Broken Shock Mounting Stud on Rear Delta Link

Beige68GTO · Post by **Beige68GTO** » 07 Jun 2010, 17:05

While removing the original shocks, from my 1994 855 turbo, I broke off the right shock mount stud on my 1994 Volvo 855, removing nearly all of the threaded portion of the mounting stud. Everything I’ve seen on the web states I should replace the entire delta link in order to repair this. Wouldn’t I be able to weld a piece of threaded rod onto what is left of the stud? If this is possible it will be much a much easier and lower cost repair than replacing the entire delta link.

Thank you for your advice!

Ron

Post by **polskamafia mjl** » 07 Jun 2010, 17:21

I'm not 100% you could do that. I have also heard that if you break it off you need to replace the entire delta arm...

volvomileage · Post by **volvomileage** » 07 Jun 2010, 17:38

well this is bad news

we are talking of the stud on the delta arm on the lower portion ?

if yes , it happend to me and all depends on the patience you have, what i did is drill out the remaining stud with lots and lots of patience being carefull to drill hole in the same exact place the stud would of been, and used a generic shock stdud that is very very close to the exact size, after drilling the hole i inserted stud, the stud i bought had a hex type head for the exterior side and a bolt for the interior side, i welded bolt in the interior side to make shure it w ont move and it stands stil from the time i have done its like new but you have to be careful of angle and size you drill the hole.

drilling was hell and quite long remeber this arm is really solid, mind you my delta arm was in top shape, if it was in a poor state i would of changed it
either way lots of work !

there is a topic somewhere on this site going in depth with this subject

best of luck

FCPEURO · Post by **FCPEURO** » 07 Jun 2010, 17:58

Either way, this is not going to be an easy fix. The last thing I would do is try and weld a rod to the end of the broken stud. This is just asking for trouble.

So, basically, you need to decide which would be harder for you. Drilling it out or replacing the delta link. If I were you, I would replace the delta link.

Post by **cn90** » 08 Jun 2010, 11:51

Well, replacing the delta link is a major PITA.

When you drive, the main force is the thrusting force upward, the nut is there to hold the lower end of the shock from coming out and that is all the nut does.

So if the remaining bolt is long enough for the shock then I suggest this.
But an exhaust "U-clamp" at local autoparts store and somehow find 2 spots to drill holes so the U-clamp can clamp on the shock's neck just above the bolt. You may want to add a piece of rubber (like fuel hose) around the U-clamp to avoid noise later. Just a moderate clamp force is all you need. Just a thought, post a feedback when you are done.

Example of U-clamp:

Beige68GTO · Post by **Beige68GTO** » 09 Jun 2010, 08:50

Thank you to all of you for the advice. I'll keep you posted and take some photos, but won't have a chance to get further into the repair until this weekend. In the mean time, my '88 240 will go back into regular service.

Also, I'll get a quote for a new delta link, and also speak to a pro at a local welding shop and ask if he thinks I'm nuts to weld this. (At least to me, it appears there is only a load on the bolt parallell to the bolt. There should be no twisting as the shock mount is tapered.) I think the muffler clamp would work, and would be a good fix in the short term, but I'd prefer to do a repair that hides all evidence of the fact I managed to break off the stud.

Thank you,

Ron

Post by **cn90** » 09 Jun 2010, 10:48

Is this Stud welded into the delta arm from the factory?
Can you "unweld" the entire bolt and place a new stud in there?

I suspect they made the delta link first, then place the botl and weld it in.

It is just a stupid design because in many many other cars, this same stud is replaceable!

Post by **Ozark Lee** » 09 Jun 2010, 17:47

Is this Stud welded into the delta arm from the factory?

Yes, as far as I know it it welded in place from the factory.

...Lee

Post by **cn90** » 09 Jun 2010, 20:04

In that case, a good welder can "unweld" the bolt.
Then find an appropriate new bolt and weld it back in.

Post by **Hoov** » 09 Jun 2010, 23:47

cn90 wrote:It is just a stupid design because in many many other cars, this same stud is replaceable!

+1 to that thought!
More so, I would really like to talk to the designer only because I'm truly curious. Was there an express reason for the design or has this person never seen other designs before? ... Fact is, this one just sucks! It is not that simple to change either without expensive equipment & skills. Or LOTS of time. ... or money. ...

My grandson ran over the "Grandmother" of pot holes here the other night & cracked the outside weld of the rear passenger side shock mount nut.
God bless his soul he immediately admitted to the crime which is how we found the damage. I rewelded it in about three minutes but shudder when I think if it had actually broken out. Do-able but what a pain that would have been & a few bucks for materials as well.
LOL ... Good news is the kid kept his access to the car! I don't have problems with honest accidents or honest kids! Just stupid designs! hehehe

Hoov