Ownership Verified: Another red one in the driveway. 1994 Volvo 940

So, tires are on... It drives really well now, still lots of drivelline vibrations, but #it'llbefine...

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Also, the new light bar arrived... The originally planned mounting location on the roof (I will need to make some adjusted brackets... No problem:

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I also tried a few other locations:

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As the mounts are magnetic I will set up the cable so I can use any location of those three I would like :D It's meant to be full stupid, and it is!

Top speed run:

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(lol)
 
So! Chris came over and we dug in to pulling the gearbox out!

Not before deciding that this is obviously the perfect position for the 52" lightbar:

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That gave the car an immediate erection...

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Here we are, no the way with the driveshaft still attached:

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The carrier support bearing is clearly the cause of the vibrations and needs to be changed... I don't have the tools to do this (Hydraulic press) but I am asking around if anyone can help. Otherwise it will be another thing I ask the mechanic to sort as this really needs to be done...

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Diff on the ground:

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A lot of levering and heaving and pulling and grunting later the box came out:

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On to the next task, the clutch itself, with all of the bolts coming out with relative ease except one ... Which tragically spun and had to be ground off (I will order a complete set when I order the next few parts...)

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The clutch came out and looked surprisingly like it had some life left in it... It's potentially original to the car, it has Volvo and Sachs written on it...
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But with 112 HP, it's not the first thing to go those are the diaphragm springs, and as you can see in a comparison between old and new it's clearly fucked:

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Time to take the flywheel off... Why? ... Because there is more work to be done underneath there... (You can see the ground off bolt near the bottom there...)

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That brings us where we stopped for the day. Other than giving it a clean and checking the hardness of the seal (it's like concrete... If the clutch is original, this is too.) A rather large rain storm came in and time was also running out as Chris needed to return home:

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I have a new pilot bearing I or we will try the bread trick to get it out, I also bought two main seals... Because if you buy one you will fuck it up :D

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On the to-order parts list now is:
  • Clutch slave cylinder (The old one fell apart and the boot is totally destroyed) (Yes, I am aware you can rebuild them but I am really not going to play that game with a car I need to drive 6000km in Jan/Feb for the sake of €30 difference)
  • Carrier bearing (I need to measure this to make sure I get the right part and also confirm if I have somewhere to install it)
  • Bolts for the clutch cover
  • Fluid for the clutch... (I have never bled a hydraulic line in my life so it will be interesting)
This will be ordered later this year so it arrives after I am back from vacation.

Thanks Chris for taking the photos!
 
Excellent car. Good color. Coco approves!
 
More parts!
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They will start to go on the car on Friday hopefully and definitely on Saturday!

I can also print out black again, I had to print and manufacture a roller for it as the big 2.6kg spool does not fit on my printer normally... Anyway, I made a nice new panel that has the switches for the 4 light bars:

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And yes... I did say 4 light bars :D

Technically the new one is two. I am nearly done with the loom to wire it all up, I will probably tackle that on Friday - I will need to build a bit of a bracket for the new one but that should be easily done.

Not decided on the mounting position, but it will be connected to the same circuit as the bumper one so it will mount above or below it.

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What a ridiculous thing :D
 
That is a very nice job and the texture is surely no more coarse than your average '70s/'80s Swedish automotive plastic.
 
So! gearbox going back in preparation! Firstly removing the old crank seal, I used the old drill a hole and put a screw in it:

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Worked:

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Next up the bearing... I used the loaf of bread trick with a 10mm socket and a hammer:

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A lot more adding bread and hammering later:

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And even more bread and more hammering, success!

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And a pile of bread for to attract the mice overnight:

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Next up is to clean the inside of the gearbox - I didn't spend 20 hours to get it perfect like @nicjasno would, but I got 90+% of the buildup off:

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I cleaned the fork and installed the new throwout bearing and greased everything up:

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Next up is the carrier bearing, getting the old one off involved an angle grinder and a lot of hammering... I didn't get any photos of this, but putting the new one involved a lot of hammering and a block of wood:

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Eventually I got it all back together:

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And I cleaned up the other part, it will get greased before being inserted:

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I checked the u-joints and they seem fine enough. I could have replaced them, but why... With just 112hp of fury they will last another 100,000-200,000km probably. And if not, it's an easy fix :)
 
And while I should be in bed I finished off the loom for the 4 light bars... the switches and trigger circuit are not on this as I need to run the cables and find the high beam positive cable to tap into... It will be easier when the car is on the ground anyway rather than on jackstands...

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Ha! I remember using the bread trick somewhere (411???) and going "what in the absolute hell are we even doing here?" It works, though.
 
So, a redone drivers seat was acquired. @loose_unit found a guy on the local classifieds that has old Volvo parts, and he reconditions seats as well. So, I drove up to Dortmund last night and got it. Seat heater works super good now too.

Before
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During
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And after
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Feels great.
 
So, things starting to go back on (I was meant to do a before and after... I did not, so here is the before, yes I did install them properly:

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Flywheel:


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I bought a generic clutch alignment tool but it was totally fucking usless ... So, I 3D printed a specific tool for this car:

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And clutch in:

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Gearbox going in:

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Gearbox in, now doing up the driveshaft bolts:
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I ordered a new clutch slave cylinder, unfortunately we could not get the hydraulic line off to put the new one in :( so we used the rubber boot and the the metal arm from the new one to sort of recondition the old one...

