V8 Sport - Catalytic Convertor Replacement Options
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    1. #1
      Global Moderator R-Pow3R3d's Avatar
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      Question V8 Sport - Catalytic Convertor Replacement Options

      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...erter-36000060


      Magnaflow makes a replacement (MagnaFlow 24358) which sells for about $500:
      https://www.magnaflow.com/products/2...ytic-converter


      RockAuto has a half dozen options from $300 - $450:
      https://www.rockauto.com/en/catalog/...converter,5808

      Muffler Express has one for about $250:
      https://mufflerexpress.com/products/...05-2011-center


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


      That's quite a spread. Any advice or experience?
      Last edited by R-Pow3R3d; 09-21-2019 at 06:42 PM.
      2004 V70R MT TiGray/Nordkap - Replica 18" Pegs - Handbrake Mod
      2007 XC90 V8 Sport Passion Red/Off-Black - Serpentine Belt, Tensioner & Idler Pulleys - Spark Plug Replacement - Y-Pipe Replacement
      1990 745 Turbo Intercooler White/Beige
      2006 XC70
      VIDA/DICE Owner - SS Lurker Since 2009 - '06-'07 Transmission Valve Body Info - SR/VR Failing Throttle Body
      Current Non-Volvo: 2007 VTX 1800 F3, 2002 VT750DC
      Previous: 2006 S60R, 1999 F250 Powerstroke, 2005 TSX, 1997 Bonneville, 1998 Concorde

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    3. #2
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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.
      2009 XC90 V8 R-Design

    4. #3
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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.
      John C
      ---------------------
      2011 XC90 3.2 171,000 miles and counting...

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    6. #4
      Global Moderator R-Pow3R3d's Avatar
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      Quote Originally Posted by PAX5 View Post
      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...
      2004 V70R MT TiGray/Nordkap - Replica 18" Pegs - Handbrake Mod
      2007 XC90 V8 Sport Passion Red/Off-Black - Serpentine Belt, Tensioner & Idler Pulleys - Spark Plug Replacement - Y-Pipe Replacement
      1990 745 Turbo Intercooler White/Beige
      2006 XC70
      VIDA/DICE Owner - SS Lurker Since 2009 - '06-'07 Transmission Valve Body Info - SR/VR Failing Throttle Body
      Current Non-Volvo: 2007 VTX 1800 F3, 2002 VT750DC
      Previous: 2006 S60R, 1999 F250 Powerstroke, 2005 TSX, 1997 Bonneville, 1998 Concorde

    7. #5
      Global Moderator R-Pow3R3d's Avatar
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      Quote Originally Posted by R-Pow3R3d View Post
      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.
      2004 V70R MT TiGray/Nordkap - Replica 18" Pegs - Handbrake Mod
      2007 XC90 V8 Sport Passion Red/Off-Black - Serpentine Belt, Tensioner & Idler Pulleys - Spark Plug Replacement - Y-Pipe Replacement
      1990 745 Turbo Intercooler White/Beige
      2006 XC70
      VIDA/DICE Owner - SS Lurker Since 2009 - '06-'07 Transmission Valve Body Info - SR/VR Failing Throttle Body
      Current Non-Volvo: 2007 VTX 1800 F3, 2002 VT750DC
      Previous: 2006 S60R, 1999 F250 Powerstroke, 2005 TSX, 1997 Bonneville, 1998 Concorde

    8. #6
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      too proper... id gut them ...they are past the main cats.
      2006 S60R 2.4 T5 mostly stock fine tuned by https://urbastuning.wordpress.com
      ipd = sways, inter-cooler, inlet/TB/OTE silicone piping, cat back exhaust, rear camber bushings, sub-frame inserts,
      Originally Posted by John C "We are in the presence of greatness! "

    9. #7
      Global Moderator R-Pow3R3d's Avatar
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      Quote Originally Posted by dougy View Post
      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.
      Last edited by R-Pow3R3d; 09-22-2019 at 05:07 PM.
      2004 V70R MT TiGray/Nordkap - Replica 18" Pegs - Handbrake Mod
      2007 XC90 V8 Sport Passion Red/Off-Black - Serpentine Belt, Tensioner & Idler Pulleys - Spark Plug Replacement - Y-Pipe Replacement
      1990 745 Turbo Intercooler White/Beige
      2006 XC70
      VIDA/DICE Owner - SS Lurker Since 2009 - '06-'07 Transmission Valve Body Info - SR/VR Failing Throttle Body
      Current Non-Volvo: 2007 VTX 1800 F3, 2002 VT750DC
      Previous: 2006 S60R, 1999 F250 Powerstroke, 2005 TSX, 1997 Bonneville, 1998 Concorde

