1994 850 Exhaust Replacement - Weaving Pipe Over Axle

[Beige68GTO]

So, today I thought I would replace my 1994 850 Turbo's exhaust and Oxygen sensors, from the turbocharger to the back. All went well other than I could not figure out how to weave the tailpipe with the projecting exhaust hangers over the rear axle. The fuel tank gets in the way, and it looks like the spot is just too narrow to fit the hangers and the pipe through. I was tempted to cut them off and see if that would take care of it, then ask a muffer shop to weld them back on, or just cut the tailpipe off and rejoin. Had anyone else run into this, and how did you resolve the issue?

I purchased a Starla muffler and exhaust, as the sales person said it would be closest in to OEM.

Thank you for your advice,

Ron

[Volvofan94]

Hi there,

You wouldn't need to cut the rear hangers or separate the muffler to get the tailpipe between fuel tank and left rear spring.

The best method I found (did this on my 94 Turbo) was to support the car securely on jackstands at 4 corners and wiggle the tailpipe through. Start installing the new exhaust pipe (muffler and tailpipe) on the passenger's side below the front passenger wheel. With the muffler nearly vertical push it through the opening. It's tight, but with some patience it will go over the rear axle. If there is an exhaust tip on the tailpipe, remove it before installing; gives a little extra room to maneuver the tailpipe through.

I think you mentioned you're replacing the whole exhaust from the turbo back, the new exhaust should have a union piece in the middle. If it does, try to install both sections separately then connect them with the union piece when both are in the car.

Good luck!

-volvofan94

[Beige68GTO]

volvofan94,

Thank you for the advice. I did not have a way to get the car high enough to turn the muffler vertical so I did wind up cutting the tail pipe hanger off to get it over the axle. (I needed a better jack than what I had available.) Then it went in just like you said.

Thank you,

Ron