How to: Remove & repair a dropped rear bumper for Volvo 940

[Ltom]

1. This procedure assumes no towbar is fitted.
2. You will need to take off the rear bumper valence (black trim under the bumper, if present) to remove the bumper.
3. The impact absorbers are not shock absorbers, they are just tubes with an interference fit. They will not retun to original length after an impact. If you've had a crash you'll need new ones.


Things you need:
- 6,8,10,15,17mm sockets
- Repair kit e.g. Skandix version (or a DIY alternative)
- Pliers
- Flat headed screwdriver
- Small hammer
- Optional, some adhesive.

1. Remove mudflaps. There are three self-tapping screws (8mm socket)
picture
2. Remove the valence (black plastic trim) under the rear bumper. It's not attached to the bumper but you need to take it off for access. If you get underneath you can easily find the screws. They take a 6mm (or 8mm) socket. It will come off in one piece.
3. Now inside the boot, in the two side wells, undo the bolts holding the bumper on, there are two on each side (10mm socket).
picture
4. While you are there also undo the two small nuts that secure the impact absorbers (not pictured but they are inside the wells on the opposite side. When you take them off a threaded stud will be left poking up.
5. Underneath, undo the bolts that secure the impact absorbers to the chassis. There are two on each side (15mm socket). Retain the bolts and the plates with the nuts attached.
picture
6. Remove the bumper by lifting the back so the studs in the boot drop down, then pull it out. If it's stuck there are two rubber grommets you can remove and use the holes to push down on the impact absorbers.
picture
7. With the bumper removed it's time to take the plastic trim off. You might be able to do the fix kit without but it will be fiddly. Start by removing the top trim. You'll need to lever off the metal clips with a flat screwdriver. Try to lift the tab that registers in the plastic and remove the whole clip. At the corners there are some smaller metal clips that are easy to remove. Retain them all to reuse them. The top trim will then be easy to remove.
8. Now remove the 14 plastic trim clips. They are hard to get out and easy to break. Use something flat and a screwdriver to push the rod from the inside out. When it's sticking out enough, grab it with some pliers and pull it out.
picture 1
picture 2
9. Remove the impact absorbers from the crash bar (17mm socket). For the detached ones you'll need a pair of vise-grips to hold the other side.
picture
10. Clean up the crash bar and get rid of all the chalky aluminium. Use some adhesive to secure the neoprene to the reinforcement plate and the impact bar, then refit the impact bars. Don't tighten them up all the way yet.
Here is a picture of the repair kit:
picture
11. From here on is really simple so no more pictures. Refit the plastic trim back onto the bumper. Use a small hammer to insert the plastic trim clips.
12. Refit the bumper assembly to the car, ensure the studs pop up and get the nuts on but don't tighten them up.
13. Refit the bolts through the chassis and the impact absorbers and tighten them up.
14. Tighten the nuts on the other end of the absorbers.
15. Now push the bumper up to the right height and tighten the repair kit bolts up, do both sides.
16. Now refit the valence and the mudflaps.
17. If you removed the rubber grommets for access, check you reinserted them then pat yourself on the back.

Hope this helps.

[Ltom]

Ok so images don't automatically resize or accept a size parameter. Do I really have to resize them all and re-upload?

[griston64]

Originally Posted by Ltom

Ok so images don't automatically resize or accept a size parameter. Do I really have to resize them all and re-upload?

It might help slightly as my eyes now really hurt

[Ltom]

I've changed them to clickable links for now. For next time I know to resize them but there is a lot of faffing.