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

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

xHeart
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Volvo Repair Database 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by xHeart » Sun Jan 05, 2014 8:47 am

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.
Image

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?
Image


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Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +140mi/225km | 2001 V70XC 1st Owner +190mi/ +305km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

xHeart
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Re: 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by xHeart » Fri Jan 10, 2014 8:19 am

There are two sizes 88" and 90".
Aluminized steel - walker $200, replacement $130, bosal $190, starla $225, and volvo $300


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Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +140mi/225km | 2001 V70XC 1st Owner +190mi/ +305km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

xHeart
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Re: 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by xHeart » Sun Jan 12, 2014 10:09 am

A little more homework...
The OD measurement of exhaust pipe is 2", and the rusted adapter clamped over the CAT measures 1 7/8" OD.

Since rusted, it needed aggressive brushing to find the head and tail which resulted in more noise generating exhaust. Nonetheless, it appears there is one adapter that goes over the CAT, and the other adapter goes inside the muffler. Not sure if it is just one adapter.

I may use cut-off rotary tool if clamps do not come off as nuts and threads are rusted. If I decide to use adapter and clamps for this repair, would it require using Permatex Exhaust and Tailpipe sealer, or likes, to prevent leaks at each joint?


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Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +140mi/225km | 2001 V70XC 1st Owner +190mi/ +305km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

joe_pinehill
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Re: 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by joe_pinehill » Sun Jan 12, 2014 10:16 am

Exhaust work in one thing I almost always take to a garage for now, I'm too old for it. Without a lift its PITA


96 850 GLT
RIP '90 240 DL, 285K, someone ran a stop sign in front of me
RIP '89 760 Wagon, 200K
RIP '83 240 Wagon, rusted out

Ozark Lee
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Ozark Lee

Re: 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by Ozark Lee » Sun Jan 12, 2014 1:55 pm

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.

...Lee


'94 850 N/A 5 speed
'96 Platinum Edition Turbo
Previous:
1999 V70XC - Nautic Blue - Totaled while parked.
1999 V70XC - RIP - Wrecked Parts Car.
1998 S70 T5
1996 850 N/A
1989 740 GLT
1986 740 GLT
1972 142 Grand Luxe

xHeart
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Re: 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by xHeart » Tue Jan 28, 2014 8:56 am

Thank you for the reply Lee.
Consensus are to DIY - repair and replace the portion connecting CAT and MUF, cost effective.
I would use two adapters and clamps, do I need joint sealer?
What would you change?
MVS_1056.jpg
repair kit...
MVS_1056.jpg (388.65 KiB) Viewed 3012 times
MVS_1057.jpg
joint sealer
MVS_1057.jpg (647.17 KiB) Viewed 3012 times
MVS1058.jpg
direction for using joint sealer
MVS1058.jpg (203.97 KiB) Viewed 3012 times
Last edited by xHeart on Tue Jan 28, 2014 9:33 am, edited 1 time in total.


--
Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +140mi/225km | 2001 V70XC 1st Owner +190mi/ +305km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

Ozark Lee
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Ozark Lee

Re: 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by Ozark Lee » Tue Jan 28, 2014 9:15 am

I've never used joint sealer when replacing stuff. I have tried to use the "muffler bandage" products to fix a big leak and they were a total waste of time and money. On the other hand, I can't see how the joint sealer stuff could hurt anything when used in conjunction with new couplers and clamps.

...Lee


'94 850 N/A 5 speed
'96 Platinum Edition Turbo
Previous:
1999 V70XC - Nautic Blue - Totaled while parked.
1999 V70XC - RIP - Wrecked Parts Car.
1998 S70 T5
1996 850 N/A
1989 740 GLT
1986 740 GLT
1972 142 Grand Luxe

xHeart
Posts: 2440
Joined: Sat Dec 03, 2011 8:05 am
Year and Model: 1997 854 NA
Location: Great Lakes - USA
Has thanked: 16 times
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United States of America
xHeart

Re: 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by xHeart » Tue Jan 28, 2014 3:49 pm

Ozark Lee wrote:I've never used joint sealer when replacing stuff. I have tried to use the "muffler bandage" products to fix a big leak and they were a total waste of time and money. On the other hand, I can't see how the joint sealer stuff could hurt anything when used in conjunction with new couplers and clamps.

...Lee
Thanks again Lee.
I will take up the task coming weekend.
Counting on my 3" rotary tool to cut away the old, with your often reminder of "safety first".
I will post the results.


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Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +140mi/225km | 2001 V70XC 1st Owner +190mi/ +305km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

j-dawg
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j-dawg

Re: 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by j-dawg » Tue Jan 28, 2014 4:36 pm

if you're doing slip joints like that repair kit, i've always found sealer to be a good thing. give it the beans after installing - heat helps cure the goop.

if you have a welder, consider welding a nut onto one half of the joint and a little bolt flange onto the other. do this on each side of the pipe. then you can use the nut and a bolt to draw the two halves of the joint together. if they're tapered, this will get you a good seal. if not tapered, at least it will prevent the two halves from moving with respect to each other, so the sealer doesn't crack off.


1999 V70 T5 5-SPD | ~270k mi | burns more oil than gasoline

xHeart
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Joined: Sat Dec 03, 2011 8:05 am
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Re: 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by xHeart » Wed Jan 29, 2014 1:05 pm

Thanks J -

Other than the two ends, the rest of the muffler would last longer than I think, hence the repair and NOT replace.

The MUF side coupler 1-3/4" ID would sleeve over the one on the CAT side 1-3/4" OD. It would give an overlap of close to 1-1/2". That is where I intend to use the sealing joint, no clamp here.

The 1-7/8" OD would slide inside the MUF. Now I am wondering if I use the sealing joint at this connection or just clamp it, OR do both - seal and clamp?

On the CAT side, the sensor is inches away from the end where the coupler goes over the CAT. I am thinking about just using clamp over the coupler for the CAT connection. What to watch for at this sensor location, and when I take off the bracket?

Any handling instruction at CAT and MUF, are the rubber hangers coming off the hooks/brackets?
I have a 2 months old exhaust manifold.


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Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +140mi/225km | 2001 V70XC 1st Owner +190mi/ +305km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

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