So I have been reasonably busy trying to get this car 100%. I started with replacing the head gasket as it was leaking. At the same time, I decided it was a good idea to just reseal the engine and put a new timing belt on it. The head gasket was fairly painless, though I did have to fight any number of rotten connectors to get it back together.
Pulled the trans for rear main replacement:
And i found that someone had previously cut a torque converter with a torch. Luckily I had a flex plate kicking around I could swap that one for.
And some new mounts to replace the saggy originals. I didn't have any issues with them really, but I figured it was a common sense item while everything was already out.
Something I don't have pictures of but it worth mentioning, is that I swapped the timing belt to the setup from a 1994 960. This was really easy to do, and stretches the service interval from 30k miles to 50k miles, and I deem that worth it. Here's the link I used to guide me through:
https://www.matthewsvolvosite.com/forums/viewtopic.php?f=2&t=43798 I kept all the stock pulleys, you just modify a idler and you're good to go. If you wanted to swap to the 97-98 style it would require significantly more parts changing.
I've also taken advantage of the car being off the road to address the suspension. It made every noise you could imagine, and was so bouncy it was genuinely concerning on rough roads. I found this when I pulled the struts...the nut that holds the insert in the sleeve was gone. It shot ball bearings everywhere.
In their place went a set of BC DS Series coilovers. I did put pads, rotors, and stainless lines all on at the same time.
I'm reasonably happy with them honestly. I did request that I get a softer spring rate than what they generally come with, so they're reasonably compliant. The only thing I wish was better would be that rebound on the rears was stiffer. Even dialed all the way up there's too much jounce for my liking, but it's livable.
Things that are currently in progress include:
S60R seat swap!
No, they do not fit. It is also not easy or straight forward, there's been a lot of cutting and welding on seat frames.
I've also got a set of BMW style 19 wheels to go on it. I'm waiting on some bolts that are perpetually stuck in customs, then they'll be refinished and thrown on there.