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Rusted connection on exhaust.

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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SCVolvo2007
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Joined: 4 February 2026
Year and Model: 2007
Location: South Carolina
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Rusted connection on exhaust.

Post by SCVolvo2007 »

Need some ideas to connect this. Can’t replace connection bolts since holes are rusted out.


2007 Volvo Xc70
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cn90
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Year and Model: 2004 V70 2.5T
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Post by cn90 »

Get a shop to weld it together?
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+
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Krons
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Post by Krons »

When my kids 2002 S60 2.4t muffler rusted at the hanger I replaced with a kit like this. Came with hardware to bolt to the catalytic converter. If you have that much rust the muffler at the back may not have much life left. I’d assume you could source similar in your country.

https://ebay.us/m/gNbN6z
08 S602.5T/05 XC902.5T/02 S602.4T
08 C702.5T (sold)
05 S402.4i (RIP, timing belt failure)
The non-Swedes:
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MoVolvos
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Post by MoVolvos »

SCVolvo2007 wrote: ↑04 Feb 2026, 10:13 Need some ideas to connect this. Can’t replace connection bolts since holes are rusted out.


2007 Volvo Xc70
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Depending on your situation. Search "Exhaust Flange Repair".
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Blessings,

BKM


2008 C30 T5 2.0 M66
2007 S60 2.5T - New Project
2003 S80 T6 Transmission DIED
2000 S70 SE Base - New Project
1998 S70 T5 Prior
1989 240 Wagon Prior
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DavidE7
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Year and Model: 01-07 V70, S60, XC70
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Post by DavidE7 »

I drilled out the rusted and broken studs on the exhaust flange and replaced them with stainless steel bolts, washers, and nuts from a hardware store. Tried to find a picture without any luck. Getting the drill bit to bite and stay centered is tricky. My angle grinder does a good job getting a flat surface.
David E
2001 Moondust V70 2.4 293,000 miles
2001 Nautic Blue V70 2.4 224,000 miles
2004 Nautic Blue XC70 2.5T 251,000 miles
new: 2004 Black Saphire V70R 193,000 miles
2007 Titanium S60 2.5T 275,000 miles
2007 Magic Blue S60 2.5T 233,000 miles
2007 Silver V70 2.4 200,000 miles
P2 Volvos for every person in my family
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jonesg
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Post by jonesg »

this s the style that held up for me, use dble steel gasket and high temp red rtv.
Measure the exh pipe diamter to get the right size.
Clean the mating flanges with a belt sander, apply rtv/gaskets and raise the pipes with a trolley jack on a milk crate, then cinch the bolts.

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

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If for some reason you aren't able to use the existing holes you can try this.
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Last edited by MoVolvos on 09 Feb 2026, 00:25, edited 1 time in total.
Blessings,

BKM


2008 C30 T5 2.0 M66
2007 S60 2.5T - New Project
2003 S80 T6 Transmission DIED
2000 S70 SE Base - New Project
1998 S70 T5 Prior
1989 240 Wagon Prior
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MoVolvos
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Post by MoVolvos »

jonesg wrote: ↑04 Feb 2026, 21:50 this s the style that held up for me, use dble steel gasket and high temp red rtv.
Measure the exh pipe diamter to get the right size.
Clean the mating flanges with a belt sander, apply rtv/gaskets and raise the pipes with a trolley jack on a milk crate, then cinch the bolts.

https://www.amazon.com/EVIL-ENERGY-Exha ... 9hdGY&th=1
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Glad those worked for you. I have a clamp that I was going to use on the 08 C30 T5 2.0 M66 but the car was put on non-op due to clutch issues.
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EVIL ENERGY 2.25 Inch Exhaust Clamp,2 1/4" Butt Joint Band Clamp Sleeve Coupler Stainless Steel for Pipes,Mufflers,Catalytic Converters

https://www.amazon.com/EVIL-ENERGY-Exha ... r=8-6&th=1
.
Blessings,

BKM


2008 C30 T5 2.0 M66
2007 S60 2.5T - New Project
2003 S80 T6 Transmission DIED
2000 S70 SE Base - New Project
1998 S70 T5 Prior
1989 240 Wagon Prior
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br0dy519
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Post by br0dy519 »

I bought one of those butt-clamps but my soup can with two clamps has help up for 3 years.
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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SCVolvo2007
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Joined: 4 February 2026
Year and Model: 2007
Location: South Carolina
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Post by SCVolvo2007 »

Thank all for quick responses. Now, who knows a guy in Columbia, SC who can help my son away at college fix this?
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