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Old 01-17-2020, 01:51 PM   #51
DET17
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Nice fab work on that light bar! Any concerns about the cooling system function with that wall of LED lights?

If the T56 will handle the torque of LS, absolutely do it.

I daily a 9 series, and have owned (and love) the 2 series. I will agree, the "more civilized" nature of the 9 benefits it's use in DD service. They are great highway cruisers to boot.... although with that rubber, I'm doubting that is a concern for you.

Tires...... I sure wish you had put some NITTO Ridge Grapplers on that guy; we can't keep any of them in stock and our dealers are clamoring for more (both TOYO and NITTO products). However, we don't make any 15" product in the States..... maybe the Japan plants might.

Fun project!
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Old 01-17-2020, 02:30 PM   #52
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Nice fab work on that light bar! Any concerns about the cooling system function with that wall of LED lights?

If the T56 will handle the torque of LS, absolutely do it.

I daily a 9 series, and have owned (and love) the 2 series. I will agree, the "more civilized" nature of the 9 benefits it's use in DD service. They are great highway cruisers to boot.... although with that rubber, I'm doubting that is a concern for you.

Tires...... I sure wish you had put some NITTO Ridge Grapplers on that guy; we can't keep any of them in stock and our dealers are clamoring for more (both TOYO and NITTO products). However, we don't make any 15" product in the States..... maybe the Japan plants might.

Fun project!
No real concerns about the cooling system, there is lots of airflow around the lights, E fan and these have big radiators, should be just fine.

Believe it or not, I plan on logging lots of freeway miles with it, the tires look huge, but really they are a 29" tall tire. They ride good and are quiet. I was surprised how civilized it is especially on the highway.

Sounds like you work for Nitto? I have a few buddies that run them with good luck. I have had a couple of less than good experiences with Toyo's quite a few years back so have stayed away from them.....dont hate me though.

Thanks for the props on the light bar, was a fun little evening project that turned out alright.

Sean
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Old 01-20-2020, 12:16 PM   #53
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What a weekend!!

I was stopping by Roys place to grab a few small parts on my way home from Eugene after work on Friday. Thanks again for the good stuff Roy.

We were shooting the **** about seats again. He mentioned a friend had some manual seats but they were cloth....I was in. He called his buddy Joe about a half hour back to the south and Joe was cool. Send him over so I was on my way. Roy said they were in good shape too.

I get to Joes and meet Joe. Cool dude, really into volvos. Go down into his basement and there are two seats, covered in some cat hair but in excellent shape, like as close to new as you could get. I was stoked. $100.00. I mentioned I will have to scrounge to find a rear seat and he asks if its a sedan or a wagon. Sedan....I have the rear seat too. Ill throw it in!!

Not at all planning any of this ahead of time and rain pouring down. I loaded all of this stuff up in the back seat of my dodge.

I spent a few hours on Saturday cleaning up the seats and getting the cat hair off and getting them cleaned up.

The pics just dont do this any justice the hair was like a coat. But the seats were almost perfect so who am I to judge.



Friggin minty seats!!





I had been working on the audio system last week.

Kenwood head unit, Hertz 5" separates, with the mid in the door and the tweeter in the dash

Hertz 6x9's in the rear deck

Hertz old school EP4 4 channel amp

Fosgate P2 DVC sub.

My buddy Andrew and Scott stopped by on Friday night and both lent a hand. Thanks fellas.

I had a few little issues, bought the wrong sub the first time around so had to return it on Saturday for a 4 ohm version.

Pre fabbed box will go away after I build something cooler and fitting for the trunk but for the time being this will work.



Got the lights all wired up and operational too.





They are oh my god bright. If anyone is considering them for $99.00 each its a great deal. 32 Cree LED's and a proper mount and everything.

https://www.amazon.com/Primelux-8-in.../dp/B01GZST326

I went junk yarding for stuff to seal up the shifter hole. Grabbed some insualation and some shift boots to try out, got some ok speaker grilles and some OEM switches to mess with for more lights. I think I need a good backup light.

Managed to get something cobbled together for temporary use until I can dig up an oem console and shift boot. I feel like those will be extremely rare and hard to find.

Got the service engine light reset and washed it up and slapped some stickers on it.



I still have a bunch of little stuff to take care of, stage zero, replace all the hoses, figure out the shutter in the driveline on takeoff, rebalance a couple tires, make the strut mounts adjustable and get an alignment.

Although I have to say this is one of the better driving Volvos I have been in, pretty comfy and civilized without being boring. Its daily driver status now.

