My kid started driving a couple of months ago and now the '90 240 wagon he's been using needs a header pipe. He can't explain the scuff marks on the pipe and I can't explain how the welds cracked on such a solid pipe.

Is it best to get the replacement from the dealer or are there perfectly good aftermarket exhaust parts out there? As with most things Volvo, I am concerned about ultimate durability.

Thanks one and all,

Rich

No explanation is needed, he ran over something, period, end of story.

Those down pipes do crack though, I had it happen without hitting anything.
I put in a used one and it has been fine. Should be no need to drill anything out, just soak all bolts liberally with PB blaster for few days before you loosen. Use 1/2" drive sockets and extensions, you may need a universal joint thingy for one of the 3 bolts at the manifold. A bit of heat from a torch may help too. Get a new gasket for each end.
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David Hunter

He can't explain the scuff marks on the pipe and I can't explain how the welds cracked on such a solid pipe.

I can easily explain it: My kid started driving a couple of months ago

Have you really forgotten what it was like to be a teenager?

Go with the aftermarket, there really is nothing to the pipes except them and the welding. Here is a tip though,

you WILL need metal drill bits. the joint for the cat. and the headers have bolts that need to be drilled. then replace them with new ones, 5/8" is what i replaced them with. don't exactly remember the bit sizes, but it took a few to work up to the 5/8" hole. Also use a hack saw to separate the cat from the old headers, you'll see what I mean once you get it out.

besides that it is easy. but you will need to drop the whole exhaust, minus the manifold. oh, and don't forget new gaskets.

good luck
chuck
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'88 244 174K, '87 BMW 325e 180K (used to feed a '84 245, '84 244, '85 744)