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.

 

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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.

 

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09.09.2005: Ramps
Raise the rear end of the car.

 

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

 

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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.

 

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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.

 

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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.

 

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09.09.2005: New vs old
Both exhausts on the ground. You can see that the pipes aren't much thicker.

 

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

 

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

 

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09.09.2005: New vs old
The sport muffler is much smaller too.

 

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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.

 

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09.09.2005: Mufflers
Even the hangers are stainless, with their ends protected by plastic sleeves.

 

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

 

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09.09.2005: Muffler joint
Install the rear muffler and join it with the other end of the pipe.

 

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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.

 

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09.09.2005: Muffler cement
Clean the front joint from the old sealant and apply some muffler cement.

 

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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.

 

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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.

 

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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.

 

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09.09.2005: Muffler
A close-up of the new muffler.

 

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

 

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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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