Replacing exhaust system

[Ohioan]

I recently replaced the exhaust system in my 2005 Saab 9-5Arc sedan.


It wasn't too bad of a job, but there were some challengesalong the way.

I documented what did and made a PowerPoint presentation. Iam hoping it can be of some assistance to others who are replacing their Saabexhaust system. Here is a link to it (pdf):

https://www.dropbox.com/s/589evnitpf...ystem.pdf?dl=0

[MikeB63]

I am curious as to why you cut the chrome-finish piece off the end of the tail muffler pipe. Did it not fit correctly?

[Ohioan]

It was too long... it was touching the inside of the bumper. I didn't want to cut a hole in the bumper, so I removed the chrome piece, and then made a cut in the pipe to angle the exhaust gases downward. (The OEM was cut in the same way.)

To make the cut, I used a standard cross-cut ("chop") saw with a metal-cutting blade. The blade was turned 45 degrees. It was a two person job... my daughter held on to the end of the muffler.

[Digger]

I recently replaced the exhaust system in my 2005 Saab 9-5Arc sedan.


It wasn't too bad of a job, but there were some challengesalong the way.

I documented what did and made a PowerPoint presentation. Iam hoping it can be of some assistance to others who are replacing their Saabexhaust system. Here is a link to it (pdf):

https://www.dropbox.com/s/589evnitpf...ystem.pdf?dl=0

Good DIY write up!!!
No small job to do while laying on your back and harder than heck to separate those rusty flanges when you don't have a torch and air tools.
Most flex sections fail from metal fatigue long before they fail from rust and now that you have a good new strong one behind the CAT you can be expecting to replace the short one in front of the CAT next. Should be a couple to several years before you need to do this, but when the time comes, if your converter is still good, get a short replacement flex from your local auto parts store and save yourself a ton of money by replacing that one bad section of pipe.

[spp1009]

Hello! Can You recomended delete or change CAT? or do nothing with it if I have a SAAB 9-5 2001 MY and mileage about 120000 km (less than 100.000 miles). Thanks a lot!