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Daz, your removal tool seems to have more to it than what I see when I search for Volvo 9995497, or when I watch other videos showing Volvo 9995497 in use. In your video at 2:22, I see what looks like a narrow plate going from roll pin to roll pin, and a couple of socket head bolts fed through the plate and down into the roll pins which hold the plate down. It looks much more substantial than just the two roll pins alone. Did you add this yourself? Or is your tool NOT Volvo 9995497?

Those five screws that hold that panel down are stainless steel with a black oxide finish. I wonder why Volvo used them there, and nowhere else. There are lots of other locations that are frequently exposed to water and could have benefited from non-rusting fasteners.

Great job, what kind of a polybushes You used ? any link ? Thanks

Did you buy the volvo tool to do this job.

Great to get a look inside the door to see how the mechanism works. Will tackle mine now I have seen this. Thanks

Most of the time those black polyethylene spindle covers are falling apart. Looks like yours were trying to hold it together.

I completely trashed my 850R -- it was running, but I thought it would be a good idea to test the spare (used) fuel relay I had in the glovebox. I pulled out the one that was working, and tried to push in the spare to test it, and that white plastic block that holds all the relays and fuses broke from the slight pressure I used to insert the relay. All I had to do was plug the relay into that green socket, which was fine, but everytime I tried to support the socket one way or another to insert the relay, the main white block broke more. It was like it was made charcoal -- it just crumbled right in front of me. I pulled one from a yard, and really carefully tried to swap all the hundreds of wires from the crumbly one to the one from the yard, and after it was all together the car wouldn't start. I figure I messed up one or more of those many connections. Then I pulled an entire wiring harness without unplugging anything from the fusebox, but I haven't finished the install yet. A thirty second swap of the relays led to being shut down for months.

Great work. And very thoroughly done. Really enjoying following your rebuild. (polite suggestion :: is it possible to pull the camera out slightly, as it's a bit difficult to actually identify the parts you are showing from so close up?) Thanks

Looking good!

that block behind the sips module, as i understand, has nothing to do with the sips module and is there to balance out some harmonic vibration only present in automatic cars. it´s not present at all in manual cars and thus the pocket in the centre console is much deeper. i saw the 2 shift cables which i´m assuming means manaul conversion so you can safely delete to block, as i did when i converted to manual.

Awesome work! Those things are a pain, they really cheaped out on the dashes. Mine is in 10 pieces😭

That handle in the middle of the tailgate panel is another piece of plastic I can never remove without breaking something. It's two parts, but the front clips into the back and the back clips into the front at the same time, so that it's impossible to ever get them apart again.

Hi. Like to follow your renovation. What rust treatment? Rust remover or rust converter? Which primer? Acid etch? I'm doing the same on a 96 T5.

Quick question bud. With rails fitted am I correct in hearing you right? It’s grey on the nearside green on the offside? With the rails fitted is it still 10 per side? Cheers buddy. 👍🤝Edit. Is it just one grey one and one green one in the positions you demonstrated?

Awesome, for the removal and installation of the rails does the headlining need to be removed?

Hi daz would you have the part number for the new rear window tailgate trim you fitted please mate 😁👍

We😢done.

I have tried many times, but I've never been able to pull one of those door seal clips (1372622) out of a car without breaking it.

Awesom.👍👍🏁🏆🇸🇪

Look at her all fresh and happy, looking good mate!

Nice!

How many cans did four doors take?

Beautiful!

I once bought an 850 from someone whose mechanic had told them the head gasket was bad, so the car wasn't worth fixing. I bought it, and after driving it home (hundreds of miles) I realized the only problem was a little crack in the reservoir which made it slowly lose coolant.

Is it true that the T-5R only came with front flaps? Reaes looks great on the but its not a factory option?

Thanks for pointing out the screw differences. I got mine apart without noticing the difference -- MAYBE I'd have caught it when I go to put it back together, or maybe not. On mine, some screws are zinc plated and some are black oxide.

Got to know how they textured the bumper!

Glad to finally see someone realizing that the screws are different! The amount of theses I've owned and have had the screws all wrong and therefore damaged the bumper is unreal, it's a pity they are so dear these screws mind you but in my mind do it properly or don't bother. Good work DAZ👍

What product are you putting on them?

Looks great, Is it an auto or manual car?

Great result in the end! That will be a nice looking motor. I am on the search for a T-5R myself, so following you closely. Looking forward to the end result!

Nice you got it sorted in the end, good work picking out all the issues from the first shop

And what did you pay the places for these jobs?

Well, that texturing and the gray color on the front and rear bumper I thought looked great!

What the bloody hell mate I wanted to cry. Another asshole taking advantage of a nice guy. Luckily you have figured it out, but man so much time and energy wasted..unbelievable

Nice work. A heat gun can also be used before the gel. Heat brings back the black colour and gel (in a way) locks it in Do you have the tow hitch cover too?

For parts like this, I like to use rattlecan epoxy. It take forever to get hard, so I bake them out at a low temp in the oven for a few hours. Then I tell the wife I have no idea what any smell could be, and that it must be her imagination.

Looks good!

Speaker brackets:))) So excited for that yellow beast to be assembled, it will be like brand new

Good job👍👍

What size wheels are these pegasus? 18 or 19 inch??

You're addressing another issue I haven't figured out.

Wow! I've pulled multiple 'whole' dashboards from the scrap yards, in the hopes of doing what you're trying -- tearing them apart and building one good one. That adhesive Volvo used has scared me off to this point, but you did a great job of separating the pieces. In my dreams, I get a good example of each panel, and set up molds to cast them in carbon epoxy. I believe the plastic for the dash is PC-ABS, and the solvent tetrahydrofuran is pricey but it will soften and eventually (few hours) dissolve pieces so you can make your own color-matched glue (or filler for holes). BTW, I've got five decent parts yards within a thirty minute drive, and they used to always have at least one 850 -- typically two or three at a time. At the moment, nobody has a single one. I drove eight hours a few weekends ago to pull a manual transmission with all the fixins. So, parts are getting harder to scrounge.

First comment! Thanks for showing the part numbers -- that helps.

I want to see what you did with the black foam and black polyethylene caps that snap over the wiper posts, and sit beneath the scuttle panel to seal those two big holes in the panel. I can find comparable foam and cut it to shape, but the old caps are always broken in any cars in the junk yard. And your Volvo dealer has a lot more of these old parts available than the ones around me.

You keep fixing problems that I've been scratching my head over forever.

Beautiful

Power folding mirrors AND power adjustable headlights?!? Was this the Queen's 850?

Very cool! I've been wondering for years what to do with old dead reflectors in headlights -- where do you send them for recoating? I think the originals are created by doing a vapor deposition of aluminum on the surface, and then not touching the surface with anything.

Good tip for the chain lube, you really go into details wit your car. How is body/chassis coming along? Was there rust to be found? Cheers!