94 850 door stay sheet metal breaking?

  • Thread starter Thread starter Doug Warner
  • Start date Start date
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Doug Warner

My 94 850 wagon's door stay has started making a snapping noise when
opening the door. A closer inspection reveals that the sheet metal
has cracked around where it mounts to the body:
(See pic: )
http://webpages.charter.net/dwarner2/doorbreak.jpg
The area just under the circle is the door stay/stop assy, and just
above it is the door electrical harness.

I'm guessing that the door will have to be pulled and the area welded
and reinforced. Has anyone seen this before?


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Doug said:
My 94 850 wagon's door stay has started making a snapping noise when
opening the door. A closer inspection reveals that the sheet metal
has cracked around where it mounts to the body:
(See pic: )
http://webpages.charter.net/dwarner2/doorbreak.jpg
The area just under the circle is the door stay/stop assy, and just
above it is the door electrical harness.

I'm guessing that the door will have to be pulled and the area welded
and reinforced. Has anyone seen this before?

To reply, please remove one letter from each side of "@"
Spammers are VERMIN. Please kill them all.
Click to expand...

That's the approved way to fix it, but try this:
http://au.geocities.com/ozbrick850/door-stay_fix.html

--
Mike F.
Thornhill (near Toronto), Ont.

NOTE: new address!!
Replace tt with t (twice!) and remove parentheses to email me directly.
(But I check the newsgroup more often than this email address.)
 
Doug said:
My 94 850 wagon's door stay has started making a snapping noise when
opening the door. A closer inspection reveals that the sheet metal
has cracked around where it mounts to the body:
(See pic: )
http://webpages.charter.net/dwarner2/doorbreak.jpg
The area just under the circle is the door stay/stop assy, and just
above it is the door electrical harness.

I'm guessing that the door will have to be pulled and the area welded
and reinforced. Has anyone seen this before?


To reply, please remove one letter from each side of "@"
Spammers are VERMIN. Please kill them all.
Click to expand...

Yeah I got this too - have to say this is a truly APPALLING build
quality issue and what makes it worse is that my 1996 model also suffers
from it - so several years later and they still have the same problem -
should have been ironed out by '96......

Am very happy with the car apart from this but there is absolutely no
excuse for a poorly designed door hinge....this is basic stuff.....
 
Yeah I got this too - have to say this is a truly APPALLING build
quality issue and what makes it worse is that my 1996 model also suffers
from it - so several years later and they still have the same problem -
should have been ironed out by '96......

Am very happy with the car apart from this but there is absolutely no
excuse for a poorly designed door hinge....this is basic stuff.....
Click to expand...

I dropped by a dealer today, and they said to stop by either of the
local bldy shops they use, as they're VERY familiar with the issue.
He impllied that they can weld & reinforce it without removing the
door. Didn't have time to get a quote then, I'll check them out
tomorrow.
It may be that the big hole for the wiring weakened the area, because
my crack ran between the two holes.
I'm at 194,000 miles now, longest ever for any car I've owned without
major issues. Or, maybe not, since I seem to have a rear main seal
leak... Waiting to see how the new body style Subarus look (the
current ones are just too ugly for me )-)
http://www.need-desire.com/WallpaperOutback/1024x768/O-1024-8.htm
250HP, AWD, not bad, but the wheel arches look awfully high, as if
they jacked the suspension up to SUV height.. I may have to wait tor
the WRX version..
(No more Volvos for me, because the service manuals aren't available,
and I can't be be sure if I'm buying a Volvo, Ford, or Mazda.)

To reply, please remove one letter from each side of "@"
Spammers are VERMIN. Please kill them all.
 
Doug Warner said:
Waiting to see how the new body style Subarus look (the
current ones are just too ugly for me )-)
Click to expand...

I just gave a '90 Legacy away. The brakes and most everything under the
car had rusted out. The tailgate rusted out and had to be replaced. I
replaced the automatic transmission but couldn't replace all the metal
that was rusting out.. It was a real rustbucket. Never again.

I drive my 850 180,000 miles and they still look like new. I didn't
even get 110,000 miles out of the Legacy.
 
Service Manuals 1-800-25-Volvo

--
"We will not tire, we will not falter, and we will not fail"
------President George W. Bush------
September 20, 2001
Yeah I got this too - have to say this is a truly APPALLING build
quality issue and what makes it worse is that my 1996 model also suffers
from it - so several years later and they still have the same problem -
should have been ironed out by '96......

Am very happy with the car apart from this but there is absolutely no
excuse for a poorly designed door hinge....this is basic stuff.....
Click to expand...

I dropped by a dealer today, and they said to stop by either of the
local bldy shops they use, as they're VERY familiar with the issue.
He impllied that they can weld & reinforce it without removing the
door. Didn't have time to get a quote then, I'll check them out
tomorrow.
It may be that the big hole for the wiring weakened the area, because
my crack ran between the two holes.
I'm at 194,000 miles now, longest ever for any car I've owned without
major issues. Or, maybe not, since I seem to have a rear main seal
leak... Waiting to see how the new body style Subarus look (the
current ones are just too ugly for me )-)
http://www.need-desire.com/WallpaperOutback/1024x768/O-1024-8.htm
250HP, AWD, not bad, but the wheel arches look awfully high, as if
they jacked the suspension up to SUV height.. I may have to wait tor
the WRX version..
(No more Volvos for me, because the service manuals aren't available,
and I can't be be sure if I'm buying a Volvo, Ford, or Mazda.)

To reply, please remove one letter from each side of "@"
Spammers are VERMIN. Please kill them all.
 
My '92 850 had the same known problem by Volvo who fixed mine free of
charge. Every time I opened or shut the drivers door there was a loud
clacking sound. The door was pulled, welded and resprayed.
 
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