Yeah, usually the first muffler / resonator is excluded.

You can use the stock rear or final muffler / resonator, yet that may not be enough to dampen some undesirable exhaust note aspect.

If you look at iPD, they offer a "turbo 240" catback (catalytic convertor output --> back) exhaust system for non-turbo 240. The exhaust note is much deeper yet the whole car vibrates as the run from the exhaust valves to the rear muffler resonates more loudly with the exhaust pulses. The piping is also larger at 3" OD. The pipe that connects to the catalytic convertor output pipe expands from 21/2" or so to 3". In short, a single pipe section merely replaces the front resonator on Volvo 240.

How far forward do you need to replace the exhaust system? Is the head pipe and the catalytic convertor good? No exhaust leaks around the exhaust ports (manifold). What about any flanges (exhaust system section connectors)? Rusted flanges can be cut out and the ends welded together as a cheaper way (versus replacing with a newly welded on flange or replacing the entire component like a catalytic convertor).

You may want to shop around for exhaust components or whole systems for your 1997 960. Starla is a well known brand that is made Europa or USA. iPD and FCP Groton sell these. Tasca may sell Volvo OEM exhaust at extra cost.

It is possible to replace an exhaust system if you have the strength, experience, tools, place, and time. Rust and undoing prior bad repairs can be a pain. If lucky, removal and replacement is a lego-bolt-in-only affair.

If you shop around at the uniform exhaust chain store nexus (Midas, Meinekey, and I forget), they may or may not have the correct parts from their vendor. Ask if you can provide your own parts for the repair if they do not have exact fit parts with warranty. Either way you save some money or time or both, hopefully.

Be certain all support are in place and that quality rubber hangars are used when installing the new exhaust piping. I've seen rubber hangars utterly deteriorate in two years on cars that average less than 4000k miles annually!

You may want to take a look at the fuel / emissions / and ignition ECUs (controller or computer) for any fault codes and remedy.

Questions?

Hope that hep kats (helps).

cheers,

Dud.
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I so love FUZZY kitties! Fuzzy kitties like eggnog! Eggnog does not like fuzzy kitties, though, as the kitties get bad gas and let you know of it!