2004 S60T AWD Rear exhaust bracket rusted

[vtl]

My car apparently came from Brooklyn new, then Providence, then Montana. I should probably take a look-see under there.

Look under plastic, especially in and around rear wheel well. Wells above fuel tank and rear subframe are also rust filthy.

[XC70Rider]

I replaced all the exhaust minus the headers 4+ years ago. Everything looks great after 64k miles due to living in the southeast now. Don't miss those salty Massachusetts roads! I painted the exhaust with VHT ceramic based exhaust paint.

Rear Muffler: Bosal 235143 (aluminized)

Center muffler: Bosal 282-909 (aluminized)

Direct Fit CAT: Eastern 40597 (Stainless Steel)

Back in 2016 O'reilly Auto parts here in the south baught out Bond Auto parts that's based in northern New England. I know the O'reilly regional manager that flew up to inspect Bond before the purchase. He dropped his mouth when he witnessed all the exhaust parts they had stocked!

[cn90]

My 2007 S60..The tail piece fix (on page 3 of this thread) just failed in one year.

My 2006 S60...the previous owner had the local muffler shop did this repair using a rebar
as shown. In a way, this is a clever fix, I like it...

If you have a shop do it this way, make sure they support the weight of the muffler using a jack
or something before welding the rod in...

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Volvo-S60-Muffler.jpg (198.77 KiB) Viewed 459 times

[abscate]

My 2007 S60..The tail piece fix (on page 3 of this thread) just failed in one year.

My 2006 S60...the previous owner had the local muffler shop did this repair using a rebar
as shown. In a way, this is a clever fix, I like it...

If you have a shop do it this way, make sure they support the weight of the muffler using a jack
or something before welding the rod in...

---
Volvo-S60-Muffler.jpg

They can tack in the rest of the missing exhaust , too.

[cn90]

Haha...

Midas muffler shop said don't waste money with tail piece
bc there is no "meat" to weld the tail piece to.

They said that fix (with a rebar as shown) is permanent fix.

I think they are right.

[MoVolvos]

Haha...

Midas muffler shop said don't waste money with tail piece
bc there is no "meat" to weld the tail piece to.

They said that fix (with a rebar as shown) is permanent fix.

I think they are right.

It's quite a liability to tell the customer that as the exhaust is suppose to be piped to the edge of the vehicle. Much easier for exhaust to enter the cabin when it's underneath especially stop and go traffic in the city.
.

[erikv11]

Haha...

Midas muffler shop said don't waste money with tail piece
bc there is no "meat" to weld the tail piece to.

They said that fix (with a rebar as shown) is permanent fix.

I think they are right.

Difficult to fix agreed, but dumping wet, toxic exhaust under the car body doesn't seem a great long-term solution.

[cn90]

The 2007 Volvo S60 2.5T muffler finally rusted through, making noise. So, I need to a new muffler.

I just bought a Volvo muffler. Questions for the gurus:

1. The factory is welding, but can you use clamp for this connection?
If so, what is the PN for the clamp?

2. Is welding a better option here?

[jonesg]

My 2007 S60..The tail piece fix (on page 3 of this thread) just failed in one year.

My 2006 S60...the previous owner had the local muffler shop did this repair using a rebar
as shown. In a way, this is a clever fix, I like it...

If you have a shop do it this way, make sure they support the weight of the muffler using a jack
or something before welding the rod in...

---
Volvo-S60-Muffler.jpg

Lack of tail pipe will fail in some states, in Maine they just check horn, make sure the radio works and off you go.$12.

[abscate]

I’m a big fan of band clamps since I gave my stick welder and MIG away when I left Albany. Add in some muffler putty and/or wrap and you can get a nice quiet clamp joint.

Example here

https://www.amazon.com/EVIL-ENERGY-Exha ... 9hdGY&th=1