850 T-5R Wagon Improvement Journey

morch_66479 · 2024-07-07T10:22:04+00:00

Hi All, After 8 years of 240 ownership and multiple 240 rescues along the way I've upgraded to an 850 T-5R. Big drive home from NSW yesterday but it gave m...

morch_66479

The BBK upgrade requires a little more work before install.

rotors centre bore machined out to 68mm and holes for guide pins
new Caliper piston seals
prep and paint
Tested paint shades and adhesion to existing red paint:

Sandblasting:

Replaced handbrake assembly hardware and re adjusted after a few months of new hand brake cable usage.
Also removed, cleaned pins and lubed components:

morch_66479

STRUT BRACE:
I got my hands on a used Volvo strut brace.
Installed and it's a tight fit against the brake booster. I modified the black bracket on the left side and rerouted the ABS wiring but I might do it differently - make 2 bends and have the connector still mounted on the bracket but it rests over the brace. See last images below for reference.

First images are of my car:

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morch_66479

LEFT MIRROR
My heated mirror function has stopped working so I purchased a compete GUL assembly from Japan as my cover had a mark on it too.
Tested and installed. Greased hinges whilst I was in there and done a test on my passenger window motor but I think it's my window switch that's Toast.
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carnut222

Interesting how that door detent thing looks similar to the old 240 door hinges, but it sits inside the door instead.

rado

Strange that the strut brace is that close , I just had a look at mine , here's a picture

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carnut222

I wonder if Martin's car has a different brake fluid reservoir fitted? They look slightly different - @rado 's one looks a bit boxier and stubbier at the front?

rado

carnut222
Yep , looking at mine they're definitely different.

timbo

rado there's different early and late abs setups, so probably different master cylinders

242GT

Definetly different brake fluid reservoir, yours is 850R Steve , Marc is T5-R has a tapered front on it which has filled the air gap shown on Steves , I don't know if they are different from factory.
Perhaps check on Skandix and FCP.
But Steve's 850R wagon has alot more clearance than the T5-R wagon and dosnt have the tapered front on the it the way Marc's dose that fills the clearance gap.
Maybe the strut brace is off a C70 or something. Image description
This is Skandix listed volvo 850 brake reservoir

morch_66479

242GT the c70 brace is the same strut brace used on T-5R & R from what I've read

morch_66479

Yeah, the brake reservoir on the T-5R is bigger than the R. I've spoken with a few T-5R owners that run this brace and they all sit close like mine.
It's possible to move the reservoir around so it's definitely not jammed up tight against it.
Let's call it Swedish Engineering 🤣

Next step is to do the ABS connector bracket mod.

242GT

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Is this the same as yours

morch_66479

242GT it sure is 😊

morch_66479

LEFT MIRROR (update)
Fully installed and works a treat. I think the new glass is the convex version and not a flat glass like my original. Heating works nicely too 👌
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morch_66479

STRUT BRACE (update):
After a couple of trials I decided to just bend the black ABS connector bracket and it looks cleaner albeit a tight fit with the bonnet protection. Freshly painted and installed.
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morch_66479

SPARE WHEEL:
The previous owner had purchased a brand new spare wheel with a Pirelli tyre.
I went through my boot stock, pumped the tyre as it was at 14psi (I'll keep an eye on this) and cleaned out the wheel well.
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rado

morch_66479
Strange that your car has a space saver , thought it would've had a full size spare 🤔

morch_66479

REAR WINDOW WASHER (update)
New parts arrived from Skandix,

Pump
Bracket
Check valves
I also fixed the electrical connector whilst I was in there.
All fitted and back in action:

morch_66479

ECC GLOBES:
I pulled apart the ECC unit to replace the T5 globes. I was expecting them to be your standard 12v 1.2w globe but they're in fact 14v 1.4w. Maybe these are used to increase life span? 2 out of 3 of mine had failed.
Of course I had to fetch the correct globes from skandix - a premium price tag is attached to these 😬
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morch_66479

rado space saver as per the petrol cap labels 😊
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242GT

It's not an R Steve , only the better R's get the full size spare 😁🤣

Jamest5r_

242GT not sure about that, my T5R had a full size spare maybe it was put there by a previous owner or was just a UK/European thing? Never really noticed that before

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