Sean
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Old 01-20-2020, 02:20 PM   #54
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Those seats are in amazing shape, that was a major score and at a very good price! This thing is turning out to be another great looking Volvo, your garage is looking like every Volvo enthusiast's dream...now you just need a 122 2 door or Wagon.
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Old 01-21-2020, 12:00 PM   #55
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Those seats are in amazing shape, that was a major score and at a very good price! This thing is turning out to be another great looking Volvo, your garage is looking like every Volvo enthusiast's dream...now you just need a 122 2 door or Wagon.
Yeah I was shocked at the condition of the seats as well. Garage is getting there, you know it wont last too long though I have a pretty short attention span when it comes to cars

Managed a little shop time last night. Adjusted the pinion down from 6 degrees down to 3 degrees with my adjustable uppers. I am at the point that I need to rotate the bushings on the axles and chop off the nipples on them to get more rotation and get the pinion down. Its really a terrible design in my opinion but its what it is.

I also spaced down the carrier bearing to try it out.

Between the two it made a significant improvement on the harsh vibration on takeoff. I am probably 80% better than when I started.

This morning I added an additional 1/8" shim for the carrier bearing and it got even better so I am headed in the right direction. Ill probably add in one more 1/8" shim in there and call it done. Running out of real estate on the hole for the driveline in the back crossmember. Ill probably need to run a limit strap on the rear so the driveline doesnt hit under droop at this point but Ill take that over vibrations.

Been driving the car everywhere. Its pretty fun, about time to crank up the boost......no, no. Alignment, stage zero, then crank up the boost oh, camber adjustment, then.....

Never ends with me. I probably need to get back on my Tan car at some point.

Sean
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Old 01-21-2020, 04:47 PM   #56
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Do you find anything more complicated with the car being so much newer than most 240's?
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Old 01-21-2020, 05:15 PM   #57
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Do you find anything more complicated with the car being so much newer than most 240's?
It has more stuff going on but its not overly complicated at all. I am actually quite impressed with how much better parts are made on it. Door panels that actually stay on the door, interior is much quieter, has some sound deadener in the doors, floors and firewall. It does have SRS system in it so airbags, seatbelt retractors and sensors but its early stuff and pretty easy.

In all, I find it a super easy car to work on.

Dumb suspension compared to great stuff on a 240 but for what I am using it for.....daily driver its nice, compliant quiet, still has enough power even stock to be kind of fun. I would totally own another one.

Sean
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Old 01-21-2020, 06:35 PM   #58
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As always, interesting build. Pretty clean starting point with this car, like the color combo. I'd love to see a more "typical" Hackster build on a nice 9 series.

Glad to hear you like the platform.
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Old 01-21-2020, 07:16 PM   #59
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Add about a 1/4" spacer (more if needed) between the center support cross member plate and the center support and that will reduce or eliminate the take off vibration.
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Old 01-21-2020, 07:40 PM   #60
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The transition to the Dark Side is nearly complete.
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Old 01-22-2020, 06:42 PM   #61
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As always, interesting build. Pretty clean starting point with this car, like the color combo. I'd love to see a more "typical" Hackster build on a nice 9 series.

Glad to hear you like the platform.
Thanks. It is a pretty clean car, but its far from perfect. The clear on the roof is peeling pretty bad and the hood paint has started to come off in places. I totally dig it for this purpose, Its a big lady to dance around with on the track though =)

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Add about a 1/4" spacer (more if needed) between the center support cross member plate and the center support and that will reduce or eliminate the take off vibration.
That is what I have been doing. Spaced up the trans as far as it would go and have dropped the carrier bearing down about .5" now.

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The transition to the Dark Side is nearly complete.
For a driver, yeah its a better car than a 240. 240 is waaaayyyyy cooler =)

Slapped some new wipers on the turd last night and spaced down the carrier bearing another 1/8" and its damn near vibration free on take offs.

Going to try and knock out some maintenance tonight, coolant hoses, fuel filter, cap, rotor and plugs are on the agenda.

Oh and a boost controller. That is going to make it more reliable

Wish me luck.

Sean
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Old 01-23-2020, 11:14 AM   #62
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I am going to need to find some photo worthy stuff for this thread

Good night last night, Asher and the twins stopped by to shoot the **** and watch me work.

Maintenance!!!

New spark plugs and rotor, (Cap on order still), new fuel filter, drained all coolant, replaced all of the coolant hoses, heater hoses, turbo feed and return hoses, new metal heater control valve, oil fill cap seal, new OEM thermostat and seal and refilled and burped the coolant.

Installed a GrimmSpeed Manual Boost Controller. Its a very nice piece, has detents in it for accuracy and a large knob for making adjustments, came with a mounting bracket, hose and everything needed to install.

Got the turd on the road. It idles waaay better with some fresh plugs and a new rotor, could have been fuel filter too so glad I did all of the maintenance.

3 psi, turn it up, 17 psi, turn it down and settled at 12 lbs. What a difference. Not only more boost but it comes on a lot faster too.

