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850 T5 ABS Woes Topic is solved

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
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abscate
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Re: 850 T5 ABS Woes

Post by abscate »

Nice. That one is jumping out at you for attention.
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Re: 850 T5 ABS Woes

Post by Cookeh »

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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IMG_20191115_101018.jpg
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Re: 850 T5 ABS Woes

Post by Cookeh »

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 »

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.
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Re: 850 T5 ABS Woes

Post by abscate »

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 »

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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Re: 850 T5 ABS Woes  Topic is solved

Post by Cookeh »

For those interested, wire harness repair kits are still available from Volvo - P/N 9442019, which comprises two crimps, two 9mm ID 3:1 adhesive lined heatshrink, one piece of approx 18mm ID 3:1 adhesive lined heatshrink and the cable harness itself (with approx 1.8m or 6ft of cable and a new connector). For those who have their own heatshrink/crimps/want to solder the splice, P/N 944288 is the part number for just the harness.

The kit cost me £34 from FRF Volvo Swansea, but that is with a discount code applied. I believe retail is closer to the mid-£40s. It was in stock for next-day collection and did not have to be ordered from the classic department in Swe. In theory, this means it should also be widely available in the US/Europe.

If it will be beneficial, I can start a new topic with a title along the lines of "ABS wire harness repair kit" and detail all part numbers with a description in there. I could just leave the info in here, but with the current title it might not be easily accessible under searches.

I should also mention that this has, for now at least, cured my ABS issues.
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