Blinky 51/480

Here you can talk about the joy owning a Volvo 480 brings. Non-technical discussions take place here, like what is the difference between an ES and a S version.

Moderators: jifflemon, coyote1980, Rachel

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Sat Jun 22, 2019 5:56 pm

Just gave them a brush down and a spray with silver hammerite.

I have planned to strip, de-rust and paint with epoxy mastic but wanted to actually finish a job the same day I started it :D

POR 15 I found a funny one, if you follow the instruction to the letter it seems to be good but I have never found great results. Redoxide and hammerite isnt a bad option.

Alan 480
480 Is my middle name
Posts: 1022
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: Blinky 51/480

Post by Alan 480 » Sun Jun 23, 2019 3:56 pm

I used ALDI metal paint on the slls of the SS1 and various parts of 480 suspension at rear and seems to be pretty good, MUCH cheaper than Hmmerite and can get it in black, green & white, ideally black but I had a tin of green for garden furniture so green will be used :-)
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Sun Jun 30, 2019 8:56 pm

When a simple job turns into a nightmare.

Refitted the front struts today and it didn't go smoothly a planned.

Started with the drivers side and it all came off easy enough but struggled for hours trying to get the bolts back in the hub. I had tried to do the job with out dislocating the drive shaft, partly because I wanted to see how it would work when I did the passenger side.

Finally got it after I dug out some small ratchet straps to compress the spring.

Knowing that I could do it with the driveshaft insitu I got a big ratchet strap to hold everything inplace whilst I wrestled the new strut. Sadly I managed to pull the shaft out of the gaiter where the bearing is and lost almost all of the Elf Tranself NFP 75W80 Gear Oil.

Cracked on and got the struts in. I do need to replace the little link rods on both sides and buy some oil.

Turns out that both springs had broken, one must have went during storage.

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Alan 480
480 Is my middle name
Posts: 1022
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: Blinky 51/480

Post by Alan 480 » Mon Jul 01, 2019 6:14 pm

Have you got plan for refitting the struts? I wish I had disconnected a few more parts. I would consider draining the gearbox oil and removing the driveshaft gaiter as it is easy to pull the shaft away from the gaiter and lose your oil, which is messy and expensive.


I seem to have mangaed to swap the struts without any issue, even with a broken spring :-(

If you pull the wish bone to lowest level and lever it down with a long bar you can wiggle the strut to the rear and then release the wish bone, simple remove top bolts/nuts and happy days.

I'd agree N/S is more difficult but managed to swap wishbones using similar method!

outer drive shaft gaiter on OFF side was also done 'in situ', but VERY messy as needed to push snap ring out MUCH further than suggested in HBOL
Last edited by Alan 480 on Mon Jul 01, 2019 8:10 pm, edited 1 time in total.
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Mon Jul 01, 2019 7:31 pm

Thats the one thing I didn't think of pulling the wishbones down.

I have had the hub off in the past but that was a long time ago, I replaced the drivers CV joint last year but ccant remember how I got it back on. Maybe the broken spring and knackered shock made it easier.

Just waiting on the new oil and drop links to arrive sometime this week. Will be interesting to see what the car drives like with decent suspension.

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Thu Jul 04, 2019 2:11 pm

I replaced the front drop links last night, I did have to cut a few mm off the thread where it meets the inner wing though.

Decided as the car was on the lift I would have a go at the PAS hoses and see where the leaks is coming from. Turns out both we leaking at the rack, there were the hoses I had made up.

I have a useable return hose and the corroded high pressure one so took them both to the local Pirtek and asked if they could make a set. You would think I asked the guy to fly to the moon. I knew I would waste some time but getting a bit demoralised.

So back to square one. I need either a company that can make a set of hoses for me or a good second hand set.

jifflemon
480 Is my middle name
Posts: 1178
Joined: Sat Dec 17, 2016 11:03 am

Re: Blinky 51/480

Post by jifflemon » Thu Jul 04, 2019 3:00 pm

never, ever, had a good experience with Pirtek.

Or heard of anyone who has! How they're still in business I'll never know....

Usually a big sign somewhere in the shop saying that they never ever ever, under any circumstance, reuse fittings.

Ask them to make something custom, they'll reuse the fittings

When it fails or leaks, they deny all knowledge, saying its their policy to never ever reuse fittings...

