Today's update.

Tie rod ends off, rack out, clean gunk and crap off everything. What a mess... I got the front suspension and springs mated up. Took them apart when I figured out I had the top piece upside down. I removed the power steering reservoir and hoses. I need to replace one hose tomorrow and start putting everything back in. New rack is ready, cleaned up all the parts I took out. Once I get the front end put back together then it's on to the rear shocks.

http://forums.pelicanparts.com/uploa...1430631138.jpg
http://forums.pelicanparts.com/uploa...1430631169.jpg
http://forums.pelicanparts.com/uploa...1430631205.jpg
http://forums.pelicanparts.com/uploa...1430631239.jpg
http://forums.pelicanparts.com/uploa...1430631269.jpg

These gloves work great!

http://forums.pelicanparts.com/uploa...1430631404.jpg

Oh yeah, and new sneakers! =)
http://forums.pelicanparts.com/uploa...1430631726.jpg
http://forums.pelicanparts.com/uploa...1430631771.jpg
http://forums.pelicanparts.com/uploa...1430631812.jpg
http://forums.pelicanparts.com/uploa...1430631842.jpg

Very nice shoes there bro!

Holy crap! The job of taking out the stock rack bushings and putting in the delrin bushings took me almost an entire day! I don't have an air chisel which was the preferred method I guess. I used a combo of diagonal cutters, flat blade screw driver, a hammer, and a graduated drill bit. I had to run to town (1 hour trip) to get the drill bit. The first one took the longest, then the next 2 were not quite as long. I sort of used a snip, snip, drill, drill, snip, drill, melt, hammer, hammer, pop method. The last one my battery ran out on my drill. I will get it out in the morning. I did get the power steering reservoir and hoses all changed out though. So I made some progress. I have tomorrow off work, so I'll get it done hopefully first thing and get back on track.

http://forums.pelicanparts.com/uploa...1430708438.jpg

http://forums.pelicanparts.com/uploa...1430708494.jpg

http://forums.pelicanparts.com/uploa...1430708527.jpg

http://forums.pelicanparts.com/uploa...1430708595.jpg

http://forums.pelicanparts.com/uploa...1430708678.jpg

Good job! I think that while I was in town, I would have bought that air chisel!! :)

I've never used mine yet, cheapo from Harbor Freight, but supposed to be one of the non junk items, just don't get the cheap cheap one, go with the deluxe like $14 on sale one.

After spending 5 hours fighting with lining the rack spline up with the u-joint yesterday, I took a break. Sent a few pictures to a mechanic friend who pointed out that I should take the bolt OUT of the u-joint to put the spline in.... D'oh! I put it there to make sure I didn't lose it and didn't even think about it being in the way. Made total sense though after he told me that. The thing went together in 10 minutes tonight. The rack is in, and tie rod ends are on. Just want to check all my power steering hoses again, then tighten them up and fill the system. I did over tighten one of the rack mount bolts and broke it. I guess I need to get them fairly tight then go the rest of the way with the torque wrench. I sort of gorilla tighten a lot of things, and this it not the first nut I've twisted off. Power steering should be fully functional tomorrow night. Then it's back to putting the rest of the front end together. Downhill side of this project now!

Yesterday's flub up...
http://forums.pelicanparts.com/uploa...1430890297.jpg

http://forums.pelicanparts.com/uploa...1430890338.jpg

Tonight's success.

http://forums.pelicanparts.com/uploa...1430890386.jpg

http://forums.pelicanparts.com/uploa...1430890426.jpg

And just for fun, our newest baby owls are out and about. We get two every year. They are a blast watching learn how to fall gracefully.

http://forums.pelicanparts.com/uploa...1430890514.jpg

Hate to be the bearer of bad news...but...

I believe I would have done those motor mounts while you were in there. Your oil pan should be just about flush with the rack crossmember, when they are in okay shape. Yours is well below the crossmember by at least an inch. Mine was less than an 1/4 inch below the crossmember...and vibrates when accelerating and need replaced eventually.

Also, I was looking back at some of your other pictures...and when you replaced your fuel filter and pump...you used a blue butt connector...not good...especially in that area where corrosion will be substantial. This type of repair will surely leave you stranded someday.

They make a liquid electrical tape that is like a putty and you could apply that around the connection instead. Might be your best option for insulating the butt connector from corrosion.

