1996 854na muffler replacement

[eriscentro]

Hey guys-
I put 1K on my 850 this weekend, and at the beginning of my 500mi return trip, I noticed that the car sounded weird and raspy. I was on Rt 80 when I noticed this, some miles from home, so I couldn't really take an in depth look. When I got to my destination, I found that the exhaust pipe had broken at the rear hanger mount, and was pushed up into the bumper, and melted a hole in it. It happened right after I did an oil change, so I figured it had something to do with that, but thankfully not. Today, I took a trip to the mechanic, and when he lifted the car up, the joint between the muffler and the catalytic converter had a huge crack in it (see attached). He told me he could not weld it back together, and that I'd have to replace the whole pipe from there to the back of the car, IE the whole muffler assembly. He quoted me 400 for a Starla 18275 muffler + 70 for labor. He then quoted me 245.60 for a walker 18932 muffler, which he said was a POS. I looked up the Starla model, which he said was OEM, and found that it was 200 at eEurpoarts. He told me he'd happily put that part on for the same labor price. This is the first time visiting this mechanic, since the car is at school with me rather than home, so does all this sound reasonable? He mentioned that there could be leaks coming from elsewhere and that we won't know where until he takes care of this one. Unfortunately I have my PCV system to do as well, but I'm hoping to save that for later on (smoke, plus a glove fills up a little bit).
Edit: He told me there was no way he could weld it or splice/patch it
Thanks, Ben

[dosbricks]

I'm no expert, because we have southern cars with only surface rust on the exhaust, but looking at yours, I would say that pipe is rusted too thin to repair and too pitted to count on in the future. Also the break is right behind the joint which is a sort of compression fit. Looks like the mechanic is giving you a straight up answer and the $270 combo price you have put together sounds decent considering he has a lift and we DIYers do not.

[erikv11]

To replace the pipe and the muffler, he will have to weld a pipe on up near the current hole so I am unsure why he would say "there was no way he could weld it or splice/patch it"

You haven't mentioned anything about the muffler being bad so I'm not sure I would replace it.

The break in the picture is a very common one, I have taken in two Volvos for that break and they repaired each one with a short piece of pipe, cost was $40 once and $50 the other. A muffler shop will have no problem replacing sections of the pipe in question, you may want ot visit one for an estimate/opinion. Not Midas or any chain store, but something like "Joe's Muffler Shop" where they know how to weld cheaply and quickly.

All that said, $270 is not a bad price for new pipe behind the cat and a Starla muffler installed, so in the long run that wouldn't be a bad route to go, assuming the mechanic is competent.

[eriscentro]

He told me right off the bat that there was no way to fix the current one, and that a muffler will have to be put on, since it's the whole assembly. Price wise, with the coupon code for eEuroparts from MVS the whole deal should run about 280. The muffler and clamp combined will be right below 200, and he quoted me 70 for labor, which after tax should be 80. I could take a trip to a muffler repairman and see what he has to say.

[eriscentro]

Hey guys, quick question. The noise has gotten much louder after about 50 miles. I can take the car to a muffler guy to take a look, but even if he can weld the crack back together, will it actually hold for some time? Is it worth the ~280 just to put the new starla muffler on? On an unrelated note, I did a full synthetic change in the car for the first time, and noticed some fluid under the engine compartment with a stain around the drain bolt. I guess I'll have to take a look at that today, and I'm really hoping it's nothing major.I checked the oil level and it seems fine and doesn't appear to have lost any, but all the other fluids seem to be okay too.
Edit: The plug was brand new with a new washer from Autozone

[erikv11]

If a muffler shop can fix the crack, and I am almost certain they can, it will be by welding a short piece of pipe in its place for about $45, and that repair will last for years. Your exhaust looks only a little worse than the ones I have dealt with here with our salty midwest winter roads. However it will also need minor repair at the hanger, right? It is not a bad route and I would go that way unless you are intending to run this car for several more years and/or the 300 is not a big expense for you.

The stain sounds like a leaky drain plug, like someone once overtightened it.

[eriscentro]

If a muffler shop can fix the crack, and I am almost certain they can, it will be by welding a short piece of pipe in its place for about $45, and that repair will last for years. Your exhaust looks only a little worse than the ones I have dealt with here with our salty midwest winter roads. However it will also need minor repair at the hanger, right? It is not a bad route and I would go that way unless you are intending to run this car for several more years and/or the 300 is not a big expense for you.

The stain sounds like a leaky drain plug, like someone once overtightened it.

I guess this weekend I'll head over to a muffler specific shop and have them take a look. If the weld repair is between 50-70, spending 4 times as much to have an all new muffler as well as a new cat clamp may be more sensible in my opinion. The hanger on the pipe currently is a coat hanger . For the oil, the bolt was EXTREMELY tight when we removed it, and we needed to hit the wrench with a hammer to finally get it loose. I didn't tighten it too hard when I put the bolt back on. Probably only about 30-45 degrees after it encountered resistance.

[xHeart]

After throwing good money, this will help a little https://www.matthewsvolvosite.com/forums/viewtopic.php?f=1&t=61022

[eriscentro]

Brought it to a reputable muffler shop. For 75 + tax, he cut the crappy rusted parts out, and spliced the cat and muffler piping. He also put a new bracket on the tail pipe. When I drove out of the parking garage to get the car fixed, I'd swear that you could hear the car at any point in the entire structure

[erikv11]

Awesome. You gotta love a shop that know how to weld.