Time for a new exhaust system for my 95 940. The eight year old existing system, plus the OEM cat which is now 13 years old, was showing wear. If I had waited for the system to fail with holes and broken pipes, Volvo would have replaced the failed components on warranty but I have no interest in getting stuck somewhere while trying to secure the warranty when a new system costs $200. Anyway, I bought the system and mounting hardware from Jon Reynolds at Borton and an aftermarket Bosal cat from EEuroparts because the existing cat shell was falling apart, the fruits of the Rustbelt on even stainless steel.

I used a reciprocating saw and a metal blade to make quick work of the pipes. Had two problems: the front header pipe was secured to the cat with a triangular dual flange squeezed by three bolts, which were totally corroded. I used a Dremel to cut through the bolts at the joint and pull the cat off. And one heat shield had rotted at the mounting holes. I could probably have used stainless washers and JB Weld to fix this, but sprang for a new one to save time.

Installing the new cat proved a bit more challenging. I ended up cutting off the front flange mount using my Dremel (I could not drill out the remains of the corroded bolts: this sucker had been hardened over time and not even a cobalt bit would make a dent). I went to NAPA and found a VW/Audi split flange ($30) in almost the correct size: just a tad too large, easily fixed by filing and slightly enlarging the bolt holes. And the new cat was missing one plug at the spot where a second O2 sensor sometimes goes: I found an 18mm x 1.5mm oil plug and Loctited this in place.

I mounted the split flange, then attached the new cat and its flange, then the rest of the system. Volvo exhaust kits fit PERFECTLY and go on like a dream. And now I have to find a buyer for the old cat; the platinum is worth a few bucks or more.
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