exhaust fiberglass and rust - what to replace?

[enotslim]

Plus this image of the volvo original replacement from fcp shows a bracket at the position of 10 in the diagram. FCP says the bracket is not included in this purchase despite being pictured and the bracket they sell is on back order.

[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.

Any suggestions for removing this clamp? The nuts come off easily but I haven't managed to budge the clamp itself despite PB Blaster, hammers, etc. Simply cutting off the muffler (Sawzall with metal blade or cutoff wheel) is one "solution" but might damage what remains. I would like to preserve as much as possible to simplify aligning the replacement.

[XC70Rider]

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.

Any suggestions for removing this clamp? The nuts come off easily but I haven't managed to budge the clamp itself despite PB Blaster, hammers, etc. Simply cutting off the muffler (Sawzall with metal blade or cutoff wheel) is one "solution" but might damage what remains. I would like to preserve as much as possible to simplify aligning the replacement.

Since you're replacing the rear muffler I would sawzall it off as far left as possible. After removing the rear muffler use a pry bar to loosen up that rusted clamp.

With the rear muffler in such bad shape I suspect the center muffler is near the end of it's life. I'm replacing my catback with Bosal after I get the Eastern direct fit CAT delivered.

[oragex]

Those two bolts are made of low grade steel and are by now welded by rust. Don't even think removing them, time to bring in the angle grinder. Try to cut the bolt on the nut side, to remove it from the clamp - with care not to cut into the exhaust pipe underneath because it's galvanized coated. An angle grinder is about $40 - a simple Bosch one is fine, with a metal cut disc (always use eyewear protection with side shields when cutting)

[XC70Rider]

Plus this image of the volvo original replacement from fcp shows a bracket at the position of 10 in the diagram. FCP says the bracket is not included in this purchase despite being pictured and the bracket they sell is on back order.

FCP notes the out of stock exhaust clamp is 62mm. I got this 60-63mm SS clamp to connect my catback.

https://www.amazon.com/Flameer-Universa ... way&sr=8-3

[enotslim]

Since you're replacing the rear muffler I would sawzall it off as far left as possible. After removing the rear muffler use a pry bar to loosen up that rusted clamp.

With the rear muffler in such bad shape I suspect the center muffler is near the end of it's life. I'm replacing my catback with Bosal after I get the Eastern direct fit CAT delivered.

It is only slightly louder now with all the fiberglass blown out. Will it be much louder with the rear muffler entirely removed? I might need to drive a little minus the rear muffler..

[abscate]

Since you're replacing the rear muffler I would sawzall it off as far left as possible. After removing the rear muffler use a pry bar to loosen up that rusted clamp.

With the rear muffler in such bad shape I suspect the center muffler is near the end of it's life. I'm replacing my catback with Bosal after I get the Eastern direct fit CAT delivered.

It is only slightly louder now with all the fiberglass blown out. Will it be much louder with the rear muffler entirely removed? I might need to drive a little minus the rear muffler..

The noise will be covered up by the moans and howls of anger during STANLEY Cup season,

[XC70Rider]

Since you're replacing the rear muffler I would sawzall it off as far left as possible. After removing the rear muffler use a pry bar to loosen up that rusted clamp.

With the rear muffler in such bad shape I suspect the center muffler is near the end of it's life. I'm replacing my catback with Bosal after I get the Eastern direct fit CAT delivered.

It is only slightly louder now with all the fiberglass blown out. Will it be much louder with the rear muffler entirely removed? I might need to drive a little minus the rear muffler..

If you're still driving it with the deformed muffler then let it be for now. It could get louder so don't remove it until you install the new muffler.

[enotslim]

FCP notes the out of stock exhaust clamp is 62mm. I got this 60-63mm SS clamp to connect my catback.

https://www.amazon.com/Flameer-Universa ... way&sr=8-3

The existing clamp is pretty "long" - to stabilize the butt joint. Like this 2.5 in clamp (62 mm = 2.44 in):

https://www.amazon.com/dp/B077GP8DRQ/?c ... _lig_dp_it

A thin material is also present between the clamp and pipe surfaces - wrapping around the pipes and bridging the butt joint - like a gasket. What is this and where can I get some?

[XC70Rider]

The existing clamp is pretty "long" - to stabilize the butt joint. Like this 2.5 in clamp (62 mm = 2.44 in):

https://www.amazon.com/dp/B077GP8DRQ/?c ... _lig_dp_it

A thin material is also present between the clamp and pipe surfaces - wrapping around the pipes and bridging the butt joint - like a gasket. What is this and where can I get some?

The long pipe on the center muffler slides into the short pipe on the rear muffler. The OD of the rear muffler pipe is 2.5". If you need a longer clamp than the one you listed should work. Until you remove the rear muffler you won't know if extra pieces will be needed. The long pipe could break which would require a sleeve and 2 short clamps. The rear muffler pipe could be rust welded onto the longer pipe. I use a torch to separate slide-on rusted exhaust pipes. Before I got a torch I would gently buff the outer pipe with an angle grinder to heat it up until they separated.

Sounds like you have aluminum exhaust tape wrapped inside the clamp. Exhaust tape would melt away on me over time. After cleaning up the long pipe lay on some muffler cement or sealant.