2004 S60 R - Introduction, Current and Future Maintenance

[matthew1]

I like that sturdy S hook to hold the caliper. I've used zip ties, and I've never felt 100% about it.

[rolsen11]

Fixed the nonfunctional front passenger window. The new window regulator sliding pivot parts from the previous owner arrived today and I got it fixed. I also found out why they broke in the first place. The rubber/felt window track somehow manage to get dislodged and wedged entirely to one side of the window within the door, causing the glass to get wedged and snap the plastic pivots. Over time this caused one of the regulator arms to get bent too. I bent the arm back to straight as best I could, removed the rubber/felt track and reinstalled it correctly and put in the new pivots and viola, the window works and the door is plugged back into the car!

[rolsen11]

Link to thread discussing woes with grinding noise when turning left:

viewtopic.php?t=108210

[jonesg]

the window control arms get bent when someone tries to roll the window down in winter, the ice freezes the glass in position.
I replaced the slider blocks at least 3 times before replacing the arm assembly, $57 amazon.

[rolsen11]

I shimmed the AC compressor clutch today. Sure enough, shimming it with three zip ties the same way as I did on my V70 solved the problem. AC now blows ice cold all of the time!

[rolsen11]

Link to thread discussing woes with grinding noise when turning left:

viewtopic.php?t=108210

See thread above for grinding/vibration to see video, the root cause wound up being the front left wheel bearing. Car drives nice and smooth after replacing. Funnily enough, the old bearing was less than 5 years old and already failed. Folks, do not cheap out on wheel bearings. Get the good stuff and they will last. Do it right, do it once.

Got an alignment done afterwards, steering wheel is nice and centered now. The shop discovered that one of the lower ball joint bolts on the front right is a little loose and would not tighten. Stripped out? I hope not, but probably .

While I had the car on the lift doing the wheel bearing I also replaced the broken windshield washer pump. Looks like somebody filled it with water during the cold months at one point and froze since the old pump was cracked and expanded outwards.

Replaced cabin air filter. I now know going forward I should buy a better quality filter. The aftermarket ProTune filter I bought did not fit well at all and I had to modify it slightly to get it to fit.

Tried to order a new (used) air box from Erie Vo-Vo since mine is missing the cover. Unfortunately theirs is also missing the cover. Evidently this is a common "mod" people do to get more intake noise. I get it, but I don't like it. The only complete air box assembly I've found so far is on ebay for 700 bucks including a handful of other bits which is absurd. I'd rather get an actual cold air intake from Elevate or Snabb for that money.

The car is in a nice, drivable state now which is really exciting! Now it's on to daily driving it for a while to shake it down and see what else comes up.

Next immediate items:

• Ball joint bolt?

• New (used) right hand taillight assembly

• New reverse lights, both currently nonfunctional. Might be why I have a brake light fault on the gauge cluster

• Source a spare tire, jack, and toolkit

• Refurb vacuum lines, particularly TCV lines

Items further down the road:

• Parking brake could use a refurb. I have to pull it up to nearly the top for it to grab

• I would like to take the gauge cluster apart again to remove that piece of tape covering the check engine light

• Replace fog light assemblies

• Air intake

• Fix rear oxygen sensor

• Get quotes from a handful of specialist shops in the region to eventually do a clutch replacement

• May have a new leather cover custom made for the shift knob by a local upholstery shop

[rolsen11]

Cabin temperature sensor (thermistor) has been replaced!

Thread detailing the replacement:
viewtopic.php?t=108318

[rolsen11]

I replaced the TCV and fixed the ruined hoses for it a couple weeks ago. What a difference! Somebody in the past made probably the most botched repair I've seen so far. One of the TCV hoses was broken so they took one end that was split down the middle, shoved the other end into it, wrapped it in duct tape and put one hose clamp over the middle. Even if that terribleness worked, there was a hole in the tube a little further down that rendered the entire TCV system inoperable anyways. Crazy.

With it fixed the car no longer falls flat on its face when trying to give it any power. I need to be careful not to beat on the car too much now because the boost is addicting .

I ordered some new parking brake hardware excluding the cable to go along with the new rear rotors and pads that came with the car as well as a new rear oxygen sensor to replace the currently broken one that's throwing a check engine light. Plus a handful of other small items.

I'm still doing some research on it, but from what I've gathered from the transmission rattling at idle with the clutch engaged in neutral, the vibrations the power train has in general, and the shifting engagement and feel, I think this car might have had a single mass flywheel installed at some point. I don't know for sure yet but it's seeming like it is. Either way, I still want to do a clutch replacement on this car sometime in the future which will include replacing the flywheel with a new dual mass one.

[jonesg]

N. Minn? you have 3 more weeks before the snow begins.

[matthew1]