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Discussion Starter · #1 · (Edited)
So, the wife's V8 Sport has started to sound a little "open pipe." Just rolled under it and found that one of the flex pipes has let go (there's about a 1/4" gap between the pipe inside the flex and the flange). Looks like it's time for a new Y-Pipe. What have you guys been buying to replace this pipe?

The OEM option is part #36000060, which sells for about $1,500.
https://www.tascaparts.com/oem-parts/volvo-catalytic-converter-36000060


Magnaflow makes a replacement (MagnaFlow 24358) which sells for about $500:
https://www.magnaflow.com/products/...-epa-compliant-direct-fit-catalytic-converter


RockAuto has a half dozen options from $300 - $450:
https://www.rockauto.com/en/catalog...5,exhaust+&+emission,catalytic+converter,5808

Muffler Express has one for about $250:
https://mufflerexpress.com/products/volvo-xc90-catalytic-converter-4-4l-v8-2005-2011-center


There's also some random fleabay replacements which can be had for about $150:
https://www.ebay.com/itm/Volvo-XC90...Converter-2005-TO-2010-12H62-67-/253428930078


That's quite a spread. Any advice or experience?
 

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If I were to buy an aftermarket brand, I would choose BOSAL. I have successfully used the Bosal brand for years on my BMW's.
 

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A custom exhaust shop can probably weld in a new flex pipe if the rest of the system is in good condition.
 

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Discussion Starter · #4 ·
If I were to buy an aftermarket brand, I would choose BOSAL. I have successfully used the Bosal brand for years on my BMW's.
Interestingly, the image of the Bosal is the exact same image as the Magnaflow, but $150 cheaper...
 

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Discussion Starter · #5 ·
Interestingly, the image of the Bosal is the exact same image as the Magnaflow, but $150 cheaper...
Decided to give it a go. Order placed through RockAuto. Should be here at the end of the week. I think I'm going to spray the non-flex bits with high temp black paint to give it a little extra life. I'll take pics and report back.
 

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Discussion Starter · #7 · (Edited)
too proper... id gut them ...they are past the main cats.
I still need something there, even if it's not cats. My problem is the disconnected pipe(s).

The V8 has a decidedly aggressive noise without mufflers.

Edit: Cat shipped. Should be here Wednesday. :thumbup:
 

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Before installing, find out from Bosal how their product may affect back pressure in your system. It may be more free flowing, or less, depending on what the cat is constructed and filled with ... You definitely do not want un-burned fuel to collect in the cat portion! That happened to me once, in a 1981 BMW 320i, with an after market cat (not Bosal!).
 

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I still need something there, even if it's not cats. My problem is the disconnected pipe(s).

The V8 has a decidedly aggressive noise without mufflers.

Edit: Cat shipped. Should be here Wednesday.
I had to replace the cat on the 06 we just bought. Now Mrs. Says the Flowmaster muffler is top aggressive. CarID.com has a bunch of universal fit modules under the XC90 search, but their CSR said they don't carry one that fits

Any recommendation on a mild to moderate one?

Sent from my SM-T580 using Tapatalk
 

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13 xc60 r design, 09 xc90 v8 RD, 12 c70, 07.5 S60r
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I’ve installed the cheap ebay ones several times without any issues..also had them removed by a exhaust shop as well
 

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Discussion Starter · #11 ·
Alright...finally, job done. Boy, what a pain! Those top bolts are SUPER inconvenient both coming out and going in. Before I start, one interesting thing I found out is that Bosal actually IS Magnaflow. Magnaflow bought them in 2016 (LINK), hence the identical photos. The paperwork in the box says Magnaflow. The cats themselves don't have any branding. I don't know if you'd get something different if you paid more for the Magnaflow unit, but I would doubt it.

The Bosal cat looks like a quality unit, although certainly not as high quality as the original one:
Automotive exhaust Muffler Auto part Catalytic converter Exhaust system
Automotive exhaust Auto part Muffler Metal Catalytic converter

Removing the old one meant cutting off four of the 6 bolts. Chris previously replaced the exhaust, so the rear two nuts came off. The four on the flex pipes were good and crusty. Almost providentially, yesterday, there was a deal on the Dremel 575 Right Angle Attachment. It showed up this afternoon a couple hours before I started work. I'm literally not sure I could have cut off all the bolts without it. After cutting them as close as I could, I then spent some time grinding off what was left of the nuts to free the studs. Once I got close to having them ground off, I drove an all in between the two flanges and it did a great job of splitting the units. I used this method of removing the exhaust hangers and it worked great:

