Replacement exhaust

mikkowus · Post by **mikkowus** » 29 Oct 2018, 10:47

I recently bought a 2004 volvo xc90 2.5T AWD. The rear muffler is pretty much done and needs to be replaced. The resignator pipe where it attaches to the rear muffler is very rusty at the clamp. So the resignator/pipe probably needs replacing too. The fitment of the exhaust on the car now looks like it is made by walker. It looks very similar, fitment wise to this https://www.rockauto.com/en/catalog/vol ... +kit,10727

The thing has about 140k miles on it and I am planning on bringing it over 200k miles if possible. What would you guys suggest for a replacement? Bosal? Walker? Some more expensive longer lasting system?

A Bosal system looks like it would cost less than $200... https://www.rockauto.com/en/catalog/vol ... nator,5872 But it weirdly only has 1 exhaust tip.. Do I care? I have read that fwd and awd exhaust fit differently and there is no option to pick between either on the rock auto site....

An OEM exhaust system is about 800+. I've seen aftermarket sport exhaust for 600+. I'm looking for something that will be the best bang for my buck miles to $$ wise. I normally put more than 30k miles on my cars a year. Any suggestions or ideas appreciated!!!

Post by **oragex** » 29 Oct 2018, 11:08

Can you post a pic? The rear muffler is unfortunately attached with a bracket welded right on the end pipe causing the pipe to crack and fail. The pipe can sometimes be welded back, but the replacement bracket also hooks on the pipe. I for one wanted to save money so went this getto way www.youtube.com/watch?v=i21XF8K1eHM

On the other side, the middle hangers is also well known to fail, but can be replaced with aftermarket. See sites such as Fcp or Ipd (also good for future parts - don't hesitate to ask us which brands are trustful and which are not)

The rear muffler also has a heatshield that rusts away, but the muffler itself is still good for many years

Walker are pretty junk in the long term. Bosal is a better choice

mikkowus · Post by **mikkowus** » 29 Oct 2018, 11:16

EDITED!!!

I'm pretty sure the rear muffler in my case was a replacement(probably walker?) It looked like a soup can. Unless you are saying the entire muffler was encased in a clam shell? which was the heat shield? The rear muffler detached from where the exhaust pipe went into it when I was installing a tow hitch and yanking things around. The hanger that is on the car is still there and solid. I'll get some pictures after work. It will defiantly need a rear muffler at minimum.

I found this exhaust system on ebay.... https://www.ebay.com/itm/2003-2006-VOLV ... .l4275.c10 not sure what the exact brand is. But the pictures make it look like more of an exact fit?

And this... https://www.eeuroparts.com/Parts/78121/ ... 254368054/

EDITED!!!

Post by **oragex** » 29 Oct 2018, 15:50

Yes, the entire muffler is encased in a heat shield which from outside looks like it's the actual muffler - but it's not, it can rot away no problem, the muffler is still perfectly sealed. You also have a second heat shield attached under the car body a few inches above the muffler.

The 'no name' parts like in the linked one are of random quality, so it's like taking a guess.. And Proparts is a terrible company for suspension parts - can't say for the exhaust

If the problem is just the rear muffler, you can have a shop cut it and weld a new one - no need to replace the whole segment of pipe. Also, if you are adventurous, a shop can easily custom install a standard aftermarket muffler from a known brand

Oh, and junk yards / Ebay are also good places to check

Post by **E Showell** » 29 Oct 2018, 15:55

I've have used Bosal replacement systems ordered from FCP. They last about three years on average on the salted winter roads of NJ, but I send them back to FCP for warranty replacement (I'm on my second). They give my '98 V70 5 speed stick a throaty exhaust roar on acceleration, so if you want quiet, I'd look elsewhere, but they are entirely serviceable and a decent price/quality ratio -- as long as you know you aren't likely to get more than 3 years from it at the outset.

mikkowus · Post by **mikkowus** » 30 Oct 2018, 08:44

Here are some pictures of what is left. https://imgur.com/a/bDH4rEn Can anybody tell if its Volvo or not? Worth keeping anything that's still there or not? I remember seeing some text stamped on the muffler before I tossed it. Would Volvo have big text on their mufflers under the heat shield?

I'll try and take some better pictures at lunch. Was running into work today and had to rush.

Post by **oragex** » 30 Oct 2018, 14:55

I'm don't feel like this is a genuine Volvo with that U clamp on it

mikkowus · Post by **mikkowus** » 31 Oct 2018, 08:20

oragex wrote: ↑30 Oct 2018, 14:55 I'm don't feel like this is a genuine Volvo with that U clamp on it

Thanks. The rear muffler that was on there seemed kinda big. Maybe too big to put a heat shield over and still fit. I'm wondering if the front part is Volvo? I should take some pictures of that section.