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After a quick clutch bleed, it works!


View: https://youtu.be/J8iUmPp1VrY

Since then I have also (nearly) completed the light bar install... The bulk of the cabling is done, I just need the switches inside wired up to the trigger system, the only issue here is just running the cable from inside the cabin to the engine bay. Hopefully I will get a bit of time to tackle this in the coming days.

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Next steps are to install the final two light bars ... (Yes, two more are being installed) :D, see if I can fix up the stereo wiring, wire up the switches for the light bar trigger circut rather than having that just directly connected to the high beam.

Tomorrow I will do a trip to the place where @93Flareside got the seat and we will be acquiring some other parts too :D

On Monday the 22nd I will drop the car off at the mechanics to get a few things done that I do not have time to tackle and then... Off to Finland! :D
 
And to go a bit further, the final light bars are officially mounted. (That's two light bars that are bolted together there ;-))

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And the final setup (excluding the grill)

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Being able to switch off the front and top light bars separately will be nice when I get the cables run... The top one does get a bit annoying in the snow:

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A nice photo at the car at Brünnchen with a light dusting of snow:

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So an American came over and he cleaned up the stereo wiring ...

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Meanwhile I put the grill back on so it looks like a proper car again:

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After cleaning up the mess that was the stereo wiring, @93Flareside discovered that everything was kind of wired up correctly... There are no rear speakers which explains a bit as to why they weren't working... The wiring and grill are there, but no speaker inside :D

Anyway, turns out the front left was borked ... So he went off to Luigi and grabbed the speakers from there as I wanted to replace them anyway this coming year... With a bit of trimming they fit in with the original speaker grill covers:

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They sound just as awful as they did in Luigi... but now there is stereo... :D. And I know with the head unit (Already pulled from Luigi) you can tweak the EQ to get something resembling acceptable sound from them...

And we pulled the cable though for the light bar switches which now work:


View: https://youtu.be/slcmdeOHYaE

Sadly, a new problem popped up... No headlights any more :D The marker lights and the high beams work fine, I get instrument lighting etc. I suspect that a cable has been disconnected or something with the fiddling under the gauge cluster etc.. I will see what I can find over the next few days when I have time, if not then the mechanic can sort it.
 
So! gearbox going back in preparation! Firstly removing the old crank seal, I used the old drill a hole and put a screw in it:

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Worked:

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Next up the bearing... I used the loaf of bread trick with a 10mm socket and a hammer:

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A lot more adding bread and hammering later:

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And even more bread and more hammering, success!

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And a pile of bread for to attract the mice overnight:

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Next up is to clean the inside of the gearbox - I didn't spend 20 hours to get it perfect like @nicjasno would, but I got 90+% of the buildup off:

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I cleaned the fork and installed the new throwout bearing and greased everything up:

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Next up is the carrier bearing, getting the old one off involved an angle grinder and a lot of hammering... I didn't get any photos of this, but putting the new one involved a lot of hammering and a block of wood:

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Eventually I got it all back together:

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And I cleaned up the other part, it will get greased before being inserted:

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I checked the u-joints and they seem fine enough. I could have replaced them, but why... With just 112hp of fury they will last another 100,000-200,000km probably. And if not, it's an easy fix :)
I have methods to do it in 30 minutes. :p

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Sadly, a new problem popped up... No headlights any more :D The marker lights and the high beams work fine, I get instrument lighting etc. I suspect that a cable has been disconnected or something with the fiddling under the gauge cluster etc.. I will see what I can find over the next few days when I have time, if not then the mechanic can sort it.

So, to update this - During the stereo replacement there were a bunch of wires connected with butt connectors and crimp connectors all bundled together. @93Flareside pulled them all. out and re-wired them into a candy bar connector for testing and then put them together properly once everything was tested.

There were some leftovers which apparently had no purpose, so they were just left connected to the candybar... I had a suspision, so I got out the electrical tester:

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I was getting 12v across these cables when the lights were supposed to be on... So:

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Oh look! the lights work!!!

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I went in and connected them properly, packed the interior back together... The car is now basically ready to go to Finland other than the work the Mechanic will do :)
 
Went for a drive and had some music playing... The speakers from Luigi are totally fucked so after some discussion with @93Flareside I ordered some JBL 3-Way speakers that should fit.
 
It snowed... This thing is hilarious fun in the snow :D Also German drivers sitting at 30 is really annoying -_-

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Back from the mechanics, a bunch of stuff is done:
(Cambelt, Water pump, fuel filter, something with the tie-rods (They did me a favour there), tensioner for the accessory belt, accessory belts x3 and a full alignment)

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Looks good:

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Got a sticker to prove it:

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This is before leaving the mechanics, but the review after driving home... It drives great! :-D

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Now my wallet is a few bux under €1k lighter... But I feel a lot happier driving the car now that the critical maintenance is done! I do not know when the last timing belt change was, there is no records and the sticker was mostly torn... Also judging by the state of the accessory belts it was quite some time ago.

Now I just need to fit the rear interior tailgate and maybe sort out the fuel filler flap (Optional) and it's ready for Finland!
 
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