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9000 exhaust system Posted by skibumm100 [Email]  (#3255) [Profile/Gallery]
(more from skibumm100) on Mon, 27 Aug 2018 06:54:15
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The intermediate muffler rotted out on both ends on my 96 Aero. When I bought the car, the kid threw in a stock replacement intermediate muffler and the rear muffler. The intermediate muffler was a Walker but it was oval and not the funny shaped flat one I usually buy. No biggie, I don't care what it looks like. Normally changing the cat back stuff is a couple hour job. Not this time. The tapered flange connector on the cat pipe was rotted to the point where there was a chunk missing. I cut the end off of the stock cat pipe just behind the flange. I also cut off the mating piece on the new flex pipe section to give me two straight sections. I tried to find a pipe connector to mate the two 2-1/4" ID pipes. They are about 2-3/8" OD. I tried the 2-1/2" OD connector from AZ but it was a sloppy fit after cutting off the swagged ends. They didn't have a belled end connector that would fit. The last thing I tried worked - I bought a 18" section of 2-1/2" SS exhaust pipe and cut off about 5" of the straight section. This provided a good snug fit w/o too much slop. The next problem was the hangers on the intermediate muffler weren't in the right place, not even close. Everything else lined up so I don't know if this was for an earlier version of the 9000. As far as I was aware, all my 9000's had the hangers in the same place. I had to cut the old hangers off the old rotted Walker intermediate muffler and weld one on the elbow going into the new intermediate muffler and one onto the hanger that's in the wrong place welded to the new muffler. The new flex pipe from Eeuro didn't have nuts on the studs. Of course I had to search high and low for the right size nuts. Shoulda bought new ones at the parts store. By the time I was done, it took 10 hours to do this job including two trips to the parts store. Not the way I wanted to spend my Sunday. The guy at AZ had a 9-5 in the lot. I asked him about a good Saab indy in the area and he didn't have one. He takes it into the dealer for service. I told him he's going to go broke doing that. Even though he works for AZ, I pointed him toward Eeuro since AZ doesn't carry all the parts he'll need.
posted by 165.225.3...
_______________________________________ long-time listener, first-time caller Saab glutton for punishment
, Mon, 27 Aug 2018 06:54:15 <-- Viewing This Message
, Tue, 28 Aug 2018 12:05:33, Mon, 27 Aug 2018 07:05:29, Tue, 28 Aug 2018 14:16:28
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