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No leaks 29 November 2009

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18th October 2006

Well I finally got to finishing the brake lines off with the correct fittings this past weekend. It all went relatively smoothly and I could not induce any of the joints to leak even with booster pressure. I also tightened up all the suspension bushing bolts as I had left them loose until I got the car at normal ride height. Finally it was all done and we went for a short ride in it. It felt a lot better than previously and the annoying clunk had completely disappeared. Oh yes, I found that the diff had almost no oil in it so I filled it up. There is now a drip from the front of the diff suggesting that the pinion oil seal needs replacing. At least the engine started easily after its long rest.

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Gearbox mount 29 November 2009

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13th August 2006

Today I painted the mounting brackets on the axle for the torque arms and then fitted them later when the paint had dried. Refitting the torque arms was easier than I had feared as I managed to use a jack under the differential to twist the axle enough to get the holes to line up. Refitting the panhard rod was much more difficult but again the jack under the differential helped. I also changed the gearbox mount as the old one was split and collapsed and not doing much of a job anymore. The new gearbox mount means that there is a lot more clearance between the prop shaft and the bottom of the tunnel now. I decided to continue work on the rear suspension by fitting new bushings to the support arms next. I started on the near side and got the bolt out at the body end but the axle end is corroded into its sleeve again so another bolt to cut out, not fun at all.

Horrible job 29 November 2009

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6th August 2006

I finally got the other torque arm out today, that was a horrible job. The old incorrect bushings at the axle end came out very easily but the ones at the body end were a bit harder. I had to drill the rubber out and then use a hacksaw to cut through the outer shell and try not to damage the arm (well not too much anyway). I have some poly bushings for the body end which should be simple enough to fit but I will have to get the big rubber bushings pressed in with a hydraulic press.

No heat 29 November 2009

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1st August 2006

I am going over some of the rear suspension at the moment prompted by the need to fix those bushings. So far I have managed to remove the panhard rod and one torque arm, the other torque arm is being held by the bolt at the body end which has corroded into its sleeve and will not come out. So I am going to have to cut that bolt out which I am not looking forward to. I cannot get heat to it as the sleeve is in the middle of a bushing and hitting it with a hammer was doing nothing. I have sanded and painted the panhard rod and fitted new poly bushes to it. I will clean up and paint the mounting point on the body as well before I refit. The torque arms will also get a clean up and paint as well as the new bushings before going back. I found that the bolts in the flange for the differential were not tight so that may have been the cause of the thump but I also need to check the gearbox mount as the prop shaft seems very close to the tunnel just behind the overdrive.

Rubbing 29 November 2009

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17th July 2006

I gave the car a wash today, it was a bit grimy but there were some patches that never got washed after all the welding so it was good to get rid of them. I fitted the new rubber straps in the rear seat frame as well. I also found the passenger side seat belt hanger while I was poking around inside the car, I don’t know how I missed it before. I had a little look under the car to see if I could work out where the thump that I sometimes get is coming from. I don’t think it is suspension so that leaves either the exhaust or the propeller shaft. The exhaust seems to be held fairly solidly. The centre support bearing is a bit loose in the frame but I am not sure if it is that loose. I’ll have to jack the back of the car up sometime and see if I can check it all out a bit better. While under the car I did notice that the torque arms seem to have the incorrect bushings in them and they are both rubbing the inside of the mountings, possibly because the bushings are not holding them in place correctly. Fortunately I did recently buy a pair of NOS bushings on eBay.

The rear seat frame

New boots 23 November 2009

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2nd June 2006

I took the car to have four new tyres fitted today, Toyo 330s size 165/80/15 which is the stock size. I wanted to see how the car felt in it’s designed form before I make too many changes. The tyre place were a bit uncertain if the wheels would take tubeless tyres but all was OK. Apparently the valve holes are larger than normal but fortunately they had some valves on hand that fitted. It had been pointed out to me that the rear wheels were wider than the fronts and in fact this is so. The rears are 5.5J15 whereas the fronts are 4.5J15. I think the 5.5J15s were standard on some Amazons. There were no balance weights on previously and there was quite a vibration at 60mph but that has now gone. We had been having a little problem with getting the passenger seatbelt to lock in position properly and I found out that was due to the mechanism being put together slightly wrong and I fixed that today. I also changed all the sway bar bushings including those on the link rods. The link rods were a pain as the spacing tube had corroded in place and required some heat from a blow torch and some not so gentle persuasion from a copper mallet before they would come off. I used polyurethane bushings that I had bought on eBay a while ago. While at the tyre place I noticed that a bolt on the front cross member was not tight, it was showing three or four threads. This is where shims can be fitted for gross wheel geometry adjustments but of course there are none there now and I have no easy way to know if there should be any or not without getting a full diagnosis done, which I will try and wait until after all the front end suspension work is finished before I get done.

Spotty Olaf

Polyurethane bushings installed

Pile gets bigger 14 November 2009

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2nd November 2005

My order from Brookhouse arrived yesterday, hurray! I intend to remove the heater matrix and give it a good flush out before I refill the coolant system though and I still need the heater valve. The poly front ASB bushes I got from Ebay are the wrong size, they are for a 19mm ASB but my car has a 22mm ASB so I am trying to get them swapped. I bought some poly link pin bushes this morning on Ebay. The pile of new parts is getting bigger, I hope to be able to make it smaller soon as I start fitting them.

Rusty box 14 November 2009

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Corroded base of battery box

27th October 2005

I attempt to put some antifreeze in but give it up as I cannot get the radiator cap off. I use a soft brush to dislodge some more of the leaves etc in the engine bay, most of it is gone now and looking better for it (see below). I notice the battery box is just about completely destroyed by rust (see above) and that the fresh air vent is not closing on the passenger side. I manage to buy a pair of vents on Ebay as well as some poly bushings. Still cannot find the VIN. Looking at pictures on the web I decide that the worrisome pipe is in fact the heater control valve and should indeed have hoses attached. Lots of the hoses under the bonnet are looking the worse for wear including the fuel pipes so I think I shall have to replace them all. When I get home the POR15 tank repair kit from Frost has arrived so if I have time over the weekend I shall start the process. I also ordered a pair of chrome air filter housings from Gower and Lee that have a washable foam element inside for less than the cost of the Volvo elements and they would need replacing after 12,000 miles or so.