:badmood:

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Thu Jul 04, 2019 5:05 pm

I have had a slight brain wave.

I have a good set of hoses for a non pas car and the rotten one from mine. The place I originally used could reuse the ends and that might get me out of trouble.

Also have a classic Volvo supplier who says he has some but needs to have a look, no mention of price either.

Fingers crossed I will get sorted one way or the other.

Alan 480
480 Is my middle name
Posts: 1022
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: Blinky 51/480

Post by Alan 480 » Thu Jul 04, 2019 5:17 pm

arthuy wrote:
Thu Jul 04, 2019 5:05 pm
I have had a slight brain wave.

I have a good set of hoses for a non pas car and the rotten one from mine. The place I originally used could reuse the ends and that might get me out of trouble.

Also have a classic Volvo supplier who says he has some but needs to have a look, no mention of price either.

Fingers crossed I will get sorted one way or the other.
you can take the return line up back of engine next to servo and it can be a 'simple' low pressure line, makes life a bit easier.

also I reckon that there is an adaptor screwed into the top of the power steering pump. the air con one uses a banjo joint and the other is a 'bit of an oddity' but you could swap the adaptor and / or the whole power steering pump from your spare car?
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Fri Jul 05, 2019 10:57 am

Have sourced a second hand one for £30, will see if the guy can remove it in one piece.

It is worrying that it is hard to source what is a basic hydraulic hose and pipe.

Whilst I am waiting on Hydraulics, (I still need to refill the gearbox too). I cracked on with some welding, really struggled to weld the outer sill, it has been a while since I have welded in anger but the metal on modern cars is thin compared the the 60'/70's stuff I am used to.

There was a small scab below the rear lamp I had ground out to a nice hole. I took the bumper off and remembers that the crash bar wasnt great so set about trying to make it more presentable and able to hold the bumper plastic in place.

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Got a few bits in the boot that are going to need a blast of the torch.

Think I am going to need more gas

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Sat Jul 06, 2019 10:36 am

Spent a few nights welding the crash bar.

To make life easier I had kept the old damaged plastic so used this imagine what the lower part looked it and get the mounting holes in the right place. It isnt pretty but will do the job.

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As my gas was running low I decided to get another gas cylinder. I use hobby-weld and they recommend hobby-weld 5 for thin steel up to 7mm think which is what I had. The supplier only had hobby-weld 15. I was starting to worry after doing some google research. The difference in the gases is the argon/co2 mix. (The 5 has 5% CO2 and 15 has 15% CO2.). I was worried that I was going to blow holes.

Turns out that the higher CO2 mix works really well and I was able to make some nice welds and the welder was running a lot smoother. So much so that I am going to cut the sill repair out and re-do it for a second time.

My second hand PAS hose is being delivered this week so all going well I can get the MoT sorted and get along to the Scottish 480 meet.

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Mon Jul 15, 2019 3:01 pm

I have been busy welding bits on the car, I had a scab that turned in to a hold and some pin holes in the boot that turned in to lace when brushed.

It has been good practice and I will re do for the third time the patch on the sill I put on, the gas is a lot better than the previous one.

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stangely on both sides of the rear panel, something has been cut away. Looking at my spares car there is a little angled piece , no idea why it would be removed.

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The replacement PAS hose arrived and I fitted it last night, Started the car up this morning and fluid was running out. It is a bit easier to see than when I had it in my lock up. The leak is coming from the top seal. I know how this has went which makes it more frustrating. When I replaced the hoses last year I got them round the wrong way, I had thought it just just blew the fluid out past the fittings but looks like it took the seal.

Now looking for a reconditioned rack has given me something else to think about. Both my pipes have the same size thread and I have only so far found ones which have 14mm for the HP and 16mm for the LP. with the troubles I have had I dont really want to try a second hand unit.

:-(

Alan 480
480 Is my middle name
Posts: 1022
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: Blinky 51/480

Post by Alan 480 » Mon Jul 15, 2019 8:13 pm

often best not to scratch that itch 'too hard' :wink:

I thought the thread on the PAS were both the same!!! mine appear to have the same thread dimensions
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Mon Jul 15, 2019 10:25 pm

Just wrestled the old rack out only managed to shear one bolt (top pass side).

