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

C70 ROOF RAIL INSTALL

From owning a few 240 wagon's over the years, my eyes are just so used of seeing roof rails so I got some from a later model 70 series that have the updated design on the trim that runs down either side of the window. The new design allows the water to be captured by a little gutter that directs the water over the roof rather than across the front driver & passenger windows like on the original 850 trims.
Volvo did bring out an accessory that attaches to either side of the 850 windscreen to capture the water but then later integrated the design into the 70 series trim. Struggling to find a picture of this accessory though.

Parked outside Monash Prestige, awaiting a new rear main seal and PCV kit, rear spoiler removed to clean, paint hardware and readjust fitment:

rado

I've never noticed tbh that your car didn't have roof rails .
Do look better with them but , going through this thread I'm liking the smooth look without them ..volvo blasphemy I know 🤔

morch_66479

SPOILER:
Remived spilier, cleaned, painted brackets and hardware. Refitted and realigned
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morch_66479

DASH PAD:
I found a dash pad at a local wreckers, much cleaner than my original and the tab to the left of the central vents was still intact.
My original tab had broken and someone had put a fist full of silicone & hot glue to keep things together. I spent 1.5hrs cleaning this mess 😩😅
I also used Volvo's anti rattle tape to replace any damaged tape

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morch_66479

REEFTON SPUR LOOP:
Most noticeable difference on this trip was the subframe bush inserts I 3D printed a while back really tightened it up in the corners.

A strut brace and big brake kit is next on the list 😁

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morch_66479

SEAT CLEAN:
Swissvax products used:
Cleaner
Matte correction
Leather milk
Colourlock on the Amaretto

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morch_66479

REAR WINDOW WASHER
bit of an unsuccessful repair, pump gear was seized but broke other components during the repair process. Also those strange 1 way valves in the rear failed.
I just need to buy one of each and I should be good to go. Terminals and connectors replaced during process

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morch_66479

MISC:
Pictures explain other jobs...
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morch_66479

KEY FOB REPAIRS:
Another fob arrived from ebay:
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carnut222

Wow you've been busy as usual. Was good to see the car on Saturday albeit briefly!

morch_66479

FL DOOR:
Issues:
Passenger heated mirror doesn't heat up. I have a complete left side used mirror on its way from Japan. Hopefully the heated mirror on it is working 🤞
When I pulled the door card off and tested voltage on the mirror connector. I was getting 12v downstream but 0v upstream of the connector. The positive terminals were corroded - extract, clean, & apply dielectric grease..... 12v on either side now but mirror still doesn't heat = failed mirror.

The black cap on the lock mechanism was missing on mine. I'd previously tried a v70 cap but they are slightly different than the 850 cap.

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Upgraded the door open warning bulbs to 5w and noticed one of the assemblies was different so swapped that out with correct part:
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morch_66479

CENTRE GRILLE:
I purchased the (allegedly rare but really it's not) centre Grille but unsure whether I like it or not.
Tips for installing: The lower rad cover needs to have the 'T' slot to accommodate the Grille.
The cut out on the left side is for the exterior air temp sensor and there's 2 metal clips and to plastic clips to hold the Grille in place.

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carnut222

So was that lower grille an option or only in some markets or??

morch_66479

PETROL CAP RELEASE (ROUND 2)
Ive swapped out the petrol cap release motor again. Taken from a sedan and just swapped over the the motor assembly onto the wagon bracket.
Worked for 1 day and stopped again.
I opened up one assembly and basically a motor, 2 gears and a worm drive with the lock pin attached. This supposedly failed unit worked when I isolated the motor and gave 12v to it.
Next steps:
Disassemble and leave hanging in the boot to monitor operation and use a test globe to do futhr tests when it fails a cycle.
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Whilst I was in the boot space I installed some recently acquired fabric trims that sit either side of the spare wheel. They're off a 70 series but the 850 has the clips to accommodate the trims:
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morch_66479

CUP HOLDER:
whilst cleaning the armrest last week I noticed 1 rubber cup grip failed.
Good used one fitted.. Easy install of removing a few screws that clamp the rubber down.
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morch_66479

PETROL CAP RELEASE (Round 3)
Another motor installed, opened up the unit and applied Vaseline to the mechanism.
I left it hanging in the car for a few days to check operation before finishing the installation.
It worked successfully but the rubber bush that centralises the locking pin crumbled to pieces so I printed a new one

We're back in action!!
Orange bush: old
Black bush: new
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morch_66479

BIG BRAKE KIT - 320mm
After a few evenings of searching factory brake options for the T-5R that fit under the Titans I discovered the stock setup is 280mm,i could easily go up to 302mm y changing the hanger and disc only.
I could also go to 320mm as this was a factory option but near impossible to find. AP Racing also brought out a kit specific to the 850 in the mid 90s... Again difficult to find.
DVS offers a 320mm kit so I've opted for this setup.... It deviates from my values of keeping factory but it can easily be swapped back.

Snippet from the accessory booklet shows 320mm option:
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I spoke with Ash Davies in person at the 200 series 50th anniversary meet at Shannon's a couple weeks back. He offered some fantastic advice and insights into my future coilover purchase.
Here's some shots of my 320mm setup with rebuilt Calipers - they're from an XR5 but the v50 t5 AWD uses exact same Caliper.
I already have the braided hose installed and plan to paint these with vht paint (cast iron colour) as the T-5R came from factory without Caliper paint so it originally had the 'cast iron' look.

Just need to choose the correct shade:
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242GT

Can't go wrong with Ash , he's very good and goes the extra mile.
You'll be happy with the results

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:

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