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Old 01-26-2020, 06:36 PM   #101
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Finally the last "big" thing on the maintenance list...replacing the differential bushings.
Differential is already out, both the upper bushing and one of the lower ones were completely shot & the rubber separated from the metal core.
Replacements are the delrin bushings from > Kaplhenke <, the big upper one is already in place





Afterwards the diff will be flushed, new oil filled and it goes back into the car.
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Old 01-27-2020, 09:56 AM   #102
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Really cool project.
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Old 01-27-2020, 07:03 PM   #103
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Differential lower bushings...out with the old ones, in with the new ones



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Old 02-15-2020, 07:35 PM   #104
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G80 modded and ready to go
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Old 02-16-2020, 01:30 PM   #105
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Diff oil refilled (Mobil1 80w90)


Diff cover cleaned up, Volvo sealant applied and cover installed


Lower diff subframe sandblasted, sealed and painted


Rear brake hoses replaced
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Old 02-16-2020, 01:38 PM   #106
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Wow! Great attention and progress!
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Recaro LX Bs - 16" ARE 398s - 25/25 Sway Bars - Bilstein HDs - SuperPro Poly/STS Derlin Bushings - MSD - R Sport Wheel - 'Skinny' Bumpers'

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Old 02-19-2020, 06:25 PM   #107
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The bump stops were bit tired...





While working on the rear axle, I've noticed the rear brakes are bit out of shape too...so there we go with the rebuild...







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Old 02-20-2020, 05:14 PM   #108
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Wire wheel, rust primer & first layer of brake paint applied

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Old 02-25-2020, 05:58 PM   #109
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Diff and lower subframe is on the car...rear calipers rebuilt...new guide pins, dust boots, piston dust boots, piston seals, brake pads etc...


And it all goes back...
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Old 02-26-2020, 06:28 PM   #110
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Brake fluid is flushed and no more air in the brake lines.
Unfortunately during testing I have found out that my brake booster leaks air a lot...afr going crazy when I apply brakes and lumpy idle.
New one on the way
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Old 02-27-2020, 12:29 PM   #111
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Wow, nice work!
Bummer about the brake booster, would have been nice if it was OK and allowed for a test drive!
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Old 02-27-2020, 03:57 PM   #112
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Wow, nice work!
Bummer about the brake booster, would have been nice if it was OK and allowed for a test drive!
Thanks! I actually went for a test drive, that's how I've noticed it
I have my MBC set all the way back for now, so almost no boost, but I've heard the turbo whistling while picking up and that was the best part of the ride
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Old 03-02-2020, 05:24 PM   #113
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New brake booster installed, also I have replaced ECT with a new Bosch unit just for sake of it.
Completely disintegrated wiring of the secondary coolant sensor has been replaced (connector #9144275 and connector pins #3523813) so now the dashboard temperature gauge actually shows something

I have also measured the oil pressure on the cold engine (around 15°C), it is close to 5 bars so there I should be safe

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Old 03-07-2020, 10:44 AM   #114
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Another issue showed up...I have noticed the idle is not smooth anymore, after some debugging found out that cyl #3 is not firing. Injector is fine, but no spark.

Seems the Bosch ignition coil that I use with the wasted spark setup went bad, only 3 out of 4 spark outputs are giving actual spark. It was a used unit, so...new one on the way

To do at least something...I've replaced the damaged door locks!




Last edited by tomasss; 03-07-2020 at 01:28 PM..
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Old 03-08-2020, 07:25 AM   #115
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As I have the doors already dismantled...I've installed the power lock to the driver's door, mounted the linkage and made an inspection window to be able to easily hook it up to the existing system







I just have to route the power lock wires through the door/pillar rubber grommet and I am done with this.
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Old 03-21-2020, 04:30 PM   #116
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Wiring of the driver's door actuator is done, remote lock works perfectly
When I was on it, I also disassembled all doors and lubricated all the window and lock mechanisms.
Wiring of the knocksense is also done, now I am waiting for a custom set of new ignition leads to be able to dial it in on the running engine..
In the meantime last paintjob - the sunroof paint was faded so here goes the rattle can again







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Old 03-22-2020, 02:25 PM   #117
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The front bump stops got my attention as I've noticed the material is completely disintegrating...ten minutes later I was already dismantling the struts
After further inspection, everything except the dust cover and the bump stops actually looks surprisingly well, the shocks are shiny new Volvo OEM units, the upper mounts are also in perfect condition...so I'll just replace the worn parts, clean it up, respray the undercoating and it goes back.







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Old 03-27-2020, 07:06 PM   #118
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Some styling changes...old cracked side turn lamps has been replaced, I have installed clear version of it with amber bulbs

before


after
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Old 03-27-2020, 07:15 PM   #119
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Also making progress with the struts...passenger side is done and back in the car. Some parts had surface rust so these has been wire wheeled, rust sealed and painted, bearings lubricated.

final assembly


driver's side before, passenger's after rebiuld


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Old 03-28-2020, 03:35 PM   #120
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Hi! Do you have cruise control on this car? I see pulley for cruise control? but no other parts of this system.
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Old 03-28-2020, 06:02 PM   #121
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Not yet, few days ago I bought the complete cruise control kit from 960 plus the steering column switch but it is not installed yet.
I guess the pulley was always the same and not connected if the car was not equipped with cruise control...
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Old 03-29-2020, 02:49 AM   #122
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Not yet, few days ago I bought the complete cruise control kit from 960 plus the steering column switch but it is not installed yet.
I guess the pulley was always the same and not connected if the car was not equipped with cruise control...
Good luck, but probably you will have problems with console of vacuum cell, anyway make photo if possible.
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Old 03-29-2020, 08:54 AM   #123
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You’re doing some amazing work brining life back to this one, love what you’re doing!
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Old 03-29-2020, 03:35 PM   #124
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Good luck, but probably you will have problems with console of vacuum cell, anyway make photo if possible.
Not the first not the last problem on this car I've already checked the console in the pedal box, there is a mounting holder for the brake pedal vacuum valve but not for the clutch pedal valve. I'll have to fabricate something.
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You’re doing some amazing work brining life back to this one, love what you’re doing!
Thanks! Now with corona it's plenty of time...and while many friends are bored at home I keep myself busy every day
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Old 04-03-2020, 03:48 AM   #125
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Some cosmetic fixes lately...working on the front grill and some other small imperfections.

The plastic tabs were missing so the fibre bondo and repainting took place.















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