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850 T5 ABS Woes

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

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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abscate
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Re: 850 T5 ABS Woes

Post by abscate » Sun Nov 10, 2019 4:40 am

Nice. That one is jumping out at you for attention.


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Re: 850 T5 ABS Woes

Post by Cookeh » Fri Nov 15, 2019 5:16 am

I went to try and address this last night, only to be met with some hurdles. I'd welcome suggestions on addressing this. I've attached a picture to hopefully highlight the issues I'll discuss.

My thought process was to de-pin the terminal, remove the knackered black insulation that keeps the two red and brown cables joined, and add heatshrink to both cables to address the insulation cracks. Optionally, I was going to add another layer of heatshrink or perhaps use loom tape to bundle the two cables.

The first problem occurred when I simply touched the cables, both the shared black and the individual red/brown insulation disintegrated, leaving me with two bare wires.

The second problem occurred when de-pinning the terminal. As it transpired, the pins can't really be separated. After de-pinning the terminal the cables are still joined by the weatherproofing insulation, which is much larger in diameter than the cables. This has scuppered my plans, as I cannot simply slide the heatshrink over the weatherproofing (even if I were to split it).

Is the best way to deal with this to cut the cables? Then the process would have to be to heatshrink either side of the cut, solder the two and then heatshrink over the soldered join? I'm not sure how I feel about cutting ABS wires in these cars as they have enough issues with ABS errors as is!

As a temporary measure I have very sloppily wrapped the cables in electrical tape (halfway through the process in the picture!) to prevent shorting issues, but this won't stop moisture ingress or damage, obviously.
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Cookeh
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Re: 850 T5 ABS Woes

Post by Cookeh » Sat Nov 16, 2019 12:21 pm

As it transpires I have a much bigger issue, which will be causing the intermittent ABS light. I have temporarily wrapped the wires until I can get the plastic motor cover off to repair it properly.

ImageABS wire break

This is the nearside (left) ABS wire sensor, with a definite break and two other heavily worn areas. I have Bilstein struts, and some digging around this forum reveals that that can occur - especially when the retaining grommet breaks, as in my case. From said research, it appears as if there was once a repair kit that can be spliced in. If I cannot find one is it possible to splice in the cable from a breaker?



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Re: 850 T5 ABS Woes

Post by erikv11 » Sat Nov 16, 2019 12:33 pm

Looks like you finally found the problem, well done.

For the wires at the module, you could use liquid electrical tape. Works really well, I love it.


'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 140k
'98 S70 NA, 210k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 280k
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Re: 850 T5 ABS Woes

Post by abscate » Sat Nov 16, 2019 1:31 pm

Those thin wires are hard to solder and keep from breaking. I suggest getting a new sensor and watching the chafe points on install


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Re: 850 T5 ABS Woes

Post by Cookeh » Sat Nov 16, 2019 1:59 pm

abscate wrote:
Sat Nov 16, 2019 1:31 pm
Those thin wires are hard to solder and keep from breaking. I suggest getting a new sensor and watching the chafe points on install
Sensor is not integrated into the wiring for the 850s, and we also suffer from the joys of not having connectors on the harness by the strut towers. New wire definitely seems the way forward though, whether that be through a breaker car or from a repair kit (if such a thing still exists). As you say, I can't see solder helping that!



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