I have had the connection between the headpipe and catalytic converter fail on all the models of Volvos I have owned. The failure is rusting away of the bolts and flanges on the pipes.


The only way I have been able to deal with this is to buy a new headpipe (about $95) and new cat ($125). A lot of money considering the cat and pipe are fine and usable.

For those not oriented, here is a view of more of the underbody of my 245, front is to the right.


The bolts and nuts I can cut out and replace, and I have started using stainless for those, but the flanges are impossible to replace as new ones ,which I have no idea where to source, cannot be put on over the flare at the end of the pipes.

(this is from a 945 turbo)


I had thought of just replacing with a short connector pipe, cutting off the flares, but I think the pipe bend and short distance to the converter will not work with that idea.

Was considering taking the pipe and converter to a muffler shop and have them weld on one flange (if they had one), but then the other would have to rotatable and some how be gotten past the flare.

Anyone solved this dilemma? I don't even know where to get new flanges.


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84 242Ti IPD bars&springs, 89 745 16v M46 IPD bars, 89 744 16v M46 IPD bars, 93 945 Turbo AW71, 91 245SE AW70 IPD bars, 93 245 CLassic M47