Dash replacement ??

Tornado Bait · Post by **Tornado Bait** » 18 Nov 2006, 17:35

Anyone ever replace the dash in a 1994 850T? I've just repaird my odometer and replaced the instrument bulbs. Upon further investigation of a very loose and noisy dash I discovered all 4 mounts against the firewall have complete broken off!!

I've got the glove box out and the entire top of the dash with passenger side air bag out and intrument cluster is still out as well. It feels like I could probably just yank the whole dash out if I pulled hard enough.

I was able to peak through the windshield enough to veiw all 4 mounts against the firewall broken. Any advise on further removal? I can't leave this in the car like this and will probably begin searching for the necessary parts to replace.

Post by **MadeInJapan** » 18 Nov 2006, 20:05

You'll either need to use some creative engineering like here: http://www.volvospeed.com/vs_forum/lofi ... 23861.html
or give www.erievovo.com a call for a used dash with the mounting surfaces still intact.

Rule .308 · Post by **Rule .308** » 18 Nov 2006, 23:48

Yes, I have done a bunch of them. My advise to you is to find a tutorial at one of the Volvo boards like this one that outlines how to do either a dash removal or an a/c evaporator as you have to remove the dash to do the evap. Just to give you an idea though, you will need to remove the center console, the steering wheel and it's covers, both the knee bolsters, the one main electrical harness connector above the driver's left foot, the cowl panel, the wiper motor assembly, the radio, climate control ecu, one screw down in either corner by the courtesy lights under the threshold moulding, two screws in the center behind the ashtray, the turn signal stalk, the wiper control stalk, the four screws under the cowl panel that go into the blown apart pieces you mentioned. It is a lot of crap to do but nothing that you cannot overcome. But, like I said, I would look around at the different sights a bit and see if you can find a better write up with pictures, I know I have seen them in the past.

Mark

Post by **JRL** » 19 Nov 2006, 06:03

Are the clips broken on one saie or all across?
We "saved" one dash when the clips were broken on the drivers side by shooting spray foam in the dash.
It dries hard like real styrofoam and silenced the dash. If they are all broken the entire dash has to be removed.
Think seriously at this time about replacing the A/C evaporator as the hard stuff, (the dash removal), has been done and it's a parts only deal at this point

Post by **MadeInJapan** » 19 Nov 2006, 08:35

Jim, apparently all of the tabs are broken off.
Great idea on the spray foam (what comes to mind is "Great Stuff sold at Home Depot, Lowes, etc.). Just hate to think of taking the dash out again after such a repair though. Agreed that this is a great time to do the Evap if it's not been done before.

Rule .308 · Post by **Rule .308** » 19 Nov 2006, 09:17

Replacing the heater core and evap is not a bad idea but it is not a simple parts replacement because you have already done the hard part. You have simply removed the dash at that point. You would still need to move the harness out of the way, take a couple pictures of it first, disconnect the evap and the heater core, pull the entire climate control box off of the firewall, seperate the case, replace the evap and heater core, and then put it all back together. You would definitely be a fair piece of the way in there but it will not be like hanging a new set of drive belts while you are doing the timing belt.

Mark

Post by **billofdurham** » 19 Nov 2006, 11:20

This one tells you how to make new tabs: http://www.volvoforums.com/m_29279/tm.htm

Bill.

Post by **MadeInJapan** » 19 Nov 2006, 11:35

Great find! If there's a will, there's a way!

Tornado Bait · Post by **Tornado Bait** » 22 Nov 2006, 08:14

Thanks for all the info guys. With all the help and advice I was able to successfully repair all broken mounting tabs. Here is what I did.

After removing the entire dash the 4 broken tabs were mostly intact and still attached to the firewall. Once I unscrewed them from the torx bolts I used super glue gel to affix them back to the dash in their original positions. The super glue was not the main fix, but merely to hold them in place for the REAL repair. After the glue was good and hard I used my dremel to slightly buff the plastic all around them and about 2" on either side along the length of the dash. I then cut 4 strips of fiberglass (1 for each tab) about 5" long and 2"-3" wide and laid them over the tabs to where they were roughly centered over the hole. Then I applied resin to the fiberglass and made sure to pat it down with the resin applicator to ensure a close fit all around the tab. The fiberglass is flexible enough to form around the corners and tuck in the creases. Once the resin hardened over night the tabs were good and solid. After installing the dash and taking it for a test drive it was nice and quiet.

Now I have a working odometer, new instrument cluster bulbs, a non-stuck horn, and quiet/solid dash thanks to all the tips from this board. Next I have to repair my driver side seat heater...already found the broken wire.

THANKS AGAIN to all the contributors of this forum!