Hello,


I have a 92/240 DL volvo who's muffler has recently cracked. I was driving down the highway, went to accelerate and the car got REALLY loud. When I came home, I found the muffler in the condition its in now. What I'd like to know is what are my options regarding repairing or replacing this. Some on here say replace the entire system at once, but I'd be interested in any fix for this really. I took a few pics of the area where the muffler broke at, and they can be viewed by clicking on the muffler image located in this post.

Broken Volvo Muffler

Actually it's broken after the cat. The cat converter is forward of the break, the thing with the tapered ends where it meets the pipe on both its incoming and outgoing ends. The cat has the long pipe coming off it; that pipe comes with the cat if you get one that's OEM or designed to fit like OEM. All one piece.

After the cat's long output pipe is the "first muffler" which many call a resonator. It's located under the rear seat area of the car, before the exhaust pipe crosses under the axle.

I can't tell if your break just before the first muffler or exactly where. But you will know for sure if you look under there. I'd think you can replace the first muffler and leave the cat where it is.

If the stuff rear of the first muffler is pretty rotten already, the shop will insist on replacing it. If it's good enough to make a good seal to the new first muffler and is not ready to fall apart, you can keep it.

Good luck!
--
Sven: '89 245 NA, 951 ECU, open-front airbox, E-fan, 205/65-15's, IPD sways, E-Codes, amber front corner reflectors. Wifemobile '89 245 NA stock. 90 244 NA spare, runs.

The break is near the front of the car. The pictures you see were taken from the drivers side of the vehicle. What I'm wanting to know is if I can get a part like and replace just that part, or if its best to get the whole system replaced.


Thanks,
Ken

Yes, you *can* just get the header and replace it.