Fix a Rusted Exhaust on a Volvo

MVS contributor xHeart documents fixing his rusted, broken, leaking exhaust on his Volvo. This saga included a Class A fiasco on the part of Parts Geek

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Need to fix a rusted exhaust on a Volvo? MVS contributor xHeart documents fixing his rusted, broken, leaking exhaust on his Volvo. This saga included a Class A fiasco on the part of Parts Geek shipping mislabeled and dented exhaust, then shipping an exhaust for a completely different Volvo. What a mess.

The two ends of exhaust muffler are deteriorating. The tail was repaired by inserting a foot long pipe and putting clamp to keep it in place.

Below is a photo of where muffler meets the CAT. There are two clamps over 3-4in adapter connecting the two. The adapter is visibly rusted and it has 1″ of open hole, hence I ask:

1) Was the muffler short, so to make up the adapter help it reach the CAT?
2) Is the CAT short, trimmed off for…?
3) If replacing muffler what make and size would work best?
4) Step for undoing the two clamps and then removing the adapter?

Nonetheless, the coupler inside the exhaust is stubborn. I have separated the exhaust lip from the coupler layer to see if there is a weld getting in the way from sliding out.

Few photos of progress. I will files the exhaust lip before installing new coupler. Any pointer for removing the coupler?

MVS moderator and generous Volvo help dispenser gives his experience:

I replaced a Bosal on my son’s car. The pipes were pristine but the muffler itself had rotted in half and the hanger arms rusted off of the body. The back pipe can be repaired with a chunk of tailpipe, a coupler, and a couple of clamps. eEuroparts has a tailpipe hanger that is real easy to install and it is cheap, around $8.00.

On my son’s car I had to replace things in pieces. The Pick-n-Pull car that I bought the used parts from had the car about two feet off the ground but that wasn’t enough clearance to get everything out without cutting off the tailpipe about 1/3 of the way back on the straight section.

The pipe diameters will vary depending on what kind of muffler you have now. I left the Bosal pipe from the joint between the catalytic converter to the muffler but it was a larger diameter than the stock pipe so I used an adapter coupler.

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Then the decision of which replacement exhaust to buy:

There are two sizes 88″ and 90″.
Aluminized steel – Walker $200, replacement $130, Bosal $190, Starla $225, and Volvo $300

Then disaster:

STARLA arrived today.
Looks beat up. Are these dings a problem?

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Then things got REALLY weird:

The customer services is mute. A quick research… Peeled the Starla sticker and discovered Fonos, notice MK 85616…

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1997 Volvo 850/na – Fitment and make of exhaust muffler

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