2007 s60 2.5 t exhaust pipe repair

Mrbadexample · Post by **Mrbadexample** » 29 Dec 2022, 23:38

I have a well maintained S 60 2.5 T AWD and am having issues with the exhaust system.
I have replaced the entire system from the cat back.
The flange where front pipe (from the cat to the resonator flanges even though they line up and all the hangers on the complete exhaust system are in the correct position, the gaskets between the cat and the resonator are not sealing the exhaust system…
Is there a fix for this?
I was thinking about eliminating the flange transition and replacing it with a straight pipe either welded or with stainless steel band clamps.
Any thoughts on this?
Thanks..
Mrbadexampel…

Post by **jonesg** » 30 Dec 2022, 08:33

is it loud or just leaking water from condensation?
The joint starts to corrode from the moisture, you can try refacing the joint with an angle grinder using an abrasive disk.
Use a new gasket and some flexible high temp sealant on both sides. Raise a jack under the resonator to make it align horizontally as you tighten the bolts. It got me passed state inspection for now.

Post by **Skymongrel** » 30 Dec 2022, 16:06

Ugh! I just went through this a couple days ago with my XC70. My cat to resonator flange just let loose. I considered a split flange clamp on both sides of the old flange as the bolt holes were shot. In the end due to cold weather locally and frustration I brought it to the local exhaust fix-it place and they did just what you are considering, cut the flange away and welded in a short piece of pipe. They did state that the split flange route is sometimes problematic due to gaskets not sealing well.

Enclosed a pic of the before ( no after pic sorry). BTW anyone know if I'm missing an exhaust hanger here....looks like there should be one but I only have a couple empty bolt holes!

: XC70 Cat to Res. Flange; IMG_4366.JPG (374.38 KiB) Viewed 286 times

Post by **MoVolvos** » 30 Dec 2022, 18:21

Mrbadexample wrote: ↑29 Dec 2022, 23:38 I have a well maintained S 60 2.5 T AWD and am having issues with the exhaust system.
I have replaced the entire system from the cat back.
The flange where front pipe (from the cat to the resonator flanges even though they line up and all the hangers on the complete exhaust system are in the correct position, the gaskets between the cat and the resonator are not sealing the exhaust system…
Is there a fix for this?
I was thinking about eliminating the flange transition and replacing it with a straight pipe either welded or with stainless steel band clamps.
Any thoughts on this?
Thanks..
Mrbadexampel…

Skymongrel wrote: ↑30 Dec 2022, 16:06 Ugh! I just went through this a couple days ago with my XC70. My cat to resonator flange just let loose. I considered a split flange clamp on both sides of the old flange as the bolt holes were shot. In the end due to cold weather locally and frustration I brought it to the local exhaust fix-it place and they did just what you are considering, cut the flange away and welded in a short piece of pipe. They did state that the split flange route is sometimes problematic due to gaskets not sealing well.

Enclosed a pic of the before ( no after pic sorry). BTW anyone know if I'm missing an exhaust hanger here....looks like there should be one but I only have a couple empty bolt holes!

IMG_4366.JPG

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Might be several different brands and types. They seem to work well enough.
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