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I have read all I could find in Massages and FAQs, but I could still use some help.
I have to replace the exhaust on my 1995 940 Turbo Wagon from the catalytic converter back through the tail pipe. I have 2 family cars that are 940s, two Turbo, one non-Turbo. I have recently replaced the exhaust on the non-turbo from the cat back with an on-line kit from Starta ($200) and on the Turbo just the rear muffler and tail pipe from Advance Auto. Thus, the comments about quality and smooth curved pipes vs. rippled pipes now make some sense to me.
Now I have to do the job on the Turbo. I'm doing this to save money, as this is not work that is meaningfully different when done by someone skilled and careful (me) as compared to someone awkward and sloppy (them). So, I wonder whether there will be a significant difference in cost having it done by a place like NTB or Monroe compared to doing it myself.
I was surprised to see the recommendations on Brickboard for using Volvo OEM exhaust replacement parts. Generally, I shy away from any parts the dealer sells, except for those that are only available through the dealer, like the speaker grill covers for the doors. My recent experience of brake caliper pricing is the reason for this prejudice. Caliper: Volvo $200, Advance $50.
I recall the Starla parts fit easily. The pipe from Advance was sold to me with a recommendation to also purchase and return (Advance's method of renting tools) a pipe expander. Without the expander, I could never have assembled the Advance parts. However, the pipe expander was free to use and it worked very easily allowing me to control the fit precisely. So I have no real criticism of Advance. Plus Advance has a liberal return policy and my local store generously offers good advice.
My questions come down to this. Am I going to save enough money doing this job myself, to make it worth the time? (I work from home and have considerable time and flexibility). If I do it myself, where should I buy the replacement parts. One benefit of buying from Advance as opposed to an online kit, is I can buy only what I need. Generally I reuse the rubber hangers and the hanging clamp that surrounds the front muffler. It doesn't save a lot, but every little bit adds up. I will probably not be able to reuse the clamps, though.
A footnote. When I first heard exhaust noise, I inspected the pipes and found nothing. Eventually, I traced the problem to a very loose down pipe from the exhaust manifold. Due to the small space between the flange nuts, it was very difficult to get a socket wrench around one of them, but eventually I was able to loosen the three nuts (each has a second lock nut as well) and tighten it up. I felt pretty accomplished until my son started the car up and although the exhaust noise was reduced it was still present. Another investigation with my hands around the still cool pipes revealed an opening where the welded pipe exits the rear of the front muffler. In order to get passed inspection this month, I plan to pack that opening with some kind of putty, I hope to find at Advance. After I get the inspection sticker, I'll replace the exhaust from the converter back.
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