TheGageinator's 2002 XC70 Build

TheGageinator · Post by **TheGageinator** » 27 Mar 2019, 11:15

Well I sold my 2002 v70 (The Ammo Can) to get an AWD model. I was so amazed at the performance of the 2wd P2 offroad, that i needed the bigger, better brother.

The Car:
2002 Volvo XC70 2.4 T
165k miles

The Goal:
Overland capable rig for long offroad trails/camping

I picked up this car for $500 about 1hr away from me. The previous owner took decent care of it for 8 years with synthetic oil changes.

Immediate attention needed:
transmission fluid flush
oil change
Strut tops seperated (never seen that before)
Gauge cluster dead
vibration at idle
oil cap seal

TheGageinator · Post by **TheGageinator** » 27 Mar 2019, 11:30

Got the tranny fluid changed. It was just about all black. The way I do these is to remove the Lower cooler fitting from the radiator and slide a rubber hose over it into a drain pan. Run the engine for a few seconds until you see bubbles coming out of the hose. Then pour the fluid into a container and measure the exact amount that came out (between 2.5-3qrts). Put that amount back into the tranny dipstick tube, and then do this over until the fluid it shiny and red! (about 15 Qts)

I used Valvoline MaxLife here, I know there is some controversy behind that.

TheGageinator · Post by **TheGageinator** » 27 Mar 2019, 11:32

Next up is the Gauge cluster. This is the easiest cluster repair you can do. here are some pics of the re flow

TheGageinator · Post by **TheGageinator** » 27 Mar 2019, 11:33

Now Ive got to decide if I want to just replace the strut mounts, or Do the complete struts...

Are the XC struts different besides the springs?

EngineeringBloke · Post by **EngineeringBloke** » 27 Mar 2019, 12:36

Don't forget to do the glove test to check the PCV is ok (rubber glove over oil filler hole - if inflates, then PCV bad and needs replacement/cleaning).

And Jimmy57, a mechanic here, has recommended Valvoline Maxlife ATF:

Valvoline Maxlife ATF Dex/Merc, Mercon LV is what I use. It lists 4 volvo equivalencies. It lists the ones for Toy and Lexus. Toyota/Lexus low viscosity newest spec is WS and it lists that. It is a full synthetic fluid

I have poured gallons and gallons of this fluid into 5 and 6 speeds and they all work fine.

viewtopic.php?f=9&t=87192&p=486935&hili ... fe#p486935

TheGageinator · Post by **TheGageinator** » 27 Mar 2019, 13:06

I do need to check the PCV system for sure. I got lucky with my v70, the previous owner took it to volvo for maintenance, and it had a fresh top end! 185PSI across all cylinders!

didnt get so lucky on this one. 145psi on cylinders 1 2 and 5. 125 psi on cylinders 3 and 4. I know I'll need to do a timing belt pretty quickly, because there are not records of this one being done

Post by **matthew1** » 27 Mar 2019, 15:31

Nice. Following. You kept the wheels/tires from Ammo Can?

EngineeringBloke · Post by **EngineeringBloke** » 27 Mar 2019, 16:51

For the reflow of the DIM, I see you have a soldering iron.
- Are you going to work each IC pin one by one?
- Are you planning to prepare the surface prior to soldering? Some have removed the blue colored coating on the pins of the larger ICs.
- Will you use flux?

And good job with the Ammo Can. It was a different project than most I have seen here, but I think you did very well and enjoyed it.

TheGageinator · Post by **TheGageinator** » 28 Mar 2019, 09:31

matthew1 wrote: ↑27 Mar 2019, 15:31 Nice. Following. You kept the wheels/tires from Ammo Can?

No, unfortunately I sold it exactly how it was. The guy was so excited to get it. He had watched all the live streams and kept up withe the race. I'm going to go a little different route on this build i think. More long term capable, and a little less aggressive haha

TheGageinator · Post by **TheGageinator** » 28 Mar 2019, 09:35

EngineeringBloke wrote: ↑27 Mar 2019, 16:51 For the reflow of the DIM, I see you have a soldering iron.
- Are you going to work each IC pin one by one?
- Are you planning to prepare the surface prior to soldering? Some have removed the blue colored coating on the pins of the larger ICs.
- Will you use flux?

And good job with the Ammo Can. It was a different project than most I have seen here, but I think you did very well and enjoyed it.

Thank you!!

For the gauge cluster, I only used a fine tip iron to reflow the pins individually. It takes a very steady hand, but not too hard. I have done alot of various board and small part repairs like this. Something interesting is, of all the Volvo clusters I have done, NONE of them needed any work on the controllers with the blue coatings. Just hit the IC pins in the photos, and you will be good to go.