I'm doing preliminary planning to replace my exhaust system and have a few questions:
1. For my 740 non-turbo wagon where do you recommend I purchase the parts?
2. Does the exhaust kit need to be assembled, or can I purchase a system already assembled (one piece)?
3. If I have to assemble it how do I prevent leaks at the joints? Do those clamps really work? Do I need to add something like "muffler sealant"?
Thanks one and all,
Keith
--
1990 740GL Wagon 228k AW70L B230F 8 Valve Non-Turbo Rex/Regina

1...no comment dont live in the states
2... has to come as a kit and be built on the car to get it in...
3.... clmaps work (buy good ones, stainless if you can get them and dont do them up too tight..you can cause leaks that way...)
4.... lightly paste all your joints..cant hurt, may help, lubricates the joint to slide as well
5... obtain a angle grinder & a thin body work cutting blade (like 2mm thick)..this will slice the exhaust up on the car liek swiss chesse and make it easy to remove...
6....remove as much as possible...eg to the cat, getting the joints apart is a PITA on an old exhaust, so you REALLY want to take as much as possible in one hit and only leave yourself one joint to fight with
7. DONT cut to close to that joint...your goign to need substantial amounts of metal to grab hold of!
8. be prepaired to get physical with the last joint (large hammers, blow tourch
etc)
9. if your planning on keeping the car fit stainless...

Bought mine through EEuroparts a year ago. CAT back cost me about $129. It was all there, and all fit perfectly.
My experience says:
Saw the old one apart near the rear axle. It won't come out unless you do.

The biggest hassle is getting the old one free from the CAT.

If you have a leak, put another clamp on it- double-up.

Andy Crosby and I had some issues.

I replaced the exhaust system on my 1991 740 last spring and found it to be a fairly easy job. I purchased an exhaust kit online ( I can't remember the vendor, but I'll look it up later) for around $150. I ordered it Monday am and it was sitting at my door when I got home from work on Wednesday.

The kit included both mufflers, all the necessary pipe, clamps, hangers, and a tube of sealant. I was glad I got the kit, because all of the parts needed were included and they all fit together easily. All of the components were of much better quality than the "junk" with the "lifetime warrenty" from my local muffler and brake shop.

I concur with Ted. Get the cat-back kit. I bought mine at the Volvo dealer for about $203 US and installed it in about an hour and a half, and most of that was cutting out the old system. Great heavy metal, pipes fit together flawlessly. It's the only way to go.
-Steve

Keith,

1) I like buying my exhaust system parts from Swedish Engineering:

http://www.swedishengineering.com/parts.html

They sell the Volvo OEM kit for a good price.

2) The kit comes in several pieces...two mufflers, pipe between the two, and tail pipe. It is all assembled with clamps. You don't want a one piece system (if one even exists). It would be really hard to get it in place. I generally buy a cat back system and replace everything from the cat back.

3) I have found that the clamps really work. I have tried the exhaust system sealant and it really didn't seem to do anything but make a mess for me.

-Ted