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1997 Volvo 850/na - Fitment and make of exhaust muffler

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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xHeart
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Re: 1997 Volvo 850/na - Fitment and make of exhaust muffler

Post by xHeart »

Slow progress. Here are few photos.
The coupler at each is welded. I imagine cutting the welds to remote the coupler?
before cutting off clamps
before cutting off clamps
MVS_1072.jpg (429.63 KiB) Viewed 2032 times
after clamps
after clamps
MVS_1073.jpg (531.74 KiB) Viewed 2032 times
view from passenger's side
view from passenger's side
MVS_1074.jpg (524.76 KiB) Viewed 2032 times
view from driver's side
view from driver's side
MVS_1075.jpg (561.69 KiB) Viewed 2032 times
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xHeart
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Post by xHeart »

The picture shows a 10mm gap, it is a tear on old coupler. Pushing each ends upward narrows the gap.

I have raise the car further up, clearing anther two inches to work from under.
Assessing if hangers need to come down and off.

The snow storm adds to anxiety.
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xHeart
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Post by xHeart »

A frustrated afternoon with a snow dump.
Nonetheless, the coupler inside the exhaust is stubborn. I have separated the exhaust lip from the coupler layer to see if there is a weld getting in the way from sliding out.
Few photos of progress. I will files the exhaust lip before installing new coupler.
Any pointer for removing the coupler?
I don't believe this how the original installed?
CAT is clear of any coupler, ready
CAT is clear of any coupler, ready
MVS_1079.jpg (618.21 KiB) Viewed 2027 times
the exhaust lip after cutting off weld points separating it from coupler
the exhaust lip after cutting off weld points separating it from coupler
MVS_1082.jpg (427.72 KiB) Viewed 2027 times
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cn90
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Post by cn90 »

xHeart,

You are funny, very persistent person.
I had the same exact issue, my advice is: go to local muffler shop (it will be noisy driving there lol).
They will use a metal sleeve coupler, weld it in, charge you $60 and you will be fine for another 4-5 years.
Anything else you do at home is a band-aid and a waste of time.
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

xHeart
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Post by xHeart »

cn90 wrote:xHeart,

You are funny, very persistent person.
I had the same exact issue, my advice is: go to local muffler shop (it will be noisy driving there lol).
They will use a metal sleeve coupler, weld it in, charge you $60 and you will be fine for another 4-5 years.
Anything else you do at home is a band-aid and a waste of time.
I am leaning that way cn90.
Preparing to take "sky is falling" story at the muf shop.

Many thanks
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xHeart
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Post by xHeart »

I say, it was best spent $65 after $140 on exhaust manifold in Fall 2013
A quieter drive afterward.
Thank you!
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xHeart
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Post by xHeart »

The muffler is making noise again.
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xHeart
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Post by xHeart »

Ozark Lee wrote:I replaced a Bosal on my son's car. The pipes were pristine but the muffler itself had rotted in half and the hanger arms rusted off of the body. The back pipe can be repaired with a chunk of tailpipe, a coupler, and a couple of clamps. [...]

The pipe diameters will vary depending on what kind of muffler you have now. I left the Bosal pipe from the joint between the catalytic converter to the muffler but it was a larger diameter than the stock pipe so I used an adapter coupler.

...Lee
My muffler problem has returned 6 month after the chain store's welding.
The new Bosal is $25 cheaper than the OEM Starla $223.
I would prefer using clamp connecting it at CAT.
Who would know if Starla is a perfect fit, and my CAT is full length -- not trimmed by the engineers at Midas?

Here is the parts diagram http://volvopartslisle.com/assembly/73477097/1997-Volvo-850/Exhaust-System
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Ozark Lee
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Post by Ozark Lee »

I don't have any experience with Starla but if the pipe to the flanged connector post cat is unmolested it should bolt right up at the funky bubble joint. If you are buying new clamps for the cat to muffler pipe junction (highly suggested) be advised that the Volvo part number is for each half, not the set. That one set me back a few days. They are identical part numbers for each half.

...Lee
'94 850 N/A 5 speed
'96 Platinum Edition Turbo
Previous:
1999 V70XC - Nautic Blue - Totaled while parked.
1999 V70XC - RIP - Wrecked Parts Car.
1998 S70 T5
1996 850 N/A
1989 740 GLT
1986 740 GLT
1972 142 Grand Luxe

xHeart
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Post by xHeart »

Ozark Lee wrote:I don't have any experience with Starla but if the pipe to the flanged connector post cat is unmolested it should bolt right up at the funky bubble joint. If you are buying new clamps for the cat to muffler pipe junction (highly suggested) be advised that the Volvo part number is for each half, not the set. That one set me back a few days. They are identical part numbers for each half.

...Lee
Thanks Lee!

Ordered parts from partsgeek - muffler W0133-1660568 http://www.partsgeek.com/catalog/1997/volvo/850/exhaust/muffler.html, and clamp W0133-1660565 http://www.partsgeek.com/catalog/1997/volvo/850/exhaust/exhaust_clamp.html.

The picture below from february repair shows CAT at right -- would it work?
Image
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Golden-German Shepherd | 2021 XC90 T6 INSCRIPTION (Nexa) | 2020 V60CC (Frska) | 2013A XC90 (Lktra)
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