780 Bertone - Nvrmnd - Volvo 745 Pickup Project

lookforjoe

True Classic
The first photo looks like the wheels from the S60R/

Same wheel, different finish. S60R were silver finish - I had them on my old wagon

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Bjorn Nilson

True Classic
The first photo looks like the wheels from the S60R. My T5R wheels have no "R" on them.
When you mention it, not all T5R have the R logo. And the logo on the picture has been painted red which is not correct. There are different replicas available here as well.
 
When you mention it, not all T5R have the R logo. And the logo on the picture has been painted red which is not correct. There are different replicas available here as well.
In the USA, the T5R was offered only in 1995. After that, the 850R was offered here but it had a totally different wheel design. The S60R wheels look similar to the T5R wheels but with the R carved in it.

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I took this photo in Death Valley. It was 122F at the time.
 

lookforjoe

True Classic
Got the plates today, so I drove it the station to get the inspection done. ABS light came on - nasty grumbling from the LF, so I pulled it all apart. Bad wheel bearing, balljoint, strut, tie rod end, ABS sensor :D I was expecting to replace basically EVERYTHING in the front and rear brakes and suspension, so not really surprising with 216K miles...
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lookforjoe

True Classic
Waiting for front end parts...

Pulled the nose off in the meantime.

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cut and modded the single headlamp brackets to fit the offset of the eCode lamps

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trimmed the cover panel to fit the egg crate/headlamps

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Also fitted the painted bumper cover

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Chopped off the dead preheat BS. Air box will go away when I do the +T anyway

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lookforjoe

True Classic
Cleaned up & reinstalled the control arms, caster rods, end links, Bilstein strut inserts, bump stops & sleeves, strut plates & bearings, backplates, brake hoses, calipers, rotors, pads

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lookforjoe

True Classic
Right side all back together, had to also change the ABS sensor on this side

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Started modding the fuel rail for the +T - cut off the FPR bung, will be welding this 1/8" NPT bung so I can install a fuel pressure gauge in it's place

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lookforjoe

True Classic
Did the left rear brake line, caliper, pads, rotors & hardware, eBrake shoes and springs. Main cable is still good, no damage to coating. Right cable broken & pivot ripped off the axle tab as per usual on these. So far all brake lines have been frozen & required heating with torch to get them free.

coated the backplate with rust convertor

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Heavy duty spring & Bilstein shock installed. Still have to do the right side, ran out of daylight (and time)

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silver-soldered the NPT bung to the rail - will look like this in place

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lookforjoe

True Classic
Right rear brake line flare stripped, even after careful heating :(. Had to make a repair section. Fortunately I saved lines off the S40 parts car, so I has a section of line and spare male/female fittings to join it

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Had to borrow this tool - the Volvo line is 4.75mm, my tool only does American sizes. Hydraulic tool is way easier to use than the clamp-in-vice generic variety I have.

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lookforjoe

True Classic
Gathering exhaust parts for the +T

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wired the left & right EU park/directionals, and included wiring to the EU side markers in the fenders

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made a problem for myself by adding a relay for front fogs without checking the wiring diagram - I didn't realize it was anything special. As a result, it created a dead short on the Y-W wire from the headlamp relay to the headlamp switch and the radio illumination. I had to open up the harness & make sure no other wires were damaged. Thankfully not, so I ran a new Y-W wire from the HL switch to the radio, bridged to the HL relay.

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while I had the cluster out I switched out the tach for the turbo version - not showing vacuum here - I hadn't connected the line to the manifold yet

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lookforjoe

True Classic
Did a few maintenance items - engine breather, IACV, couple vacuum fittings. Then I ran the harness for the AEM WBO2 over to the pass side, I'll need that when I add the turbo setup.

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routed through the bulkhead & along the stock harness

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While I had the under dash apart I added a 4x40W amp from a 760. I also have to fault trace the cruise - it doesn't work, May just be the 3523880 module - apparently that version is prone to malfunction. I have a 9130207 module that I thought was from a different era, however it is apparently a viable update to the 3523880 - so I'll try just swapping that out first
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EDIT - I rechecked the parts schematic - I have the vacuum supply from the diaphragm connected to the wrong port on the pump - I didn't T the two together as shown below

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lookforjoe

True Classic
Cruise control works as intended with the vacuum properly hooked up.

Been futzing with the power mirrors I added - the wiring and/or switches changed in production, so the switches I'm using don't match the mirrors - tried to rearrange the pins in the mirror switches, to no avail. Switches listed for the late model mirror also apply to the 91, so I'm not seeing how getting late switches will help here. I'll play with this more DTR

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lookforjoe

True Classic
OK - so I got two switch sets off an 850 - they have the 3545090 - can be identified by the white switch base vs. the black base of the earlier switch.

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Not one of the 4 works in all 4 directions, however between the 4, each properly operates one axis - so 3545090 is the correct switch for the 2-motor mirror setup, along with repinning the switches as I have.

I've dismantled 2 of the switches to clean the contacts - before cleaning here

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lookforjoe

True Classic
Still taking care of Stage Zero.

3 Shifter & 1 reaction rod bushing. Circlips were still good!

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Problem arose when I tried to remove the selector arm - end of shaft snapped off.

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For now, I just added a blob with the MIG. I'll have to source a selector shaft. Shaft seals is dry, so at least there is that

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Also the fuel filter bracket is completely toast

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so I made one out of an aluminum ruler

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Need to source all the exhaust hangers bolted to the body before I do the exhaust - they are all seriously rotted

Stripped & scrubbed the foam off the headliner - kinda like the texture

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EDIT - swapped out the roof panel with one with an excellent seal

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lookforjoe

True Classic
Finally got the repair kit for the handbrake pivot. Had to make a bracket for the guide bushing that goes over the axle diff

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lookforjoe

True Classic
Started on the engine servicing - timing belt, engine seals, water pump and so on

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new seals in

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New water pump & Volvo t/stat as well

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need to make up my mind about the intercooler / radiator setup - If I use the later issue wide IC & radiator, the air-to-oil cooler won't fit in the stock location. I'm leaning to the stock rad, early IC so I can use the oil cooler, and modify the later fan shroud with electric fan to fit.

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