850 T-5R Wagon Improvement Thread

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...

Forg

Looks good!

Was she already within the OzV family, or is she a new family member?

morch_66479

It's already been in the Volvo family but not sure about here. The original advertisement for this car is still here on ozvolvo from 2022.

morch_66479

RWC TIME:
I've decided to turn this into a bit of build thread (not really a build but more of an improvement thread with updates and works carried out along the way) My Obsession for attention to detail will shine bright in this thread!! haha

After collection I've got straight to work with getting a RWC at Monash Prestige in Clayton - right around the corner from my work at CSIRO. Very high attention to detail and great communication from Ryan.

It was in Monash Prestige hands for a while as it required:
- a steering rack rebuild (I knew something was off with it on the way home in fast sweeping bends - felt a bit disconnected from the road)
- Lower engine mount
- Front tint removal as it was too dark. I'm considering removing all the tint but concerned about damaged rear demister and RL antenna. The tint was only installed last year.

Upon return of the vehicle i realised it urgently needed a pollen filter and another engine mount for my stock as its on the way out. All genuine parts of course 🙂

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morch_66479

VICROADS EXPERIENCE:
After passing the RWC I visited Vicroads to put it on club plates. I still had my club plates from my recent sale of the my 1989 Volvo 245 GL so I asked could I reuse the plates on the T-5R.

When my ticket number was called and i arrived at the counter i was met with a lady (Julia) who wasn't overly friendly but soon warmed to me as I handed all the completed paperwork over the counter. There was 20 mins of talking/reading vicroads policies and the technicalities around the wording - Shall VS May, speaking with higher management who said it was not possible to reuse the plates on another vehicle. Once higher management left, Julia gave me the nod of approval & said she had reused plates in the past as long as:

It was the same permit holder
within the same club

Lucky for me, It's going on my own club that my matesetup, so I signed off on my own permit and walked out of vicroads with approval to reuse my old plates. This also saved me the hassle of handing them back to vicroads ;-)

morch_66479

OTHER ITEMS TO PASS THE TIME:

Of course I've been looking through the entire car and creating a list of items:

Decals: https://shop.zengraphics.co.uk/volvo-850-t5-r-labels
Hot wheels models & some of the best marketing material from the mid 90's: Ebay
Clips/Trims: Putting together a basket with Skandix/IPD over the coming months before hitting the Buy button.
OEM booklet: https://robertdiy.com/products/oem-owners-manual-binder

Tyre type & size is incorrect so I'd like to get the Pirelli P Zero that came on it from factory:
Currently running: Continental - 215/45/17
Factory: Pirelli P Zero - 205/45/17

Also the wiper size are incorrect, currently running 20" x 2 but purchased Bosch 21" x 2 wiper with metal spoiler to be period correct

I also managed to get my hands on a Volvo Composites Splitter when I brought an old group buy thread back to life here in OzVolvo. Turns out @Ghettobird had one he never used so that might go onto my car if i get over the fear of drilling holes in my bumper. Seems a shame :-O

242GT

I brought the splitters in several years ago now , if you decide to put it on use at least 8 preferably 10 , 6mm stainless nylock nuts and bolts BUT make sure you buy the larger diameter 6mm mud guard flat washers to maximise clamping pressure without pulling into the fibreglass splitter or plastic bumper.

This allows you to remove when reqiured for fibreglass repairs and repainting to match top of bumper colour. Use the Bunnings fibreglass repair kit , cheap.

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morch_66479

Thanks for the tips I'll decide at a later date whether I'll install or not. Love the splitter and suits the car so much 👌

morch_66479

ODOMETER, SUNROOF & DECALS:

Fixed the usual broken cog in the odometer and replaced any blown bulbs while I was in there. Parts sourced from Ringwood Speedometer Service:

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Sunroof adjustment to sit flush with the roof:
Had to really take my time removing the plastic trims on the inside and had to adjust all 4 corners, lube rails and check drain pipes for blockages:

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Followed by the Zengraphics arrival:

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morch_66479

RADIO WORKS:

Radio removed to replace the front panel bulbs, I tried to reuse the original globe holders but decided to take the easy route and just order some from eBay but the base needed slight trimming to open up the notch to fit the thick circuit board it screws into. 3 x T3 bulbs were replaced:

The car was randomly throwing the ABS/TRACS warning light and I discovered the radio power wire was connected to the TRACS button. Not sure why but I reverted back to the proper factory wiring.

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I managed to source an OEM remote for this radio too, another rare item to begin my obsession for collecting parts etc. I got the heads up from reading @rado build thread.
I also ordered and installed the GROM bluetooth adapter kit from Cushie Audio which means i can connect and control my phone/ipod and take calls all with my original radio. Great piece of kit https://cushieaudio.com.au/product/grom-usb3/?attribute_option=VOL94U3

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WHEEL/TYRES:

The wheels were tidied up y the previous owner and look great but I might go down the road of full refurb at a later date.
- New tyres ordered fitted - Pirelli P-Zero in correct factory size 205/45/17
- New valve stems due to the old valve stems threads being corroded/damaged. I ran a die over the original valves but they were too far gone so ordered a new set. Turns out the entire valve stem was seized on every rim so my visit to the tyre shop extended to 4 hours. I ended up using my own tools to drill out each valve.

