Helpful Information - "How To" DIY Repairs - For 960 and S90's from 1994 - 1998
 

This is a list of common problem/repairs for the 960 / S90. If you want a link added here, please search the thread or instructions and PM me the link so I can add it. Video instructions are highlighted in orange.

Door Panel Removal:
Door Panel Removal Instructions for Volvo 960

Climate Control Repairs:
https://volvoforums.com/forum/volvo-...ion-fix-78676/

Electrical Issues After Start, Multiple, Bad Ignition Switch: VIDEO
https://volvoforums.com/forum/volvo-...-issues-56256/

Head Gasket Issue, Suspected:
https://volvoforums.com/forum/volvo-...-issues-67963/

Instrument Panel Removal:
Instrument panel removal instructions on a Volvo 960

Parking Light and Turn Signal Problems:
Problems with lights - left reverse light always on... - Volvo Forums - Volvo Enthusiasts Forum

Power Seat Movement Repair:
https://volvoforums.com/forum/volvo-...k-video-80451/ Video

Radiator removal / installation:
https://volvoforums.com/forum/volvo-...70/#post406262 - Video

Shift Lock Repair (gear shifter will not move out of park):
Shift lock repair instructions for a Volvo 960

Sunroof Leak Repair:
Sunroof leak repair instructions on a Volvo 960

Timing Belt Replacement, printed & video:
https://volvoforums.com/forum/volvo-...t-video-73597/

S90 power seat
 

Had the problem of one side moving and the other not. Great hint from a member advising to shorten the plastic sheath. My solution was to remove the cable. I did it the hard way by removing the seat, placing it on a stand to ease access, had to remove the gear drive to get the cable out. Separated the sheath from square drive. With a drill slightly smaller than the i. d. of the metal coupling, slowly removed the plastic to the four tiny cleats. Separated the couple from the plastic. Inserted the butt end of the bit into the small end of the couple and forced the gripping cleats out to the point where the shortened sheath would re-insert. Used a small punch to re-grip the cleats into the sheath. Insert the drive cable and assembled the mechanism. Works great so far. Thanks to the member who put me on track.

I repaired one seat the 2 hour method as well. Then I figured out the 30 minute method and decided to share it. :)

S-90 driver's door lock repair
 

How do you get at the inside of the door to fix the electric lock? This Swedish built S-90 is built like a MRAP! Is there a SIPS unit in the door? I have the inside panel off but need tiny hands to get at the inside. Any suggestions? (No, my wife won't help) Thanks.

It's near impossible. You have to pull the bolts out of the door and remove the latch that way. No the door doesn't have SIPS, the seats do.

Do you have instructions on how to take out and replace a starter on a 1998 S90?

Becky