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  1. #1
    Saab Fan
    Join Date
    23 Dec 2014
    Location
    Ohio
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    24
    Saab(s)
    9-5
    Thumbs Up:   4

    Replacing exhaust system

    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

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  2. #2
    Saab Enthusiast
    Join Date
    30 Jan 2017
    Location
    Trumbull, CT
    Posts
    110
    Saab(s)
    2007 9-5 2.3t
    Thumbs Up:   3
    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?

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  3. #3
    Saab Fan
    Join Date
    23 Dec 2014
    Location
    Ohio
    Posts
    24
    Saab(s)
    9-5
    Thumbs Up:   4
    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.

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  4. #4
    Saab Owner Digger's Avatar
    Join Date
    28 Oct 2016
    Location
    Minneapolis Minnesota
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    1,131
    Saab(s)
    2006 9-3 2.0t SportCombi
    Thumbs Up:   156
    Quote Originally Posted by Ohioan View Post
    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.

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  5. #5

    Join Date
    03 Jan 2018
    Location
    RUSSIAN FEDERATION
    Posts
    1
    Saab(s)
    SAAB 9000 CDE 1995MY, SAAB 9-5t 2001MY
    Thumbs Up:   0
    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!

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