94 850 door stay sheet metal breaking?

Discussion in 'Volvo 850' started by Doug Warner, Apr 6, 2004.

  1. Doug Warner

    Doug Warner Guest

    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 Warner, Apr 6, 2004
    #1
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  2. Doug Warner

    Mike F Guest

    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.)
     
    Mike F, Apr 6, 2004
    #2
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  3. Doug Warner

    v56k Guest

    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.....
     
    v56k, Apr 6, 2004
    #3
  4. Doug Warner

    Doug Warner Guest

    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, Apr 7, 2004
    #4
  5. 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.
     
    Stephen M. Henning, Apr 7, 2004
    #5
  6. Doug Warner

    G Klein Guest

    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
    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.
     
    G Klein, Apr 7, 2004
    #6
  7. Doug Warner

    ramjet Guest

    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.
     
    ramjet, Apr 30, 2004
    #7
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