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2004 S60T AWD Rear exhaust bracket rusted

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R
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cn90
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Re: 2004 S60T AWD Rear exhaust bracket rusted

Post by cn90 »

I need advice from the exhaust gurus...

It is 2007 Volvo S60 2.5T with 115K miles.

- Unlike other cases where the hanger broke off, the tailpipe broke clean (well, P.O. had it welded by a muffler shop a few yrs ago). Please see photo.

- Options:

1. I certainly will add a strap (like metal plumbing strap to hang the muffler upward like @oragez did.

2. Should I ask the muffler shop to add an "inside sleeve" (BLUE color in my sketch below) and weld it in to help strengthen the weld?
This design is bad bc the whole weight of the muffler is on that single hanger, which is part of the tailpiece.

3. Ebay has "Rear Stamp Exhaust Muffler" for ~ $140: is this you can install yourself or you need a muffler shop for it?
Any feedback on this particular muffler?


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2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+
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vtl  
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Post by vtl »

3 you can do yourself. May need a coupler, if this one does not come with it.
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erikv11
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Post by erikv11 »

If it is a decent muffler shop I would definitely just ask them what they recommend. They will have seen issues like this all the time.
'95 854 T-5R, Motronic 4.4, 185k
'98 V70, T5 tune-injectors-turbo, LPT engine, 304k, daily driver
'06 S60 R, 197k
'07 XC70, black, 205k
'07 XC70, willow green, 212k
'99 Camry V6 :shock: 153k
gone: '96 NA 850 210k, '98 NA V70 182k, '98 S70 NA 225k, '96 855 NA 169k
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hu5ker555
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Post by hu5ker555 »

Ha. I did a "ghetto fix" on this several years ago. I doubled up a stainless steel chain between the rubber grommets.
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cn90
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Post by cn90 »

On a related note, has anyone here delete the Muffler and just weld a "curve pipe" and done with.

YouTube video suggests it is a bit louder with Muffler delete???
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+
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cn90
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Post by cn90 »

YT 2005 S60 2.5T Muffler Delete video...

2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+
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cn90
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Post by cn90 »

Curious any legal issues (inspection etc) with Muffler Delete?
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+
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cn90
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Post by cn90 »

I have a little time to play with the bracket...

UPDATE using Menards hardware store.
But you need an angle-grinder to cut the metal corner a bit.

Items:
1. Metal Corner (Zinc type), 5" x 1".
2. Some Loctite if you wish.
3. Galvanized steel strap, the stuff in the plumbing dept; 3/4" x 10 ft.
4. Stainless Steel nuts and bolts as shown.

Total cost ~ $9.00

1. I cut the Metal Corner a bit. After the cut, the end product is one hole on one side and 2 holes
on the other side.
On the longer side, I bent the metal tip 90 degrees as shown to hook under the muffler edge:
this was done using adjustable wrenches.

2. The bolt is 3/4", a tad too long for the small hole (this small hole is part of the mounting bracket,
look upward and you will see it). So I added another nut as shown.
To counter-hold the nut, use 1/2" wrench.

3. I added the strap around it just to hold it in place. You don't have to do this step bc the bracket
is solid. The metal strap was added just in case the aftermarket bracket (installed on the pipe part
upstream of the muffler) fails...

4. The entire system is now supported by the:
- Aftermarket bracket (installed on the pipe part upstream of the muffler, tons of youtube videos on it).
- This new bracket that I made.
- Now the weight is evenly distributed to avoid stress on the system.

PS: I will have to go to muffler shop to have them weld a sleeve in, just to be kosher.
The muffler is now supported by this bracket.

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2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+
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br0dy519
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Post by br0dy519 »

cn90 wrote: ↑16 Feb 2022, 13:02 On a related note, has anyone here delete the Muffler and just weld a "curve pipe" and done with.

YouTube video suggests it is a bit louder with Muffler delete???
Yes. I had my muffler shop cut me a 3 foot piece of 2.5" ID pipe opened up on the end that connects to the existing exhaust. Also had them do a 45 deg bend about 1 foot in. Then I installed this bracket on it : https://www.ebay.ca/itm/353537764976


It's annoying loud but all-in cost was $30. I just replaced the muffler 2 years prior and the new aftermarket already rotted out. Not spending another $500 on a POS aftermarket muffler. I'll live with an annoying loud car. My argument with police would be that my car already has a muffler (centre resonator). Not sure if that would hold up in court.
04s60 2.4
04xc70 2.5t
prwood wrote:I wish I had a permanent car repair area that was covered, had a level surface, lighting and fans, a workbench, and tool cabinets. You know,like a garage. Much of my time during the job is spent hauling things up and down the stairs to the basement or in and out of the storage shed, or running back downstairs when I realize I need something else,or taking a break from standing out in the sun,or using flashlights or work lamps when it gets dark.
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cn90
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Post by cn90 »

Question re muffler welding technique...

- The shop I have used for a few yrs use ? acetylene + O2 for welding, so no risks to electronics such as ECU etc.

- Is TIG welding safe for cars with ECUs etc.?
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+
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