General: 850: - door stay repair - Page 2

Clan · Dec 8th, 2009, 21:57

The cause of this is the checkstrap bolt loosening , it gives ample warning by clicking everytime you open the door , then the noise gets louder , its trying to tell you something ... people ignore it for a long time until the A Pillar is torn due to metal fatigue due to the constant hammering over time .. when you tighten the TORX screw at the first sign of clicking you wont have the problem ... This is happening to S40/V50 now and xc90 , but not seen any damage caused ... YET!

Sprintman · Dec 8th, 2009, 22:40

Not sure that a loose check strap torx bolt is the cause of the problem? The bolt hasn't been loose on my car but still the spot welds broke out. The A post metal appears thinner [on my 850, don't know about other models] than I would have expected [though I'm no expert, and only speak from experience of other vehicles], and as this has happened to a number of cars it would seem that the metal is too thin for the application and thus allows flexing at the check strap mounting point, over time leading to the spot welds tearing out.

rabbitsworld14 · Dec 9th, 2009, 07:51

I agree with Sprintman. Surely that cant be right, if the strap takes the tension, it'll be that that caused the strain on the spot welds. If the strap was not tight, there wouldn't be any tension? Or am I just talking rubbish?

Mine didn't give a warning, it just went.

scimitar · Sep 5th, 2010, 12:35

I have just repaired my door check strap as both spot welds had broken through the door pillar. Using two 6mm bolts and large washers, plus a 10mm spanner with the end bent over about 15 degrees; the job was a fiddle due to poor access but was completed in about 1 hour. Gaffer tape is superb to hold the nut to your finger whilst getting the bolt to screw on.

02GF74 · Jul 10th, 2013, 08:31

I have this on dirver side and was considering the welding it ack on but worried in case the electronics could get damaged so the bolt method seem to be safer.

re:

Quote:

Drill a 6mm hole(s) through the pillar and the stay's back-plate (close to where the spot weld(s) have failed.

How do you hold the stay in place so it does not move to be able to drill the holes - the spot ways have goen on one side so that the whole plate can move.

02GF74 · Jul 10th, 2013, 12:02

ok, here we go.

0. put window down
1. undo the small screw holding the connector together, trun connector cover anti-clockwise and then pull apart
2. remove torx bolt holding check strap to door pillar
3. undo two smaller torx bolts for the door hinge pins.
4. remove door - since you have the window down (step 0) you can rest the door top on your shoulder to take its weight
5. drill hole where the spot welds are - this can take some time as the welding process can harden the steel making it more difficult; I did it in 2 stages, 3mm followed by 4 mm
6. tap the holes to M5 (I chose to use M5 instead of M6 bolts)
7. fit M5 bolt with penny washer so that the slot in the panel is covered, with a dab of loctite to prevent loosening
8. optionally paint bolts and washer, then refit door, the bolts and connector.

first photo shows a drift and a small piece of wood being used to hold the check strap base in place so that it stays put when being drilled and tapped.

second photo shows after fitting and painting the bolts - notice the rag to stop the bolt falling into the gap between body and front wing (yes, it did happen but I was able to retrieve it with a stick magnet so put it in prior to trying to fit the bolt.).

we'll see if M5 bolts are adequate, if not, then I will need to drill to 5 mm and tap for M6 ..... maybe ????

Antz · Jul 10th, 2013, 12:53

Just found this. Thats a job for one night this week on my 850.

Been meaning to investigate the loud clacking sound ever since I bought the car.

02GF74 · Jul 10th, 2013, 18:27

take a look at the check strap when door is partly open - it could be the big bolt come loose but more likely the metal panel to which the strap is spot welded will have fractured - very common problem.

one evening is plenty of time - the worst part was drilling the hold though the hardened steel due to spot weld.

MikeS100 · Jul 11th, 2013, 19:43

This is a great thread! The drivers door on the V70 has been making this noise since I got it, had a look once before but couldn't see the problem so just lived with it! I'll be having a go at this!

monkeh · Jul 11th, 2013, 21:49

My check strap plate snapped in half. Punching the outer skin of the door every time I opened the door. Now I've got a nice dent on the door.