Its so much different from what I normally work on. I am usually having to figure out every single part and piece, this was easy order parts, remove parts, install parts.

This has been a nice pretty easy fun project and it actually drives really well. I still have a few things left to do but its damn close to daily driver. Been driving it exclusively since last Thursday and no problems so far.

Ill probably take this thing up for XXX in March. Who else is going?

Sean
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Old 01-27-2020, 05:05 PM   #63
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So wait... you're not going full hydro and 20+ inches of wheel travel?
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Old 01-27-2020, 11:11 PM   #64
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Thank goodness they still make round lights!
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Old 01-30-2020, 04:33 PM   #65
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So wait... you're not going full hydro and 20+ inches of wheel travel?
Not for now at least. Its pretty damn civilized as a daily driver, far better than expected to be 100% honest. If anything it needs an LS swap. I believe if I am resourceful I could LS Swap this thing for close to the same amount it would cost me to regear it...

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Thank goodness they still make round lights!
I agree, I love how they look on the front of this turd.

Been driving this thing everyday for work now. Had a little stumble the other day where the idle dropped when the defrost was running. It dropped so much that the check engine light came on.

So I got the new cap installed and also threw on all new plug wires. That did not fix the low idle.

Checked the TPS and same thing set as per the manual.

So last weekend I tore the throttle body off the car and gave it a good cleaning, removed the IAC and cleaned that as well.

Idle was up, way up. Made a few adjustments to Base idle and linkage and its better. Idles about 1000 rpm which is better than the 450 it was before.

I am thinking about grabbing a junkyard throttle body and cleaning it up as good as I can and throwing a new IAC motor on it for good measure.

I am also going to swap out to Amsoil fluids in the trans. The Mobile 1 synthetic ATF doesnt do much to quiet the thing down and its a little loud. I suspect that the adapter isnt 100% centered and that is causing the coast noise. So I am going to swap out to Amsoil Manual Trans Synchromax and see how that does.

Still have an oil leak to deal with as well, hoping that a oil filter adapter to block o ring and new oil fill cap will get me back to a clean garage floor soon.

Sean
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Old 01-31-2020, 05:05 PM   #66
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Replaced the Mobile 1 Full synthetic with Amsoil Manual Transmission Synchromax last night after work. Huge difference, trans still makes noise but its probably 70% reduced from what it was. I am an Amsoil dealer and will probably exclusively run their product from now on after placing and receiving my first order....it was uber easy.

Been messing with the non functioning Cruise control for a while and was messing with it last night, checking the brake pedal switch and and hoses and discovered that I have no brake lights.

Started checking things, and after checking the fuse and the bulb failure relay out I found a dead switch at the pedal.

Picked up a new one today and that should be fixed.

Also reset the SRS light about 100 miles ago and it has not yet returned.

Have one really annoying oil leak left to deal with and I believe its either at the block to oil filter adapter or the turbo drain tube to block, there is a lot of oil in that area.

Picked up the o ring so Ill give it a go this weekend.

Found I need some inner and outer tie rods up front too. Starting to remember why I drive newer **** for the daily =)



Sean
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Old 01-31-2020, 05:19 PM   #67
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It is probably both the aluminum housing to block o-ring and aluminum housing to water cooled oil cooler o-ring that is leaking. They are always leaking by now if they have never been changed. Make sure you have the o-rings for both before you start the job.
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Old 01-31-2020, 06:29 PM   #68
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It is probably both the aluminum housing to block o-ring and aluminum housing to water cooled oil cooler o-ring that is leaking. They are always leaking by now if they have never been changed. Make sure you have the o-rings for both before you start the job.
I already did the adapter to oil cooler o ring.....so this will be the second time.

It doesnt look like its been opened up in the last 20 years so this will be the time. It looks like it should be easy enough to replace, undo the large bolt, separate, clean the area, install new o ring maybe with some grease to hold it in place and reassmble.

Do you happen to know what size the head on that bolt is Roy?

Thanks for the pointers, I believe I have either a bad vacuum pump or turn signal stock on the cruise either that or it was tied into the automatic somehow and its not getting a proper in gear signal.

Since I have you, is intermittent wipers an easy upgrade?

Thanks in advance,

Sean
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Old 01-31-2020, 07:11 PM   #69
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You have intermittent wipers. Push the stalk up to turn on the intermittent mode. Remember, an article on the brickboard tells you how to ask the cruise control what is wrong. It will self diagnose. A 1 1/4 inch socket works perfect for the banjo bolt.