Unfortunately one of the shop workers failed to used the plastic wheel weight scraper and badly scraped the inside of the rims with the metal scraper :-(
- New centre caps

The tyres really have changed the look of the car and just looks neater compared to the 215/45/17

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BOOTLID LOGO's:

The boot lid was previously sprayed and all the logo's were mounted wrong - maybe thrown at it from a distance haha The race emblem was on upside down too. I corrected this but sourcing the original dimensions and marking it all up.
Much cleaner now (although i need to adjust the rear plate mounting location and center the exhaust tip)

The exhaust tip sat in underneath the car when i bought it so i made an extension to bring it out close to flush with the rear bumper

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rado

The rear looks very neat and tidy , shame about the wheels at the tyre shop .
Where on earth did you find the remote control ? Took me a while to find mine ..

morch_66479

rado Yeah, i think this is pretty common to use the metal blade but super frustrating when you ask for it not to be used.
I just seen it on eBay but i have a bunch of other items to collect yet too!!

carnut222

Looking great! Following!

morch_66479

So I've decided to find out what i need for the getting remote central locking and alarm (Volvo Gaurd) system setup in my T-5R.
I already have Central locking but not remote. It also has the little sensor in the dash pad - mine has 2 duties apparently:

LED for indicating alarm status and also a deterrent for criminals

A sunlight sensor which is apparently connected to the Climate control system to assist with setting when in Auto mode.

Unfortunately i think i burnt this little unit out when testing with my DC power supply and looks like i need to chase relays/remote fobs/horn etc to complete the remote locking & alarm system. Anybody with parts available let me know but I've in chats with someone in the USA to source these items as we speak.

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Taken from: https://volvo850wagon.wordpress.com/category/relay/

Another item i ordered from Ireland was number plates for any display days i might attend:

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morch_66479

GLOVEBOX REPAIRS:

Continued works on the dash meant more jobs in the glovebox:

- Hinge mounts were crumbling apart like a cookie so i managed to salvage a few pieces, glue them back together and lather it with fiberglass matting.

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After mounting all the clips I redrilled the holes so purchased this 90 degree drill adapter:

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The glovebox lock didn't turn all the way to the locked position but it turns out the door had been stripped in the past and reassembled incorrectly. I just flipped this rod around and we're good to go:

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Next step to find the compartment box as mine is broken on all the mounting holes.

morch_66479

HOT WASH, EXTERNAL TRIMS, CLIPS, SATEFY FEATURES, WRECKERS HAUL:

Hi All, I'm back after many weeks of hoarding parts and doing the odd job on the T-5R. my work rate has slowed down as we welcomed our first child in the world in mid Aug.

I've been receiving parts orders from all over:
Sweden
Japan,
UK,
Western Australia - the best goodies came in this delivery :-)

I managed to attack it with a hot wash and get it a little cleaner but it was pretty clean already.

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I removed some earth wiring and bus bar that must have been installed in Japan for some audio system I guess? Turns out some of the leads were incorrectly fastened (note the one going to the hose clamp with a rubber seal on it) and some were just tucked behind covers. Since removing this harness I've lost my GROM Bluetooth connection and have a whining noise from the radio when driving. So i may need to install one lead back into the system:

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I removed the 2 front mud gaurds and they had cracks and replaced them with good used ones and also used new Volvo rivets for the install. Of course i hot washed behind behind the arches whilst i was in there. I also replaced the FR wheel arch liner as the original one was torn (maybe from previously running a large sized tyre)

Right side sill clips were also missing and tabs slightly bent so this was all corrected in the process:

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Further to this i added a fire extinguisher bracket in front of the passenger seat. It's neatly tucked away but only concern might be that the seat may collide with it so i may need to change design at a later date.

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I also noticed that the front passenger kick panel had 2 holes in it where the JDM roadside flare used to reside so i installed one to fill the holes:

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Turns out a local wreckers was wrecking an 850 so I went ahead and grabbed a bunch of parts f

orm it and also managed to get my hands on the headlight wiper kit but the right motor has failed. Also the trims under the headlights need paint. I'll finalise all the parts before getting paint done.
Other items from the wrecker:
- Washer bottle cap
- English owners manual
- Clips, screws, trims etc
- Rear mud guards
I'm a big fan of the headlight wipers and also have a v70 roof rack set aside but unsure whether to install or not.

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Tzantushka

This is a great start and love the attention the wagon is getting!
And Imlachs can be a treasure trove of goodies - just depends on what arrives.

will you be coming to the Bosch / Highball Cars & Coffee in Oct?

morch_66479

Tzantushka
Thanks, It'll be a long road with the little details but so worth it. The more i work on it the more little things i need to go back to Imlachs for haha They rarely get 850's in there though.
E.g: today i discovered I need: A-pillar clips & various clamps.

Yes, I do plan to attend Highball if weather is decent. I've never been before.

morch_66479

FOG LIGHT & ASSOCIATED WIRING:

I ordered a broken LH fog light from Jauce and built one good fog out of 2 not so good fogs.

The silicone terminal wraps fail in the connectors which are used all over the car from indicators, fuel pump relays, door lights etc etc.

I purchased new kits from @p80r_etrorebuild on instagram. He's coming out with a better version as we speak.

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old dome was damaged but easily swapped out.

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final product, now onto the wiring!

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mew terminal covers being heated in hot water to make it easier to slide over the wires.

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