P80 AWD rear suspension control arm 9157302 installation tips

Post by **abscate** » 08 Feb 2022, 15:07

Quick document on putting on the arm and jack point back on AWD cars

This is called a support arm in VIDA and a stay in the Volvo parts web store. It’s part number 9157302 and bolts to the rear axle carrier, the lower control arm, and the to the body forward with one long bolt up into the “ snout” and three shorter bolts thst also hold the jack point onto the car

1998 1999 2000 AWD ONLY

First step, chip your jack out of the ice.....

First, get the brake lines in the right place. See pictures. The hard lines go outboard of the main big poly and snout, the cross over brake line to the right side goes onboard.

The big snout bolt is easy to put in , but the plate and jack point bolts are tensioned inboard and are hard to lineup.

Find your self a long M14 and out the snout bolt in loosely. Now take the long bolt and get it in one of the plate bolts. Now use a screwdriver to pull the plate into position and get the bolts started. Once you have one in, run it down hard while prying the plate into position, the start the other two.

Finally slacken off the three plate bolts, tighten the snout bolt, then torque everything up to spec

Part numbers
Snout bolt 1x 987455 M14x100 (985761)
Plate bolts 3x M12x35 (949773) 985055 washer 986445

**** there are chassis break and discrepancies on these bolts and sizes

Measure yours and compare carefully

Torques
front longitudinal stay mountings and the jack attachments to the body.
Press up the link arms to their normal position.
Connect the left-hand three-way branching to the left-hand jack attachment.
Fit the longitudinal stay brackets and the jack attachments using new bolts.
Tighten the three bolts for the longitudinal stay bracket to 65 Nm + 60° .
Tighten the bolt through the jack attachment to 105 Nm + 90° .

Post by **scot850** » 08 Feb 2022, 15:36

Remember this is all fun!! Well someone told me that!

Neil.

Post by **abscate** » 09 Feb 2022, 03:16

scot850 wrote: ↑08 Feb 2022, 15:36 Remember this is all fun!! Well someone told me that!

Neil.

It’s a lot easier if you sort this out on the lift than lying on an inch of ice and snow pack in the driveway.

Post by **scot850** » 09 Feb 2022, 19:22

I hope you remembered that the parking brake cable is sandwiched between the front jacking plate and the floor. It is held in place by one of the cable mounts with a single hole that you open up and put around the brake cable. It is then riveted from the top.
If you forgot to rivet it from the top, use a small #6 or #8 washer on the top side of the mounting clip so that the rivet has something to draw against other than plastic. Then rivet from below.

Neil.

Post by **abscate** » 10 Feb 2022, 04:36

Looking at my pictures I got this wrong, but the cable is loose right now so easily fixed

I’m awaiting a magical arrival of brake parts from

Post by **abscate** » 10 Mar 2022, 04:56

It’s even more important to not pinch the brake line between the torsion arm and body as you won’t be able to bleed the brakes. My cost per use of my new Neiko bubble flare kit just dropped again

New brake pipe 9438280 $85 from Volvo

2 feet CuNiFe brake line and fitting, $5 and free instant shipping!

The outboard swage is a bit tough to make up. You have to drop it that ugly 1/2-2cm, always a tough adjustment on a flare fitting as it has to
Line up perfectly. You can grab about 4-8 mm of bend with pliers in CuNiform pipe easily though

I had the thread referenced suspension parts off three times today fitting the brake line. If you fit the long bolt and the outboard bolt first, that seems to be the easiest combo to line up the other two

Ekaterina zooms, steers, and stops now.

Now it’s time to spruce her up

Post by **scot850** » 10 Mar 2022, 09:59

Ah, yes. Crimping the brake line. I believe that our friend bmdubya did a similar thing when swapping his rear suspension from AWD to FWD. It does tend to make the make brake bleeding a bit more challenging! Glad you found the issue and solution!

Brake parts? What brake parts? We have no stinking brake parts (well maybe, but who knows where?)

Neil.

Post by **abscate** » 10 Mar 2022, 18:32

I had forgotten all the lessons of flaring lines but here is an important one

Measure your line length and cut it.

Now put your flare nuts on, right way please , and flare your ends. Now tape the nuts so they stay near the flared end

Once you start your bends , the nut will end up captive behind any bend and you have to start over

News lines are available for $85

I was into about 2x $4 for these