You mentioned that the air directional dampers are working, but are you sure they are all working? That one on the right side of the climate control unit, left of the glove box, is notorious for splitting out the damper shaft which is made of plastic. That might be one thing to check and repair if n...

There are several plastic springlock tools that look very similar, and a scissors type metal one. Different folks tend to have their favorites. What I found works best is the plastic one with the flange. The tool shown in this link has worked best for me, though it will still take some effort: https...

Having refurbed 2 850 systems this summer, I will suggest removing the compressor to get at the clutch. One thing cn90 confirms is that the pulley is very robust, made of hard steel and will withstand some serious prying. With my compressor on the bench, using 3 5mm bolts actually did work, but ther...

The #12 fuse on my 93 850 was blowing, taking out my brake lights. I went through a lot of tests like you've done. Finally, a Volvo indy shop tech clued me that the bulbs need to be matched. I checked, the tail light bulbs were not matched for wattage. Installed a new matched set and that solved it....

While it would expand your scope of work, with the additional clearance you'll have under the oil pan it wouldn't be too hard to replace the o-rings in your oil uptake system. Seems like you're going to run this car for a while and since it's a hot rod version, you'll want things to hold up inside t...

I made the switch to an S70 right-side arm to my drivers side 850. I'm happy with the complete wiping range and don't any longer notice that it hits the hood, a tiny bit. Not a big deal. Sure, it will wear the paint off at that point, but that should never cause a further problem because the occasio...

A bearing that is worn enough to cause a knocking sound should be dropping oil pressure. At idle is your oil pressure light coming on?

@viper69: that's some testimonial! Do the vendors know about this post? They should be paying you a commission. Looks like the one I'll be installing.

I haven't read this whole post so I apologize if any of this is redundant. Always be sure your car is SAFELY SUPPORTED. THE SAFEST SUPPORTS ARE PROBABLY SQUARE CUT PIECES OF TIMBER AND WORKING ON A LEVEL SURFACE. Replacing the rear calipers on an 850 can be really hard because their brake line fitti...

Autozone (Duracraft) has what you need. 12 bucks. Plus it even has an auxiliary pigtail with bullet plug.

For the 850, 32 inch seems just about right.

https://www.autozone.com/ignition-tune- ... 6_309932_0