Edit...removed shrink tape advice...

Also, I believe you were suppose too only snug the rack mounting bolts, then let the car down and drive it some, allowing the suspension to settle into its correct location and then tighten them to desired torque.

Brian.

Weird, I don't know why the picture is upside down. It wasn't when I posted it. Thanks for the advice on the motor mounts. I don't currently have a way to lift the engine to do the motor mounts, so I am not sure what to do. I can get access to a cherry picker once I get it running and drive it to my shop at work. I am not a woodworking guy, so I don't feel comfortable building the 2x6 thing I have seen some people use. As far as the blue butt connector, I will make sure it is protected and water proof. The torque on the rack nuts is what I read in a few different places. Do you have a link to the procedure you are referencing? I bought the manuals on CD but cannot get them to work. My laptop will not read them. My plan was to torque them to 35 lbs, drive it for a bit, then torque them to 65 lbs.

ok, I have engine mounts, oil filter/crush ring, and the oil pan seal on the way. I will figure out how to get this thing in the air tonight. I will get the rack back off and out of the way. Luckily I didn't tighten any power steering hoses or and ruin the crush rings yet. I can at least get the other suspension parts put back together while I am waiting. Maybe even knock out the rear suspension before parts get here on Saturday. I am shooting for a May 16th deadline. It's going to be close....

Try the method used in Dwane's Garage: Dwayne's Garage

Awesome, thanks!

Rack is back out, driver side upper a-arm is installed and torqued. Drivers side shock and spring is back in. I'll get the passenger side in tomorrow night, as well as drain the engine oil and get whatever I can out of the way to do the oil pan seal. Possibly get the rear suspension done Friday night. Hopefully won't be too far behind schedule by the end of the weekend. Maybe...

I believe in Dwayne's motor mount link he mentions everything you need to know about torquing stuff. I think the general conscientious is that the wood blocking device works best, instead of a cherry picker, since the reach of a cherry picker is normally to short, considering how long the nose of these cars are, some guys have come in from the side after removing the fender/wing...but then you also have to content with the legs of the cherry picker under the car that will most likely be right in the way of every move you make.

This job is on my list to do this winter and I will be using the wood blocks.

What style mounts did you get, original or Volvo?

I think you will be glad you did this job in the long run, it is rather annoying, the vibration while accelerating.

Good luck...and I will say one thing...you are one ambitious guy.

Brian.

I love this car. She told me I could fix her. What more motivation do you need? I am learning along the way and having a blast. Now...if I could just fit a car lift in my garage, I'd be even happier. =)

Front suspension and a-arms are installed, engine is drained and ready to get lifted tomorrow. Started on the rear suspension. Just keep swimming, just keep swimming...

Roger that. But Rome wasn't built in a day, right? I'd let the PCA folks see the before and after. :)

Plenty of small lifts, I have one of these mid rise lifts;

http://forums.pelicanparts.com/uploa...1431144258.jpg

Works very well with 928 which has little to do in the middle of the car.

What a day...

Got the new rear suspension installed. The new wheels and tires are on. I got the cross mount bar and engine mounts out. What a mess. It'll be good to get the oil seal done while I am in there. It is leaking even worse than I thought. The engine mounts and seal were supposed to be here Saturday, but somehow were shipped to my office by mistake. I'll get them tomorrow. Tomorrow night will be getting the pan off and cleaning as much as possible. It is such a mess. Still going strong!!
http://forums.pelicanparts.com/uploa...1431306742.jpg

http://forums.pelicanparts.com/uploa...1431306812.jpg

http://forums.pelicanparts.com/uploa...1431306857.jpg

http://forums.pelicanparts.com/uploa...1431307340.jpg

http://forums.pelicanparts.com/uploa...1431306936.jpg

http://forums.pelicanparts.com/uploa...1431306985.jpg

http://forums.pelicanparts.com/uploa...1431307044.jpg

http://forums.pelicanparts.com/uploa...1431307094.jpg

http://forums.pelicanparts.com/uploa...1431307145.jpg

http://forums.pelicanparts.com/uploa...1431307214.jpg

http://forums.pelicanparts.com/uploa...1431307508.jpg

http://forums.pelicanparts.com/uploa...1431307545.jpg

http://forums.pelicanparts.com/uploa...1431307596.jpg

http://forums.pelicanparts.com/uploa...1431307649.jpg