    10. #8
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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!).
      2009 XC90 V8 R-Design

    11. #9
      Junior Member SteveP's Avatar
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      Quote Originally Posted by R-Pow3R3d View Post
      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
      His: 2015.5 V70 Premiere E-Drive Silver/Black Hers: 2006 XC90 V8 Silver/Black
      Gone But Not Forgotten:
      2010 C30 T5 R Design Passion Red, 2004 V70R Ti/Gobi, 2004 S80, 2001 V70, 740GLE and too many 240s to count!
      To R is Still Human!

    12. #10
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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
      03 XC90 2.5T
      02 C70 HPT
      06 s40 AWD
      98 S70 T5M SOLD
      05 XC90 v8 SOLD

    13. #11
      Global Moderator R-Pow3R3d's Avatar
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      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:
      20190925_154214.jpg
      20190925_154311.jpg

      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:
      20191018_200935.jpg

      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:
      20191018_214416.jpg

      The old unit, torn apart, for reference:
      20191018_215837.jpg
      2004 V70R MT TiGray/Nordkap - Replica 18" Pegs - Handbrake Mod
      2007 XC90 V8 Sport Passion Red/Off-Black - Serpentine Belt, Tensioner & Idler Pulleys - Spark Plug Replacement - Y-Pipe Replacement
      1990 745 Turbo Intercooler White/Beige
      2006 XC70
      VIDA/DICE Owner - SS Lurker Since 2009 - '06-'07 Transmission Valve Body Info - SR/VR Failing Throttle Body
      Current Non-Volvo: 2007 VTX 1800 F3, 2002 VT750DC
      Previous: 2006 S60R, 1999 F250 Powerstroke, 2005 TSX, 1997 Bonneville, 1998 Concorde

    14. #12
      Junior Member Orange's Avatar
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      Nice job. How was the fitment ?
      The old cat converters sell for quite a bit for recycling being genuine and double

    15. #13
      Global Moderator R-Pow3R3d's Avatar
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      Quote Originally Posted by Orange View Post
      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.
      2004 V70R MT TiGray/Nordkap - Replica 18" Pegs - Handbrake Mod
      2007 XC90 V8 Sport Passion Red/Off-Black - Serpentine Belt, Tensioner & Idler Pulleys - Spark Plug Replacement - Y-Pipe Replacement
      1990 745 Turbo Intercooler White/Beige
      2006 XC70
      VIDA/DICE Owner - SS Lurker Since 2009 - '06-'07 Transmission Valve Body Info - SR/VR Failing Throttle Body
      Current Non-Volvo: 2007 VTX 1800 F3, 2002 VT750DC
      Previous: 2006 S60R, 1999 F250 Powerstroke, 2005 TSX, 1997 Bonneville, 1998 Concorde

    16. #14
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      Quote Originally Posted by R-Pow3R3d View Post
      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.
      John C
      ---------------------
      2011 XC90 3.2 171,000 miles and counting...

    17. #15
      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 :/

    18. #16
      Global Moderator R-Pow3R3d's Avatar
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      Quote Originally Posted by simon_templar View Post
      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.
      2004 V70R MT TiGray/Nordkap - Replica 18" Pegs - Handbrake Mod
      2007 XC90 V8 Sport Passion Red/Off-Black - Serpentine Belt, Tensioner & Idler Pulleys - Spark Plug Replacement - Y-Pipe Replacement
      1990 745 Turbo Intercooler White/Beige
      2006 XC70
      VIDA/DICE Owner - SS Lurker Since 2009 - '06-'07 Transmission Valve Body Info - SR/VR Failing Throttle Body
      Current Non-Volvo: 2007 VTX 1800 F3, 2002 VT750DC
      Previous: 2006 S60R, 1999 F250 Powerstroke, 2005 TSX, 1997 Bonneville, 1998 Concorde

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