My 1995 940 needed a new muffler so I got a Walker ($65 lifetime) and it needs to mate on the overpipe which was installed by Craven Tires (prior owner) 3 years ago so, it is also aftermarket. I know the quality is not up to Volvo standards but it seems too late to turn back now. It looks like the clamp on the overpipe cause that pipe to flare out so it is too big to mate. That's my theory. Consequently I got a flaring tool to make my new pipe flare out so I could fit it over the old too-big pipe. I had partial success but the pipes mate only about one inch, if that. Any ideas? Is there a way to make the overpipe smaller so it will fit into my new muffler? Should I cut slits in it and try to squeeze it or would that just make it oblong and leaky? I am even wondering if both pipes are so out-of- specs that that really can't be made to fit right. I've put on a few mufflers over the years and this is the first time I've seen where the two pipes appear to be the same diameter and therefore mating is nigh impossible.

Had the same thing three yrs ago....a copy cat. was fitted to the original cat back system....the flares would not fit and it leaked like hell with the clamp and some exhaust paste....In the end had it welded by the garage who supplied it and no problems since....when you have a new one again they only cut the old one off so whats the difference?...........

Use a sleeve/collar over the two ends. Make sure the inside dia. is the same as the outer dia. of the pipes. Use two to four clamps. You may have to shorten one of the pipes so everything lines up.