The OEM tailpipe arrangement on all Volvo 240's was under the axle --- so I thought I'd stick with that. It makes it SO EASY to remove the system for other work. Exh mani collector is 3" with a 3" x 2.5" reducer. 2.5" pipes (with H-pipe) all the way back. The mufflers have 2.75" inlets/outlets. And you can see, everything tucks up quite nicely.

Attachment 714678

 

Nice! I didn't realize LS3 manifolds had 3" outlets. Unless you have headers, and I didn't catch it..... either way, a nice system!
Always liked the 240 and previous Volvo 2-door sedans. Practical design, very sturdy. Then when injected with 400+ HP..... ohhh yeah....

 

They don't - I'm running cast stainless steel units from Speedway Motors. Bigger primaries too. Figured I'd use them in the event the rest of the system should need to be upsized for some unforeseen future shenanigans.....

Attachment 713689

Attachment 713690

 

Ahhh yeah I had forgotten those were available. Probably uncorks things a little. They look nice!

 

Yeah - when you see all the stock dual pattern cams crutching the exhaust side on these motors, a little help on the exhaust side seems to be the right thing to do.

 

I learned something new today, never seen an OEM exhaust run under a live axle. I've needed to put tailpipes on my car for years but under the axle is the only way to do it and I've been reluctant to do it, good to know some OEM's do it that way. I just have to remind myself that I don't really do much Duke's of Hazzard driving any more, and I'm really over the drone....

 

Of course, the 100 horse Volvo 4 cylinder just has a single - under the passenger side and then a transverse muffler at the rear exiting on the driver's side.

Below was the first version I used for about 10 years on the car -- replica OEM Boss 429 muffler - dual in, dual out. Quiet until the packing burned out, then too loud for me. But no drone whatsoever.

Attachment 712966

About 5 years ago, I replaced the Boss 429 muffler with a pair of 2014 Coyote 5.0L mufflers. Cut the case and turned the exit out the side for duals in the middle of the trunk. Then welded the two cases together for a 32" x 12" x 9" mega muffler. Quiet, bit of a bark under throttle. ZERO drone because the factory cases have Helmholtz chambers inside.

Attachment 714676

Attachment 712967



To drop the system -- 4 bolts on the ball joint connectors; 6 bolts - 3 hangers for each side

With the factory Panhard rod, there's no way to get a tailpipe over the driver's side.

 

I like it! Any way to get a sound clip of it? Gotta sound cool, yet nicely subdued...

 

Page 1, post #14 of this thread. FWIW, it sounds the same as it did before the swap (fox body 5.0L power before the LS). I did this exhaust about a year before the swap. Seems 90 degree pushrod V8's are 90 degree pushrod V8's.

 

love this build!! Thanks for sharing all the details, it's been a big help for my build as well.

 

In post #10, page 1, there's also a bit of audio --- this is the first start video. And it truly was a first start -- first time I turned the key. My bride was uncomfortable with the video and told me "Just tell me what you want me to do!"

 

I didn't catch what your 8.8 came out of but I have seen guys use the speed sensor in the newer 8.8's with antilock to report to the ecu. Mine came from an Explorer and has the ring and pick up.

 

I started with a bare housing out of a Lincoln. Added TrueTrac and 3.55 ring/pinion; Moser axles; plastic rear cover from the JY. No tone ring. No place in the cover for pickup.

 

Explorers and Mountaineers have the speed sensor in the top of the housing, guess not all 8.8s have that. It's a super convenient place to fill the rear end with gear oil, do it all the time at work.

 

You can see from the pic above, I 'made' my own fill plug this time to make filling easier. Just curious -- how much fluid do you add for Exp/Mount application? I used an old Fox body spec I found that called for 1.8L. Seem to work fine over the last 10 years, so that's what I went with this time too.

 

I used a diff cover from a 2002+ Explorer with IRS. Trim the sides off and it makes a nice finned aluminum cover. Took just under two quarts.

 

Looks nice! As you can almost see from the pic above (post #159) my Panhard bar sits so close to the stock cover that I had to heat/flatten it a bit to clear the ring gear. So a bigger/finned cover will put me into a situation where I'd have to re-fab my Panhard. Love those fins though....Hmmm.....and looks like built-in drain and fill plugs.

What year Explorers/Mountaineers came with that cover? Looks like 2002 (no Sport Trac) - 2010....

 

Here ya go...

 

Unless it’s a 2003 2dr Sport Trac...

 

Well yeah.... there IS that....