Dear wally660,

Hope you're well and stay so. Volvo VADIS - a superseded dealer parts/service database - shows two down-pipes for a '940, non-turbo. For engine without Exhaust Gas Recirculation (EGR), the part is #9135306 or 9139285. For an engine with EGR, the part is #9135305. Volvo no longer supplies these pipes.

I recall a post - possibly by "rstarkie" - that there was no obvious difference between these pipes. But that recollection could be faulty.

I supply the part numbers, in case an after-market pipe-maker can use them to identify one of its products, that will fit and work properly.

As the oxygen sensor on non-turbo 940s fits into the catalytic convertor, perhaps a custom exhaust shop could replicate the worn-out down-pipe. If the factory-original flange - that attaches to the exhaust manifold - is not rusted-out, that section could be salvaged and welded to new pipe.

If the flange, that attaches the down-pipe to the catalytic convertor (cat), can't be salvaged, the down-pipe can be welded to the cat.

At a custom exhaust shop, a craftsman might be able to use stainless pipe, which will last for a couple of decades.

I hope this information is helpful.

Yours faithfully,

Spook