Reminder to check exhaust mounts

[Forrest]

My two “daily driver” 940s have recently suffered exhaust problems. The first was caused by the failure of the rubber hangers on the middle silencer. This ultimately caused the exhaust to break in half on a rutted lane. Repair at the garage cost £400. Seeing the new exhaust appeared to hang much higher than the one on my other 940 I investigated the latter. On that one the metal hanger on the rear silencer had broken. Fortunately, I caught that one in time and an easy DIY repair only cost £13.99 for a new silencer bracket from eBay.

Might serve as a helpful reminder to others about “a stitch in time”.

[gpl1968]

Also, if like me you have a stainless exhaust, check the clamps holding the sections together. A few years ago the MOT inspector drew my attention to the clamp on the section behind the cat which was nearly rusted away.
A friend of mine has a land rover which also has a ss exhaust and it fell off one day due to corroded clamps and hangers, which were not ss.

[Ian21401]

Just had to replace all four rubber hangers on my 940, again. They were aftermarket ones by Klarius from my local factor. Seems the two for the centre box are different (thicker) than the two for the rear box and hence have different part numbers.
The whole exhaust system is Volvo with the exception of the cat.
Another anomaly is: the rear box has hanger hooks at it’s extreme rear on the out pipe at 180 degrees to each other. The car’s subframe has the hanger hooks welded to it at points about halfway along the length of the rear box, BUT, they are not opposite each other. They are offset by about 40 mms. This means that two separate oval support bands need to be fitted to the rear box with their hooks in positions relative to the chassis hooks. I mentioned this when I bought the system from my main dealer sometime ago but I was assured that it was the correct system for my car.
I think that I will order some Volvo rubbers for next time.

[Laird Scooby]

Originally Posted by Ian21401

J
Another anomaly is: the rear box has hanger hooks at it’s extreme rear on the out pipe at 180 degrees to each other. The car’s subframe has the hanger hooks welded to it at points about halfway along the length of the rear box, BUT, they are not opposite each other. They are offset by about 40 mms. This means that two separate oval support bands need to be fitted to the rear box with their hooks in positions relative to the chassis hooks. I mentioned this when I bought the system from my main dealer sometime ago but I was assured that it was the correct system for my car.
I think that I will order some Volvo rubbers for next time.

You only need one support band on the rear silencer Ian, it also has offset hooks to line up withh the hooks on the bodyshell. Use the ones above/halfway along the silencer box.
The hooks on the rear-most end that are closer together are for a different version of the back box only available on certain 740 Turbo models with twin tailpipes, as i discovered on my last 740 when a NOS Turbo tailbox came up on ebay as i was about to order the new back box to complete the system
I struggled to try and fit the oval band to it until i realised i didn't need to!

[Ian21401]

Originally Posted by Laird Scooby

You only need one support band on the rear silencer Ian, it also has offset hooks to line up withh the hooks on the bodyshell. Use the ones above/halfway along the silencer box.
The hooks on the rear-most end that are closer together are for a different version of the back box only available on certain 740 Turbo models with twin tailpipes, as i discovered on my last 740 when a NOS Turbo tailbox came up on ebay as i was about to order the new back box to complete the system
I struggled to try and fit the oval band to it until i realised i didn't need to!

Dave, is that support band you refer to a Volvo part?
When I originally raised the issue with the main dealer I was advised that no such item existed. I tried shopping around but could only find bands with one hook so fitted two bands with their hooks aligned with the chassis hooks.
So, despite what the dealer said about the back box being the correct one for my car it appears that they were wrong.

[Laird Scooby]

Originally Posted by Ian21401

Dave, is that support band you refer to a Volvo part?
When I originally raised the issue with the main dealer I was advised that no such item existed. I tried shopping around but could only find bands with one hook so fitted two bands with their hooks aligned with the chassis hooks.
So, despite what the dealer said about the back box being the correct one for my car it appears that they were wrong.

https://www.ebay.co.uk/itm/Exhaust-H...2/401445707709

That's the sort of thing Ian, the OE part is similar. Should fit straight on to the back box you have.

[Forrest]

I wasn’t aware of the hooks on chassis being offset. This is the part I used which, whilst non-oem, looks identical to the genuine Volvo part just fitted to my other car by the local garage.

https://www.ebay.co.uk/itm/VOLVO-740...9/274066516433

It seems to fit just fine. However, the part which I removed and which was broken looks exactly like the offset one in the link posted by Laird Scooby. I wonder whether Volvo used a mixture of offset and straight. If mine had the wrong part fitted last time it might explain why it broke.

[Laird Scooby]

Originally Posted by Forrest

I wasn’t aware of the hooks on chassis being offset. This is the part I used which, whilst non-oem, looks identical to the genuine Volvo part just fitted to my other car by the local garage.

https://www.ebay.co.uk/itm/VOLVO-740...9/274066516433

It seems to fit just fine. However, the part which I removed and which was broken looks exactly like the offset one in the link posted by Laird Scooby. I wonder whether Volvo used a mixture of offset and straight. If mine had the wrong part fitted last time it might explain why it broke.

Are both of your cars the same year, fuel, engine etc? I know i had one of those "straight" clamps/straps from Charlton Volvo, it wouldn't go anywhere near fitting mine because of the offset (i'd ordered the offset one originally) and they sent me the correct one after i pointed this out.

Sadly exhaust fitters often go with "what they're given" assuming it to be all correct and just fit it and hope.

[bob12]

Think I put up a post about all this stuff a couple of years or so ago when one of the off-set 'rubbers bonglers' on the back box clamp hanger of my 745 (same a 940's) gave up the will to live whilst driving (the noise of the tailpipe dragging on the road and effect sends strange vibration up the driver's seat!!).

Fixed the back box on the road with some wire enough to 'do' a 40 mile round trip. One 'bongler' was still attached to the a snapped clamp hanger and the other had left company with the remaining hanger and the chassis.

Basically, the off-set back box hanger bracket as ^^^^ had failed at the minimal electro spot weld on one side and the other side couldn't cope with the stress.

Subsequently, I welded the hanger back on to the clamp (that will never snap off again!!).

Trouble was that the stress very shortly cause the mid-box hanger clamp bracket to play up. As it was Winter and, after a preliminary skirmish underneath to assess the extent of the 'problem', I took the sensible decision to get my mechanic to attend to it once and for all (or at the least until rust and age reappeared!!). For £100 he put in a new mid-box and set-up the length of exhaust pipe and silencers without stress.

Two years later with only a new mid-box we are still happily motoring!!

Bob

[Forrest]

Originally Posted by Laird Scooby

Are both of your cars the same year, fuel, engine etc?

The one that just had the new Volvo exhaust is a 1997 2.3 LPT estate and the one I fixed myself with the bracket from Charlton Volvo is a 1994 2.0 Wentworth estate. I wasn’t aware of having to force anything to get the new bracket to fit. I think it was probably the offset one that was wrong.