Installed a Bosal downpipe on my 90 240 in March. Downpipe showed up with welded flanges at both ends, which matched the cat. converter. Fit-up was very good, including the bell-housing bracket.
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The bad news: After a few weeks I noticed the S-pipe on the outlet of the rear muffler was pulled forward and had contacted & melted the plastic fairing. On closer inspection, I found both rear muffler hangers stretched forward by an inch or so. Failed to see this when cinching up the new downpipe to the cat converter flange. Sure enough, the overall length of the old head pipe is an inch longer than the Bosal part.
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I've ordered a cat-back system since the resonator-to-muffler pipe has now eroded through (at the elbow, of course, on a car driven <5 miles to school). My question is: Should I have a local shop add the length back into the rear pipe (new, but cat will still be slightly forward), or pull the 4-month old downpipe & add the length there (weld problems on “old” pipe vs. original configuration/dimensions)? Thanks for any insights.
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Jim (90 244DL 170K miles) turbo sways w/poly, front struts & bushings, OD wiring