It seems that it is time to replace the muffler on my '90 240 again. Up here in the rust belt it seems like I need to do this every 2-3 years. Might anyone out there have a source for a decent set of stainless steel replacement mufflers that will last longer than a few years? The Bosal/Starla ones just don't seem to last and I'm getting tired of replacing them.

 

ouch. our 1987 240 with around 500K miles has its original exhaust ... left coast car. we did have to replace the original cat to pass smog a couple years ago.

 

Ouch, but yum.

Volvo 240 Polished Stainless Steel Exhaust System 2 Mufflers Clamps and Pipes | eBay

 

Looks tempting - but pretty steep price. The Starlas run at $150. I can buy three of those for the same price. I'll have to decide whether the car will last another 6 years.

 

I hear you. I just bought a whole new muffler system for my 940. Used a Bosal catalyst, but a Starla header pipe, resonator, axle pipe, and rear muffler. They seemed pretty decently made, but the rear muffler just didn't do the job for me- its too loud. I don't know how long its going to last, but I painted it with tremclad high temperature brush-on paint. Here's hoping it will help through the harsh winters and associated road salt.

I'd recommend drilling a small hole near the bottom of the outlet-side on your new mufflers. This will help drain the water that collects inside, and avoiding the muffler from rusting out from the inside prematurely.

I don't know about the 240, but Walker makes a stainless steel version of their quietflow mufflers, and sound-wise, they're pretty much just as quiet as OEM. Its the "Quietflow SS" series. Durability, I can't be certain, but if its stainless steel, it should last decently long. For the rear muffler, it cost me about $90 to replace the loud starla muffler.

 

The problem I am seeing with the Bosal/Starla models is that they rust at the weld joints. Really the mufflers are still pretty solid when I take them off. Just the inlet or outlet pipes have come off.

 

Out of curiosity, how long did your original muffler last you?

 

mufflers are original on our 1987 500K mile 240, and my 1992 240k mile 740T.

-salt free left coaster

 

Normally I am getting two years out of the rear muffler, axle pipe and tailpipe. I get a year or two more out of the front muffler.

Back when we had our '89 wagon, I would get 3 years out of the rear muffler, axle pipe and tailpipe when I purchased from Volvo. Not much better. However, the front muffler from Volvo lasted a good 8-9 years. I have never had to replace a Cat as of yet on any of our cars. The front downpipes have lasted a good 22 years.