exhaust fiberglass and rust - what to replace?

[enotslim]

2004 XC70 has quite a bit of fiberglass exiting from part 12 in the attached diagram - on and off for a few weeks. Then the terminal pipe rusted through and hung free (still connected to the rubber hanger) as shown in the attached image. Exhaust is noticeably louder. Seems to me the fiberglass and rust may be largely unrelated. Regardless, time to replace part 12. I assume this cannot be repaired in a reasonable manner. Plus it is louder.

My question is, what is the origin of the fiberglass? My reading says it could be either 12 and/or 6 in the diagram. Both parts are variably referred to as "muffler" and "resonator" so it's impossible to understand the meaning of, "the resonator contains fiberglass". Do both contain fiberglass? If I see fiberglass upstream of 12 during replacement I will know 6 does and also needs replacement.

Thanks.

[Rattnalle]

12 is filled with fibreglass. I'm unsure about 6.

12 available on it's own though quality is poor compared to the original factory exhaust. If more convenient any universal muffler that will fit will do but might change the sound.

[enotslim]

Thanks. FCP sells a Starla muffler (well reviewed on fcp) for only $84 less than "Genuine Volvo". Not worth it if truly inferior, except for the fcp lifetime replacement policy. But who wants to do the job twice. Hmmm...

[abscate]

One data point on the Starla - i think thats what I have on my S70

Its louder at idle, but quieter at turnpike speed, IMHE

[Rattnalle]

Thanks. FCP sells a Starla muffler (well reviewed on fcp) for only $84 less than "Genuine Volvo". Not worth it if truly inferior, except for the fcp lifetime replacement policy. But who wants to do the job twice. Hmmm...

Genuine Volvo doesn't last any better. The OE replacements aren't anywhere near the same quality as was fitted at the factory.

[enotslim]

My only real concern doing this job is removing clamp 10 to separate 12 from 6. Any suggestions on the best way to do this? As a test I easily loosened the bolts on 10 in the image attached here (after PB Blaster, hammer taps and overnight wait) but the rest of the clamp seemed just as secure as before. I didn't try (yet) to loosen it. I didn't have a new 10 or 12 with me for reassembly.

[BlackBart]

#10 appears to be just a hanger bracket and shouldn't need to come off. The rubber donuts (11) hang off of the pins. I would guess the long exhaust pipe is welded to the muffler. I don't see any sleeve fitting.

[BlackBart]

^^ I may have to edit that - I see a clamp fitting on the new Starla muffler.....

starla muffler.jpg (60.01 KiB) Viewed 2746 times

[oragex]

That is the correct bracket for the S60. Just cut the old muffler and weld the new one or use some quality clamp if the diameter permits. You may as well replace the middle bracket and the two flange bolts & gasket between the cat converter and the front muffler - because you will have to drop the exhaust to weld the new muffler in place. Be sure to choose a knowledgeable garage to position the new muffler properly when welding it - my garage did a terrible job. Otherwise, the muffler will knock on the car, buzz rattle and be noisy because it sits quite close to the bumper cover and to the top heat shield

https://www.fcpeuro.com/products/volvo- ... 0-30681626

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As mentioned above, there have been problems with the OEM replacement sold by Volvo, rotten in less than 2 years. Not sure how these Starla will do if they have the same furnisher. You can also try any brand of aftermarket product if you have a good muffler shop nearby - really not a big job to fit one

[enotslim]

Just added the image of part 10 to my last message (I forgot it when originally posted). Doesn't this look like a clamp securing 6 and 12?