Found my sputtering exhaust noise :)
I've had a tiny exhaust sputter for some time, but knowing what a cash disposal and pain it would be to fix anything on this car, I've just lived with it. When I started it last night, it immediately roared, something catastrophically failed right them. Driving home, it was louder than driving the Chevelle with the headers uncapped, but it was an embarrassing exhaust note (ricer-like), not a cool one. I told my wife, that was the sound of $1-2K problem.
I put it on my lift today to take a peek. Not good! The downpipe broke completely away from the flange. I just drenched the nuts and O2 sensors with Kroil rust penetrant to soak until parts arrive and left it.
From the lack of forum posts, it doesn't look like this failure is very common. I'm guessing that getting the flange welded back on wouldn't have good results, the flange needs to be precisely clocked, and the way I weld, I would warp it. Don't know if I would trust a muffler shop guy to do it any more than I trust me. It looks like the Volvo OE part is around $1,300 on-line. An aftermarket from FCP is about $480. IPD has a performance unit for the V70, which I would like, but it doesn't fit an XC 40.
OK, what should I do? It looks like if I can get the 3 nuts off, it should come out easily(?). The nuts on the resonator look impossibly rusted, they may be coming off with a dremel and use bolts to go back together. Thanks for any advice or warnings. Or musings.
'04 XC70, Ice White, Taupe. Original owner (196K miles as of may21). 6 wheel bearings, broken ignition switch, broken turbo downtube flange, failed throttle body, many warped rotors, and a myriad of weird crap. Still my favorite car ever.
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