S60 - Exhaust and front muffler

[ionianp2]

Hi Everyone!

New here, but been following the forum for some time. I have an ‘04 S60 NA 5spd, which I intend to keep running for a long time. Recently, I’ve noticed that I have some exhaust leaks that are getting progressively worse.

A quick diagnosis with the shop vac and soapy water, shows the front muffler flange and flex pipe. My front muffler is on its way out so I figured, I'd replace it as well. There was an excellent video on youtube, I believe by Oragex, detailing how to replace the flex pipe how to keep the existing cat converter.

I did some research on the front muffler and there seem to be two options:

- Go with the Genuine Volvo, the more expensive route
- Starla, which is listed as an OEM, though not sure of its accuracy and there aren’t enough reviews to draw a conclusion.

Has anyone here had positive experience with the Starla? It’s less than the price on FCP euro. I wouldn’t mind going with the Genuine option if the Starla will only last a couple of years.

As for the flex pipe, would one overlapping the exhaust flanges be a better option than one going inside the exhaust flanges?

I'm a fairly good DIY-er, but never welded before.

Your insights are much appreciated.

[matthew1]

Welcome to MVS, ionianp2. What serendipity: Starla exhaust advice reviews

[oragex]

Perhaps see this discussion for OE replacement parts viewtopic.php?t=86230

Look first for small holes in the cat itself, where the bracket is welded to the cat

I bought a $250 downflex and cat for my 2003 NA off Ebay. These came prewelded but as I expected, they fitted poorly both at the bracket and at the manifold flange - this causes the flex to stay under stress and possibly start leaking at some point. I was lucky, my cat isn't throwing a Check Engine light - cheapo ones will do

My take on this, I would either try finding a complete used genuine exhaust from a Florida car, or I would get a custom exhaust done by a place with good reputation. I guess they could do it for around $1000 or so (just a guess). Existing aftermarket parts can be a gamble - there are a few brands like Walker that may not give good results for this specific car.

[ionianp2]

Thank you folks.


Oragex the video you made about welding a new flex pip to your OEM cat, was that after trying the ebay downflex? In the end I wasn't quite clear on which flex you bought. I believe it was an 8" 2" ID with interlock, correct?

[Katten]

On my 2.4 NA Volvo S80 i removed the resonator completely. Im not sure but I think that is what you mean with front muffler? is does not sound horrible in any way. I clamped a piece of pipe in its place.

[MDK]

Rockauto... 225$ ..2004 non turbo S60

[oragex]

Thank you folks.


Oragex the video you made about welding a new flex pip to your OEM cat, was that after trying the ebay downflex? In the end I wasn't quite clear on which flex you bought. I believe it was an 8" 2" ID with interlock, correct?

I first put a good quality flex pipe (Vibrant brand - they also sell off Ebay) and kept the original cat (so cut and swapped the downflex section and welded the new one to the original cat). However, the garage who did the job was really poor and it didn't weld the flex section in the correct position, which put stress on the flex section and caused it to leak soon after. This is why it's really important to find a place who knows how to adjust the new part when welding it to the cat. If you go this, way, I absolutely recommend the TurboFlex Couplings with Interlock Liner. https://vibrantperformance.com/catalog/ ... =1527_1064 Saying this because there is confusion over Internet if you really need the Interlock Liner or not, some people think it's only for turbo engines, etc.. In reality I recommend spending a few extra dollars for this feature no matter the engine, because the construction is much more solid. Having said that, the chinese flex couplings all say they have interlock liner which often times is not true.

Then I went with a full aftermarket flex and cat prewelded - much like the one posted by MDK above. These are not bad - if you get lucky to get one that doesn't cause a CEL, but I found out they are very often times poorly positioned (brackets, flanges) so fitting is a problem and when this happens it puts stress on the flex section which can cause it to leak prematurely.

About the size of the flex pipe alone, it's good to keep in mind that these measures are always only an approximation. It will depend how is the flex pipe welded both on the front flange and on the cat side - depends where exactly the old flex pipe is chopped off the exhaust, the angle is positioned, etc. It is pretty much an adjustment thing, so any measure may or may not work the same on every car. The very best is to find someone really used with such welding and who knows where to cut and how to position the pipe sections. They may even lift the car and recommend a seize for the flex section. Surely an exhaust shop should be a good place to try

[ionianp2]

Thank you all for your helpful feedback. The next step would be to get an estimate on what it costs to replace the flex at a good muffler shop. I’d rather do that and save the OEM cat.

As for the muffler, maybe I’ll take my chances with the Starla unless I find a southern used OEM muffler.

I don’t think it would hurt to drill some small holes for any moisture to escape. Maybe even paint the welding spots with high temp engine block paint to prevent them from rusting.

Once again thank you!

[vtl]

Rockauto... 225$ ..2004 non turbo S60

Snabb sells a stainless steel 3" downpipe for $495, a piece of workmanship. I wish I can weld like this some time The quality is on par with Volvo original downpipe.