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Torx bolt to door-stop snapped off

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70
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tailor
Posts: 570
Joined: 12 November 2006
Year and Model: 2004 XC90 2.5T AWD
Location: Toronto
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Very painfull extraction!

Post by tailor »

Ok! enough already :wink:

Update on the situation, I managed to screw it all up. :cry:

In my efforts to get the remainder of the torx bolt out, I wound up drilling at the wrong angle and drilled through the nut on the back of the hinge. I started by using the smallest bit to give me a pilot hole....well it all went rapidly pear shaped thereafter.
The screw extractor was no good as I was into the nut already and the remainder of the bolt would not move.
I now find myself in a position to re-tap, but it will be off centre, slightly closer to the interior of the car.
I am hopefull that the re-tap will be a success.

Methinks that the door removal might haver been a good option as MIJ just suggested.

More tomorrow.....
1994 850 Auto Turbo wagon 306000km (Sold)
2004 XC90 AWD 188000km

"Life is like a reel to reel tape recorder,
the closer you get to the end,
the faster it spins."
Abe Gottschalk
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larryh
Posts: 256
Joined: 28 March 2006
Year and Model:
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Post by larryh »

no big deal. put a very small bit back in the drill and simply remove the rest of the bolt by drilling a bunch of little holes in it until the thing just falls out in pieces. A small punch will help knock the pieces out. Then get the helicoil kit and drill it & tap it and put in the new bolt.
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MadeInJapan
MVS Moderator
Posts: 13434
Joined: 31 March 2005
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
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Post by MadeInJapan »

You'll need someone to hold the door or place a jack under with a thick cloth or other way to protect your door it to get it off...it's really not a one man job and it's heavy.
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
'07 S40 T5 AWD 6 speed manual! Silver/Black Stage1 Heico & Elevate
'07 S60 2.5T Blue/Taupe- my kid's Volvo
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tailor
Posts: 570
Joined: 12 November 2006
Year and Model: 2004 XC90 2.5T AWD
Location: Toronto
Been thanked: 2 times

Post by tailor »

Ok, I now have it fixed...seems I have a spare part.....forgot the rubber protective cap.Will have to do that this weekend.
I finally did a re-tap.

Thanks to all for your input.

Stealership "nailed" me for another 0.54c when I went to pick up the part, seems that it was upgraded...blah,blah. I should try adding 40% to the price of a suit after the customer has already paid the quoted price.
Now I really do not like the parts guy. :lol:
1994 850 Auto Turbo wagon 306000km (Sold)
2004 XC90 AWD 188000km

"Life is like a reel to reel tape recorder,
the closer you get to the end,
the faster it spins."
Abe Gottschalk
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Kappy5003
Posts: 98
Joined: 17 March 2008
Year and Model: 1994 960
Location: Wagin West Australia

Post by Kappy5003 »

MadeInJapan wrote:Yes, you are lucky that the bolt broke rather than the weld on the door piece (which is usually what happens). Drill her out and you should be good to go.
This has happened on my driver's door(right hand in my case)
have notice a bit noisy for a while that has become quite loud and have noticed the weld has cracked.

Is there a realistic solution to this problem (by a reasonable handy man) and is there a reason this happens or is it just one of those things.

Cheers in advance.
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