Dec 8th, 2009, 21:57	#11
Clan Experienced Member Last Online: Today 16:58 Join Date: Jun 2007 Location: L/H side	The cause of this is the checkstrap bolt loosening , it gives ample warning by clicking everytime you open the door , then the noise gets louder , its trying to tell you something ... people ignore it for a long time until the A Pillar is torn due to metal fatigue due to the constant hammering over time .. when you tighten the TORX screw at the first sign of clicking you wont have the problem ... This is happening to S40/V50 now and xc90 , but not seen any damage caused ... YET! __________________ My comments are only based on my opinions and vast experience .

Dec 8th, 2009, 22:40	#12
Sprintman VOC Member Last Online: Mar 13th, 2023 22:39 Join Date: Jan 2006 Location: East Herts	Not sure that a loose check strap torx bolt is the cause of the problem? The bolt hasn't been loose on my car but still the spot welds broke out. The A post metal appears thinner [on my 850, don't know about other models] than I would have expected [though I'm no expert, and only speak from experience of other vehicles], and as this has happened to a number of cars it would seem that the metal is too thin for the application and thus allows flexing at the check strap mounting point, over time leading to the spot welds tearing out. __________________ VOC Member 19553 '03 V70 R AWD, standard, so far. '96 855 AWD, BSR twin outlet exhaust, Polybush engine steady. HID Dips. '98 V70 AWD. '98 V70 SE. '96 855 2.0 20v - Gone. '82 244 GLT- Gone, but not forgotten. '61 122S - Long gone!!

Dec 9th, 2009, 07:51	#13
rabbitsworld14 Niall Clark Last Online: Apr 25th, 2011 21:08 Join Date: Dec 2009 Location: Bungay, Suffolk	I agree with Sprintman. Surely that cant be right, if the strap takes the tension, it'll be that that caused the strain on the spot welds. If the strap was not tight, there wouldn't be any tension? Or am I just talking rubbish? Mine didn't give a warning, it just went. __________________ V70 2.5 Petrol Turbo 20V 1998 (113,000 Miles)

Sep 5th, 2010, 12:35	#14
scimitar Scimitar Last Online: Aug 20th, 2017 13:45 Join Date: Dec 2003 Location: Solihull	Door Check Strap Repair. I have just repaired my door check strap as both spot welds had broken through the door pillar. Using two 6mm bolts and large washers, plus a 10mm spanner with the end bent over about 15 degrees; the job was a fiddle due to poor access but was completed in about 1 hour. Gaffer tape is superb to hold the nut to your finger whilst getting the bolt to screw on.

Jul 10th, 2013, 12:53	#17
Antz No I'm not the redhead Last Online: Nov 25th, 2022 09:49 Join Date: Jun 2009 Location: North Yorkshire Coast	Just found this. Thats a job for one night this week on my 850. Been meaning to investigate the loud clacking sound ever since I bought the car. __________________ 1988 Volvo 240 GLT T5 Swap a T5 motor into your RWD Volvo:The Guide

Jul 10th, 2013, 18:27	#18
02GF74 Junior Member Last Online: Feb 23rd, 2024 15:29 Join Date: Feb 2009 Location: se	take a look at the check strap when door is partly open - it could be the big bolt come loose but more likely the metal panel to which the strap is spot welded will have fractured - very common problem. one evening is plenty of time - the worst part was drilling the hold though the hardened steel due to spot weld.

Jul 11th, 2013, 19:43	#19
MikeS100 Premier Member Last Online: Mar 21st, 2024 21:39 Join Date: Oct 2011 Location: Sevenoaks	This is a great thread! The drivers door on the V70 has been making this noise since I got it, had a look once before but couldn't see the problem so just lived with it! I'll be having a go at this! __________________ 1999 V70 TDi (auto) 2002 C70 T5 GT Convertible (manual) 2008 XC90 D5 Executive (auto)

Jul 11th, 2013, 21:49	#20
monkeh Pain in the backside Last Online: Today 15:42 Join Date: Mar 2007 Location: Newport	My check strap plate snapped in half. Punching the outer skin of the door every time I opened the door. Now I've got a nice dent on the door. __________________ 'Designed by a computer, built by a robot, and driven by a f***ing nutter' '09 XC70 SE - 2" lift, D5 225bhp, poverty spec.

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