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Exhaust removal 700 1989

I've ordered the Volvo exhaust kit and am planning to change my exhaust this weekend.

The FAQ has a section about using a cutting tool to remove the exhaust from the Cat. Is this necessary/usual? My front muffler is original or a Volvo replacement so I don't think a muffler shop would've tinkered/welded the connection there.

I'm trying to determine if I'll need to get a cutting tool or torch prior. I'll borrow a tailpipe cutter from Autozone. Would the Tailpipe expander be useful to borrow as well?
--
Paul NW Indiana '89 740 Turbo 110,000








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    Exhaust removal 700 1989

    gte hold of everything u can..my experince is cut the old system up on the car and remove in pieces, haet every joint you have to split and hit it with a bloody big hammer.....but then again i was removing the nasty fragile cat whilst doing this and skiping it!








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    It’s All About Leverage 700 1989

    You start off with the normal tools and keep going back to the garage for more. I used the cut-off wheel to slice the resonator pipe lengthwise at the cat, not all the way through, and again at the muffler. The crow bar was used to spread open the cut without damaging the cat pipe and the dish washing detergent was used for installing the new rubber hangers. Vice grips were used to peal back the old pipe.
    --
    Tom F. Three 940s. '93 T-Rex now running. Mods, RainX. Lien holder on two more (the kid's). Rust In Pieces, '78 245









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    Exhaust removal 700 1989

    In EVERY exhaust job I've ever done I've had to use some kind of cutting tool to either make the job possible or easier. I'm partial to a cheap Harbor Freight 4" dia. 1/16" cutoff wheel for both bolts and pipe. It WILL help to cut the pipe in front of the rear axle to remove the exhaust pipe. Cutting the pipe behind the cat also makes the bolts easier to get to that hold the pipe to the cat.

    A compressor and an air impact wrench are also useful...some of the bolts may come apart (or be broken when removed...results are the same..the pipes are off!) and in any case use new bolts. Use antiseize on them too!

    You may also need a new rear muffler mounting bracket...they don't come with the muffler kit and they're often unremoveable from the rear muffler.








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      Exhaust removal 700 1989

      I'll have an exhaust pipe cutter to cut pipes and a grinder. My concern was getting the pipe off the Cat without damaging the cat. I don't have a dremel tool, yet. Is the dremel tool neccessary to slit the pipe to get it off the Cat or can I just cut the pipe near the connection and use a tailpipe expander to expand the sides and push out the crimpes to get the pipe off?

      This is the expander from Autozone





      --
      Paul NW Indiana '89 740 Turbo 110,000








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        Exhaust removal 700 1989

        I have never done any muffler work until I changed them on my 740T and this week on my 940T so I don't have much experience. I did find that it was pretty easy to use a dremel to cut down the side of the pipe, pry it a bit with a large screwdriver and squirt some blaster in it. Then you can rotate it back and forth until it comes off. Not that bad of a job unless you have severe rust I suppose. It is funny such a little tool helps to get a muffler loose.

        R Duke







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