, “How is that even possible? The manifold and gaskets (Elring) were brand new!”
Well, today when I had the car at the mechanic’s to check the prop shaft, and he goes, “Man, you’ve got a nice crack in the manifold.”
Check out the photo I took, zoom-in under the nut and enjoy:
https://postimg.cc/dLKwpqGQ
There’s no sign of discoloration or overheating on the manifold, so clearly, it’s just another case of poor-quality Volvo spare parts.
Volvo offers a 1-year warranty, and the dealer in Germany tacks on an extra year—but obviously, that doesn’t help much with a part that failed after 3 years.
The dealer is sending the photo to Volvo to see if they can offer some kind of compensation.
When I bought it, the part cost $450. Now? It’s more than $900 for the same junk.
At this point, I’m seriously considering switching to a stainless steel manifold. It seems like a safer bet, though I do have concerns about thermal expansion and long-term effects.
Anyone here have experience with stainless steel manifolds and how they hold up over time?
Welding the existing manifold is not an option, it will not last and I do not want to go back there in a few years.
As always, thank you for helping me out with another unexpected one.
Alex
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Two Thoughts for you to consider:
1. I would be concerned about the noise level with a stainless steel manifold. Could be substantially louder??
2. This may be difficult considering the age of your car, but another far cheaper option would be to find a good used manifold. Here are a couple of companies with good reputations that specialize in used Volvo parts:
https://erievovo.com/
http://voluparts.com/
Voluparts is probably your best bet.
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Will I buy another Volvo??? We'll see....
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Hi,
First, I am well familiar with the two companies you recommend, they are indeed reliable suppliers.
1) I wouldn't think you have a difference in noise level with the exhaust manifold being in stainless steel, but I am hoping some one may chime in on this.
2) I went through that kind of thought/research before buying the new one in 2022, I then opted for the new one because all of that was available at the time is 'nice ones with minor cracks' so, I have no reason to believe the situation has changed, and eventually it would be for the worst, given that we are now in 2025, and there are less and less parts available.
I am really curious to hear from anybody else who went for the stainless steel version, I hope there is :)
Thank you,
Alex
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Hi Alex,
I put a stainless exhaust manifold in my 850 which had a broken flex section with no issues.
Purchased on Ebay, It was made in EU, Latvia or Poland?
Later I found out that one of the local Boston Muffler shops were welding aces,
and they could have welded in a new flex link and saved a lot of hassle.
If you do install the stainless exhaust you might order a set of titanium exhaust flange studs. I found mine at Ebay, Race Ti, UK (www.raceTi.com) less than $20 shipped.
I don't know if aluminum exhaust manifolds can be welded, but it wouldn't hurt to inquire.
If you can see the crack, plan B might be to try High Temp JB-weld which is designed to repair high temp cracks.
https://knowhow.napaonline.com/how-to-use-jb-weld-extremeheat/
This is worth a look, and easily wind up being Plan A?
Good luck, Bill
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Hi Bill and Alex,
Bill, interesting that you mentioned JB Weld. I used it on a cracked down pipe in my 240 years ago. Yes, it does work! At least on a down pipe. Whether it would work on a cast iron manifold with greater heat is another question. Maybe if the crack or damage isn’t too big? Worth a shot anyway…
I have never heard of a manifold being successfully welded but that doesn’t mean it can’t be done.
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Will I buy another Volvo??? We'll see....
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Hi All,
I am not even going to try that, the welding process has to be done by experts who do that every day, and I have never heard anybody saying this is going to last long, so no, I am not going that road.
I hope somebody with a stainless steel manifold will chime in, there must be somebody who went for that option.
Let's wait a couple of days and see.
Thank you all!
Alex
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Hi Alex,
I called my muffler ace and they do not weld exhaust manifolds.
He suggested taking it to a muffler ace to confirm its a cracked exhaust manifold because he's had a lot of misdiagnosed "Cracked manifolds".
You didn't comment on whether you can see the crack.
Did you read the item on the Hi Temperature JB weld? Maybe you can return it for your money back if it doesn't work?
Bill
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Hi Bill,
I posted the image in my first post, the crack is very evident.
I did not read yet the item on the Hi Temperature JB weld, regarding the money back, I am waiting for Volvo to reply, let's see, but I am not very optimistic.
On another forum they said that if I go for a stainless steel one, I'd need a new downpipe, new oil and water lines, and new intake and boost pipes.
Not sure why though, is it because of the difference in the material? If the connections are the same I wouldn't see why otherwise.
Alex
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Stainless steel runs hotter. Without researching the topic, that is my quick explanation for others saying you’ll need all those new parts…
JB Weld is a cheap ($6.99) fix. What have you got to lose? If it doesn’t work move on.
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Will I buy another Volvo??? We'll see....
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