My motivation at work is lacking, so here's some pics of my latest project on my '93 Volvo 945 turbo.
I originally bought this car as a fun side project, but once my son was born it magically turned into the family-mobile since it was the only vehicle that could haul everyone. However, it rode like shit. I originally thought it was due to the IPD sport coils I put on and the horrible mid-west road conditions. So, I put the stock coils back on and it still rode terrible. Now, I think it is due to the 20-year-old dry rotted bushings and Bilstein shocks/struts I put on. (I'm turning into James May. I put Bilsteins on the Volvo and my Dakota, and I hate them. They have 'tested at the Nurburgring' sticker on them. I'll never buy Bilstein for a road car again.)
Anywho, so I'm ripping out the entire suspension and brakes from the car to replace anything that needs it. Here's the list of stuff I found wrong so far:
- Blown and wobbly ball joint on pass. front side
- Cut rubber boot on pass. front tie-rod - leaking grease
- semi frozen slide pin on pass. front caliper bracket
- frozen slide pin on driver front caliper bracket
- sheared off wheel stud from driver rear (knew about that from recent tire rotation)
- worn out driveshaft bushing
- tear in pass. front brake hose (not leaking think it's just protective cover)
- tear in pass. front brake caliper piston dust cover (not leaking but still bugs me)
- Dry rotted bushings everywhere!
So, I will be replacing some wheel studs, the front ball joints, tie-rods, front lower arm bushings, front strut rod bushings, rear trailing arm bushings, rear torque rod bushings, and driveshaft bushing. I have new OEM-style Sachs shocks and struts. I also got stainless steel brake lines and caliper rebuild kits for all four corners. I will cut one full coil off the front spring and will probably cut about the same off the new 30% stiffer overload springs I bought for the rear to give it a good appearance while still having a decent ride. I also bought an IPD lower chassis brace to stiffen things up. Wheel hubs, rotors, and brake pads are recent, so they'll be reused. I also already have an adjustable panhard bar and polyurethane strut rod to lower are bushings, so those will be reused. I'm leaving sway bars alone until I can just buy the IPD sway bar kit. I'm also going to powdercoat the calipers and suspension components. Why? Cuz I can!
And here's the pics for far. I'll update as I get more disassembled.