Everything finally removed:
Auto part Automotive exterior

To put the new unit on, I started by installing the new rear gasket onto the studs of the exhaust. I then sprayed lubricant onto the exhaust hangers to make it easier to install onto the new cat mounts. I then placed the cat onto the rear studs and slid the exhaust hangers onto the mounts. I put the rear nuts on to secure the back. Then the fun begins. The two lower nuts on the front are easy. The two upper ones are annoying. The top passenger nut is the hardest because access is very poor. I eventually jammed my hand up and around the cats so I could use a 1/4" ratchet above the unit to tighten the nut. Eventually, after much frustration, pain, and swearing, the new unit is installed:
Auto part Automotive exhaust Muffler Metal Pipe

The old unit, torn apart, for reference:
Muffler Auto part Catalytic converter Metal Ammunition
 

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Discussion Starter · #13 ·
Nice job. How was the fitment ?
The old cat converters sell for quite a bit for recycling being genuine and double
As best I could tell, it fit perfectly. I verified the dimensions before removing the old one and they matched up. Once installed, everything matched up nicely. I would recommend this unit.

Yeah, I'm not sure where to send it for recycling. I'll have to do a little research.
 

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Yeah, I'm not sure where to send it for recycling.
Around here there are places with signs in the window reading "We buy catalytic converters". I'm surprised there isn't a bigger problem of converters gone missing, what with the opioid problem and all...

Anyhow, ask an exhaust shop, for starters.
 

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Hi all,

I need to have a total exhaust replacement done on my car (catalytic inverters mufflers, oxygen sensors, gaskets / nuts / bolts hangers / etc..) I see that you used non Volvo parts. How is it going so far ? I'm afraid about the engine check light going on if something does not work correctly, then I would need to pay full price with Volvo parts :/
 

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Discussion Starter · #16 ·
Hi all,

I need to have a total exhaust replacement done on my car (catalytic inverters mufflers, oxygen sensors, gaskets / nuts / bolts hangers / etc..) I see that you used non Volvo parts. How is it going so far ? I'm afraid about the engine check light going on if something does not work correctly, then I would need to pay full price with Volvo parts :/
Everything I replaced is after the o2 sensors, so there should be no effect. The aftermarket unit I used for the Y-Pipe replacement seems to be working fine so far.
 

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R-Pow3R3d - Can you please tell me what other items you replaced? Gaskets and bolts came with the bosal unit? I have the same situation and see the wide spectrum of aftermarket units. Was the exhaust note better.?

thanks
 

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Discussion Starter · #18 ·
R-Pow3R3d - Can you please tell me what other items you replaced? Gaskets and bolts came with the bosal unit? I have the same situation and see the wide spectrum of aftermarket units. Was the exhaust note better.?

thanks
Hey, got your PM, figured I'd respond here so everyone could see it. I'm pretty sure that everything (parts) needed for the replacement came in the box with the pipe. I don't remember buying anything else. I'll try to check my receipts and see if I ordered anything else at that time.

I would say the exhaust note is unchanged by the Y-Pipe replacement (at least compared to when the original was still in functional condition).
 

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2004 S60R M66 AWD and 2008 Volvo XC90 V8 AWD - Climate Pkg, Versatility Pkg, and Convenience Pkg
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I have a 2008 Volvo XC90 V8 AWD with 68K miles on it. I'd like to change the exhaust tips from circular to the weird rounded rectangular-looking ones that look 1000x more sporty in my opinion. Any way to do this without having to take off the entire exhaust system? Any way to replace only the tips? Also, is it worth it to install a new exhaust system like this? Does it increase performance and/or economy? Is it easy to do for a reasonably-competent home mechanic (just did all 8 spark plugs, will be doing coolant flush and oil filter/oil replacement later)?

Curious to see what this offers.
 

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I have a 2008 Volvo XC90 V8 AWD with 68K miles on it. I'd like to change the exhaust tips from circular to the weird rounded rectangular-looking ones that look 1000x more sporty in my opinion. Any way to do this without having to take off the entire exhaust system? Any way to replace only the tips? Also, is it worth it to install a new exhaust system like this? Does it increase performance and/or economy? Is it easy to do for a reasonably-competent home mechanic (just did all 8 spark plugs, will be doing coolant flush and oil filter/oil replacement later)?

Curious to see what this offers.
Just do the dual exhaust.

Available as a kit. Includes all hardware and rear valance skirt.

You won't regret it.

Volvo p/n 30756337

 
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