Ex850R

Yep, the plastic in the car is now all brittle thanks to eco crap and wanting to sell new cars.....

I tried all sorts of glue and stuff but beware,adding mass to the tailgate brings it down real quick as the gas struts are big but finely balanced.

A new flat or shaped light weight thing to replace the whole lot would be better.

Carbon fibre?

Yeah I'm not running the spoiler atm since it seems to weigh it down too much. Do you know of anywjere where someone has tried making a flatter tailgate?

      Will Get new gas struts for the tail gate of eBay there and easy to replace and make a difference

      Regarding the tailgate, I wouldnt have any additional sound deadener in the tailgate itself. I'd replace the tailgate struts with good quality replacements (do both). Source a replacement tailgate lower trim from a wrecked car (yes they're getting harder to come by but are around) and fit a tailgate trim repair kit to it before fitting. Replace all the clips that fasten it in place and then put it all back together.

      Some of the trim is getting old and terrible now but some of it is just too hard to repair as well.

      The above is what I'm doing with mine anyway. If I do add additional sound deadener, it certainly wont be inside the tailgate.

      The roof spoiler isn't that heavy, but I am also fitting a full carbon one to mine (it'll save me painting the original).

      Thanks everyone, I plan on removing some deadener. I added it due to drone.

      I have already replaced the struts and i almost never use the boot anyway. The old tailgate struts were dated as 2012 on them anyway so I've kept them.

      I'll try and find a wrecked tailgate to sort it out. It's better with it off and not squeaking than in a broken state.

      Yep , same here . Change the struts , makes a big difference ?

      Drwillis

      https://ozvolvo.org/discussion/comment/194509#Comment_194509

      Yeah I'm not running the spoiler atm since it seems to weigh it down too much. Do you know of anywjere where someone has tried making a flatter tailgate?

      Only when I played with my v70r one adding goop to strengthen it and some noise damping material and it kept falling on my head .

      Thought of just using an old panel and laying up fibreglass or something but never got that far .

      Even flat thin ply would be ok I reckon, carpet it and be done .

        6 days later

        Have left the tailgate for another day. In the meantime I've fixed my dodgy radiator fan plug and done some handling improvements.

        My front sway bushings looked like crap and the bar is marked yellow which apparently means its 21mm.

        I fitted 21mm whiteline sway bar bushings, shackles and lateral locks.They were easy to find and cost me about 80 bucks for all three (on sale). Pns I used are W21105G, W21301 and kll122. The dimensions were very close to stock.

        Had to drop rear of subframe to get the clearance and still couldn't pull the full bar out due to steering guard and angle gear.

        While I dropped the rear, I added bne delrin subframe bushings. Drilled the edge of the old bushing with a 5mm drill bit to crack the liner(careful not to score the subframe) . I could then pull it out by hand and a little prying.

        I used the old bolts and a spacer to drive the bushing in. Once seated in subframe, I used new subframe bolts, replaced front washers and torqued to spec (77ft lbs +120 degrees) .

        Car is a bit tighter feeling now but need to do a bit more driving to really get a good idea of handling.

        Steering still seems a bit heavy. Have flushed power steering fluid so I might try lubing the steering u joint and seeing if it feels better.

        Delrin subframe bushes are much nicer and far more predictable than a worn out oem bush with a urethane insert. Nice work!

          AshDVS

          Delrin subframe bushes are much nicer and far more predictable than a worn out oem bush with a urethane insert. Nice work!

          This car wasn't feeling too bad but my other car had the full 'driving on ice' front end floatyness.

          They also pressed easier than the xc90 ones I put in my other car. Those had to be perfectly lined up or else they Flexed.

            4 days later

            Those delrin bushes look a lot better than the oem set up . I went with the inserts but thinking now I've seen yours to go with those ? hhmmm

            Stevo I have a set I recently fitted and they are a good thing?

