Sport exaust installation on the 1996 Saab 900. The old exhaust system is being replaced with a "sport" cat-back exhaust from the Saab Catalog. The new exhaust is fully stainless, has a straight throught middle pipe and a small muffler in the back. It produces a nice rumbling sound at idle and a proper aggressive note on acceleration. In the same time it manages to remain quiet at cruising speeds.

Tools:

  • 13 mm socket;
  • ratchet handle;
  • muffler cement;
  • ramps or jacks and stands.
09.09.2005
Old exhaust

This is the old exhaust system. The muffler sits strangely low, but it's always been like this. It's in a good shape, and will go to a fellow club member.
09.09.2005
Ramps

Raise the rear end of the car.
09.09.2005
Flex pipe joint

Undo the clamp at the joint between the flex pipe and the silencer.
09.09.2005
Silencer

The silencer is old and has a couple of rust areas. The U-shaped pipe that goes around the fuel tank had seen its better days also.
09.09.2005
Muffler joint

The other clamp is right in front of the rear muffler. Undo that, and remove the old exhaust system from the car.
09.09.2005
Sport exhaust

The sport exhaust as it came out of the box. It is used, I bought it on eBay. However, being stainless, it hardly shows any wear.
09.09.2005
New vs old

Both exhausts on the ground. You can see that the pipes aren't much thicker.
09.09.2005
Old vs new

The old one consists of two pieces, while the new one has an extra joint in the middle.
09.09.2005
Old vs new

The old one has an extra silencer, while the sport version is just a straight pipe.
09.09.2005
New vs old

The sport muffler is much smaller too.
09.09.2005
Mufflers

It is odd that the joints on the mufflers are different. Perhaps, it's made on purpose to prevent you from mixing old and new parts.
09.09.2005
Mufflers

Even the hangers are stainless, with their ends protected by plastic sleeves.
09.09.2005
Flex pipe joint

Put the centre pipe on and connect it to the flex pipe.
09.09.2005
Muffler joint

Install the rear muffler and join it with the other end of the pipe.
09.09.2005
Clamp

Adjust the position of the exhaust system, make sure the pipes are level and don't rub against the body or the heat shield. Tighten the clamp on the middle joint.
09.09.2005
Muffler cement

Clean the front joint from the old sealant and apply some muffler cement.
09.09.2005
Front clamp

Tighten the clamp. Be careful not to place too much strain on the flex pipe, it doesn't like that.
09.09.2005
Muffler cement

Apply more muffler cement on the rear joint. You can see how low the Intrax springs are. I have perhaps only an inch between the bump stops in the rear.
09.09.2005
Rear clamp

Tighten the clamp. This one has a shiny new bolt -- I snapped it when removing the clamp and ended up hammering out the old bolt seat and using a regular nut with a washer on that side.
09.09.2005
Muffler

A close-up of the new muffler.
09.09.2005
Muffler

Another view of the muffler. The 22 mm Genuine Saab sway bar is seen in the back ;]
09.09.2005
New exhaust

The new exhaust sits a bit higher and fits the cut-out perfectly. It didn't come with a chrome tip, and I won't bother buying one. It has a good spartan look, like a proper sleeper should.

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