Hiya Folks,

On my fabulous, if rumbly and vibrating, 1992 Volvo 240 GL, I have what appears to be the iPd Volvo 240 "Turbo Exhaust" kit for N/A Volvo 240s

I've had this 1992 Volvo 240 since August of 2007 or 2008. Trying to heal the neglect this poor 240 suffered, yet quieting the rumbling exhaust and all matter of interior vibration that vary by speed and temperature will help.

When I bought this wee green beastie, I did not peer enough under the unibody to realize the entire exhaust was secured to the vehicle at the three manifold-to-header securing studs. And, all the way back at the rear, the North American (as you sit in the car) passenger side rear muffler hanger.

Then a several hundred mile drive from Boise, ID to the residence. Ever have your rust or failing exhaust fall out on a highway at highway speed? Catastrophic!

I secured the entire exhaust line some weeks there after. The exhaust piping and unions did not suffer (much, I guess). Save for the side of the muffler that was secured by the hanger, were a crack was on the side at the muffler inlet, and that was welded up (the crack).

That crack may have opened, or perhaps interior baffles have failed. Yet there has been no change in rumbling vibrating performance since welding up that muffler. (I could be wrong.)

It remains a bolt-together exhaust (thankfully). I can replace the rear muffler myself.

I'll keep it a single-muffler system, if I can. The piping is good. Though I'd want to treat the header pipe output to catalytic converter input securing hardware. Press out the rather thin three catalytic converter inlet studs for the largest diameter hardware of the best carbon-steel.

I'd not measured the inlet pipe diameter, or that of the muffler, yet. I mean to. Even if it mean buy a muffler, and having a muffler shop weld or modify the hangers so the replacement muffler installs and remains securely, while being a whole lot quieter.

I'd also not quite yet started research into optimal muffler for a single-muffler system.

Would anyone have suggestions as to a replacement at a notion, please?

Thank you kindly Volvo-Brick-ing folks.

(Oh, and PLEASE treat them rear wheel bearings on your Volvo, please, as 83GLT has ventured into? I have to do this also on six rear wheel hubs, when I get a garage. Just be prepared to encounter a rear axle you can treat versus a rear axle wreck you may need to replace.)

Thank you,

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