            2 months later

            Started on replacing my fuel pump and wiring the other week. The awd design is a bit harder to fit especially since my old housing had been modified/broken and the filter sock was torn. Using extensions and the sock that came with it, I came up with something that works albeit not perfectly fitted (car is running atm with only 10l in it).

            I had to resolder and run new wiring since it had been poorly stripped. I used seal all (fuel resistant) on the wiring pass though and deutsch plugs for the pump and level sender.

            Unfortunately someone's replaced the high pressure hard-line with a pinched soft line and its started pissing from the top of the tank when running above idle. I will come back to it and fix it but don't have room to drop a subframe atm so it'll just sit a while. I'm sure I can just drop tank a little and be able to thread it through. If I did drop the subframe, I will be wanting to weld up hole in floor and fully rebuilt the rear control arms and subframe bushings, possibly chuck in a different Diff (mines a little noisy) and maybe even do wheel bearings.

            Have got a fuel line that I have run under the seat in case I need to move it a short distance.

            I was thinking of rerunning a nylon braided fuel line in place of where the hard line was given hard-line is NLA. The current replacement soft line was routed in the wrong spot so that's why it probably split.

            I needed new rubber strut spring mounts since one of mine is cracking but decided to just rebuild the whole front suspension while the cars off the road.

            I ended getting some koni orange strt (I didnt want it too much more sporty) and some 2nd hand springs (p/n: 3546640) from @AshDVS

            I also had all the new hardware needed since I wanted to originally be able to drive around and fully rebuild these in the side. Went with pretty much all Volvo bits but the spring mount is Sachs xc90 ones and the bearing is INA/FAG. Even bothered to get the little crush gasket?. Most part numbers should be visible in photo if anyone's doing the same

            All in all, it was pretty easy to assemble. Springs seems a little curved when in assembly but I expect this is fine since it is fully seated at each end (correct me if I'm wrong) .

            Look forward to eventually chucking them in and driving the car.

            2 months later

            Finally got around to swapping my turbo out.

            Basic list of stuff I swapped was :

            19t (mellet core with mamba housings and new wastegate and cbv)Green bosch injectors (low kms off xrt6) Aem wideband (ecu runs on wideband only) 3 inch stainless down pipe with resonator Vast ecu ( mods factored in and base tune atm) R manifold (new hardware)

            Was an okay job but took a few weekends since it has been hot and needed to order stuff halfway through.

            Had to cut out the bash guard in order to fit the downpipe (adding heat shielding later to pipe and manifold) .

            The turbo is a bit of pain to fit all lines to on AWD and the downpipe needs to just be attached to catback.

            Primed turbo and it started straight away and Idled okay. Still have to fix some routing, thoroughly check for leaks but a success so far ?

            AshDVS

            What downpipe did you use?

            Aaron from Vast tuning made a batch of awd ones and I grabbed it (was expensive but the dollar was a bit better then). Preferred to pay a bit extra and not have to mess around too much.

                Drwillis

                https://ozvolvo.org/discussion/comment/200527#Comment_200527

                Aaron from Vast tuning made a batch of awd ones and I grabbed it (was expensive but the dollar was a bit better then). Preferred to pay a bit extra and not have to mess around too much.

                Ah, gotcha. it's really nice. well worth paying for.

                TL_V70

                Thats a really nice dump pipe

                Agreed.

                • rado replied to this.
                      AshDVS

                      https://ozvolvo.org/discussion/comment/200529#Comment_200529

                      Ah, gotcha. it's really nice. well worth paying for.

                      https://ozvolvo.org/discussion/comment/200535#Comment_200535

                      Agreed.

                      +1 ?

                        9 days later

                        Hey @Drwillis , as yours is an early '98, badge placement looks to be as per '97 - any chance you can grab some measurements for me, as per - https://ozvolvo.org/discussion/15201/tailgate-badge-placement-1997-p80-v70r#latest

                        Cheers!

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