The UJ was a bit of a pig too but finally got it, covered in my favourite ATF mmm.

Not sure when they changed but there seems to be 2 different racks, the rack that Sylvia got me last year was a 14/16 fitting. All the ebay ones bar one have 2 sizes. I have read about variable assistance racks maybe the one which are have the same size ports or the later ones changed.

From the diagram in the parts book the top pipe is for the high pressure.

The guy who sorted me out with the HP hose reckons that the rack it was fitted to is good, so going buy that along with the LP hose, that way at least I will have a matched set. Getting a bit tiresome this PAS business.

Thought I would tackle that sill patch tonight, cut out all the previous mess and joddled the edge only to find I have no gas. Really wish I had went back out the the garage and checked last night when I had the nagging doubt.

Alan 480
480 Is my middle name
Posts: 1022
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: Blinky 51/480

Post by Alan 480 » Tue Jul 16, 2019 4:56 pm

fs
Last edited by Alan 480 on Tue Jul 16, 2019 4:58 pm, edited 1 time in total.
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

Alan 480
480 Is my middle name
Posts: 1022
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: Blinky 51/480

Post by Alan 480 » Tue Jul 16, 2019 4:57 pm

arthuy wrote:
Mon Jul 15, 2019 10:25 pm

Not sure when they changed but there seems to be 2 different racks, the rack that Sylvia got me last year was a 14/16 fitting. All the ebay ones bar one have 2 sizes. I have read about variable assistance racks maybe the one which are have the same size ports or the later ones changed.
On damn, I just assumed they were the same, the spare I have has 'same fittings' now I need to go and check the ones on both cars!!!
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

eye of ra
Can tell where the 480 was built
Posts: 352
Joined: Tue Dec 04, 2012 7:33 pm

Re: Blinky 51/480

Post by eye of ra » Wed Jul 17, 2019 10:44 am

My rack has 14/16 ports but my hose connectors are both the same size.

This is because of parts 16 and 18 in the parts diagram.

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My guess would be the ones being sold as 14/16 are without the adaptors and the ones the same come with them. Could be wrong though.
Current:
480 ES Auto 1989
480 ES Auto 1991
CLK430 Conv 2001
Hyundai i10 2015

Alan 480
480 Is my middle name
Posts: 1022
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: Blinky 51/480

Post by Alan 480 » Wed Jul 17, 2019 11:40 am

eye of ra wrote:
Wed Jul 17, 2019 10:44 am
My rack has 14/16 ports but my hose connectors are both the same size.

This is because of parts 16 and 18 in the parts diagram.

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My guess would be the ones being sold as 14/16 are without the adaptors and the ones the same come with them. Could be wrong though.
thanks, saves me crawling around looking for the differences :hopping:
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Wed Jul 17, 2019 12:12 pm

Not 100% sure.

The celebration i have has male ends with a seal. others are like the photo and have tube nuts and ball end (whatever the correct term is) .

The other rack I got had 2 sizes, when the guy made the hoses for me the pipes had same ends but the adapters were different.

You only know when you crawl underneath or dismantle.

arthuy
480 Rookie
Posts: 428
Joined: Wed Apr 20, 2016 8:02 pm

Re: Blinky 51/480

Post by arthuy » Mon Jul 22, 2019 6:13 pm

The 2nd hand rack arrived with the low pressure hose complete with the cooler.

I decided to see if it leaked before fitting and cleaning it up. Very pleased to say that it didnt leak so have fitted it with the standard low pressure hose and adapter. ( now have two of them spare).

Should anyone search the forum for the answer, high pressure hose is the upper port and lower is low pressure. Hope that saves someone repeating my mistake and blowing the seals on the PAS rack.

The only problem changing the rack is that my wheel alignment will be out. I did try and keep it equal length to the one I removed but you never get it spot on. Will get it to a local place that is ok at wheel alignment once I get the MOT sorted.

I have been trying to track down a mysterious coolant leak which has been happening since I got the car. I have a new radiator but haven't got round to fitting it, this is partly down to the car having air con and doesn't look like a 5 minute job. Whilst I was searching I came across a UV dye. This is pretty neat stuff, there are a few different types (coolant/Air con etc). All you need is a UV torch and you should find the leak and your very own CSI-480.

The radiator is still suspect, the loss occurs even when parked up and leave no obvious traces.

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