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Hi Marty,
This job can vary a lot depending on the rust due to short trip driving or your road salt. I've done it a half dozen times at least, on 240s a lot older than a 93, so I can tell you to go for it, without hesitation.
I've used both the Starla kits and the Volvo kits. The Volvo cat-back kit was absolutely the dreamiest under car exhaust work I've ever had to do. Everything fits right and the kit is complete. Caution here, I've just read a couple accounts on the forum where the Volvo kit is now an over axle scheme. I have not tried that one yet, and don't particularly want to.
You should be able to snap the clamp bolts with a wrench, or if badly rusted, large vise-grip pliers. Torch not necessary. Worst case; hack saw. The only clamp you need to remove is the one in front of the resonator, then just drop the whole assembly as a unit. I usually wind up coaxing the pipes apart, once the clamp is gone, with the help of the two pound maul. Anything with a bit of inertia will move the pipes apart until it drops. That is the most difficult part, and not bad at all.
Then, assemble the new parts loosely on the ground. A bit of balance required, but you can guide the front muffler onto the cat pipe with an arm outstretched holding the axle pipe, holding the rear muffler up on your chest. Once connected, the pins on the rear muffler are locked into the hangers, and the second most difficult part is left.
Getting the ears on the front muffler (resonator) hooked to the bracket under the car is tough, unless you can boost the muffler toward the floor with a jack. Then I use a pair of large screwdrivers to aid in stretching the big hanger o-rings over the resonator's ears.
The Starla kit goes on the same, and it does fit well too, but when you pay close to half of the dealer price, the oohs and aahs just are not expected. I wish I could be more specific about the differences.
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Art Benstein near Baltimore
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