Cruise troubleshooting article.

https://www.brickboard.com/FAQ/700-9...iseControl.htm
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Old 01-31-2020, 07:40 PM   #70
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It is probably both the aluminum housing to block o-ring and aluminum housing to water cooled oil cooler o-ring that is leaking. They are always leaking by now if they have never been changed. Make sure you have the o-rings for both before you start the job.
I have the 940 oil cooler on my 242 and can confirm that it was the source of an annoying leak and that it was easy to fix with new o-rings.

The car is looking more & more fun Sean. Nice score on those fuzzy seats.
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Old 02-01-2020, 11:11 AM   #71
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Well yesterday was a **** day. Ever have days where everything goes sideways and you are just pussed off at the world? Yesterday was that day.

Pucked up a new block to filter o ring from IPD. It was black not green so I questioned it. They said its the right one they just changed the color.

It had a twist to the oring, i tried heat and worked it out with my hands installed it and apparently that little piece of **** fell out of the groove when I tightened it up and left a massive ****ing mess on the garage floor.

Luckily for me the Twins had a new in package one and a valve cover gasket.

They stopped by last night and hung out whichbwas the highlight of my day. Installed the new O ring, adjusted the valves......all of the intake were waaaay too tight. Removed leaking vakve cover gasket and installed the new one.

Started car and it didnt puke out all its oil this time.

Thanks again for the help fellas, much appreciated.

Going to try fixing the turbo oil drain tube leak next, replace a weeping water pump seal, new inner and outer tie rods and get an alignment.

Cheers!!!
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Old 02-03-2020, 11:29 AM   #72
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I had 2 different sets of plans for the weekend that both fell through so I decided to take on the rearend.

I had snagged some parts off a maroon 740 wagon from Sherwood pick n pull a few weeks back. NA, auto car.

So I got up early on Sunday loaded up my tools, some straps and a hand truck and went for it.

No tag on the rearend so stuffed a pry bar on one brake and counted driveshaft. Spun the drivers side brake around 2 times and counted 4.+ revs. Good for me.

Yarded that thing out in just a little bit of rain. Not too terrible all things considered.



And created this to get it from the very back of the wrecking yard up the hill to the cashier.

It was a heavy sum bitch but worked great!!



Luckily this was not a dana 60 or something heavier or I would have needed some help.

They were nice and charged me for a drum brake rearend so I think it was $120.00.

Got it home and cleaned it up, Pulled the diff cover off, open diff, 41-10 so confirmed it was a 4.10 gear. Cleaned up the cover added new fluid and its ready to go in.

I have a couple issues that stopped from swapping the locker. I have bolt on wheel spacers from the previous owner that are stuck on the axle. I have tried everything I have to get them off with no luck including heat and hammers. But I like them so I am going to try more heat at a later date.

Also want to see how the 4.10's do and if they are enough gear.

Onward we go

Out with the old and a nice driveway **** show for sunday.





Got the new axle swapped in with a little help from the wife to get it in place.

I also cut the small locators off of the pads for the axle so I could rotate it and set the pinion angle and hopefully take some bind out of the rear suspension with the adjustable links installed.



I didnt expect it to make a huge change going from 3.73 to 4.10 but it is huge. The car drives much better, gearing is drastically improved and the car takes off from a stop effortlessly. Before you had to feather the clutch on flat ground and when you would get the clutch engaged it would bog down. 25 mph corners can now be had in third instead of second. 6th gear is usable above 60 on the freeway.

The other big benefit of this was getting a functional emergency brake. I truly use this as my daily driver and not having an e brake just plain sucked.

I installed the cable that was on the junkyard axle so that required a console and rear seat removal.

E brake cable installed and adjusted. E-brake works fantastic!!

I removed the IPD rear sway bar and I like the additional flex, but it does make the car much more of a handful to drive. I will likely reinstall it or if someone has a stock 940 rear bar I would be willing to try that too. Feels like it needs something in the rear its very squishy on accel and decel now and doesnt track that well.

All in all, totally worth a day and $140.00 including fluids.

As of this time its pretty damn civilized. Stereo sounds killer, fun to drive a turbo manual, all of the small maintenance items have been addressed.

Fun car......who is ready to buy a killer lifted t56 swapped 940

Sean
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Old 02-03-2020, 01:22 PM   #73
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I have some stock bars lying around if you are willing to pay shipping from the wrong coast
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Old 02-03-2020, 02:18 PM   #74
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Hah nice work! Most later na 7/9 were 4.10 pretty much. Some with g80 as you know.
I use the same cart but with trunk wood from a car to support axle when going out of yard.
Probably scoots now with turbo and 4.10 now!
Buy!? Find another project?
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Old 02-03-2020, 02:59 PM   #75
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I don't quite understand your spacer comments. IIRC, the locker requires the axles from the locker to be used. At least one of them. One of the axles in a locker rear end is shorter than the open differential versions. IOW, swap the G-80 carrier and axles into the rear axle you just installed.
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