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Replacing Door Stop (Check Strap)

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Old Jan 26th, 2020, 01:01   #1
theseriojca
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Last Online: May 28th, 2022 23:21
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Default Replacing Door Stop (Check Strap)

Good time of the day,

have been a member on this forum since last April when we bought our XC90 and have really enjoyed and appreciated all the advice and support (and the saved money!) so decided to add to the common knowledge base.

So, a quick guide on how to replace a bent/broken/squeaky driver stop (check strap) on an XC90.

Preamble: A gust of wind slammed the driver's door as I was opening it and the door stop got over-extended. It took a lot of force to close the door and it would now only open wide enough to slide in sideways.

Replacing the door stop is a pretty basic procedure, I'm a moderate DIYer and managed it in about half of an hour.

You will need:

Trim removal tool - £6 of Amazon - but you can use a flat screwdriver or a similar tool, just be careful not to scratch the paint.



Torx Screwdriver - T25 and T40



10mm socket



I have tried to put back the original door stop, but couldn't figure out how it works and wasn't sure it's not broken/missing parts. A new one online costs 72 Euros, so I looked up 'XC90 breaking' on ebay and managed to get a used one for 15 quid - profit!

Here's a few pictures of the donor door stop:







The process starts with removing the tweeter cover on top of the door:



You can slot a screwdriver in the slit at the top and pry it off - held by 2 clip ins and a grey connector:





To get started on the door panel, you need to remove the silver surround of the interior handle - slot the tool under bottom of the 'legs' and pry upwards, while helping it from sides and top at the same time, it will pop with a bit of effort. After it's removed, you will see two T25 bolts that need undone. Sorry, no pictures of this, as I was using both hands to do it.

Next, the door panel, which is held in place by white plastic clips (and one yellow one), which are quite tight and sturdy - I had to use the metal tool with a plastic one underneath to protect the paintwork. I started prying at the bottom right corner of the door.



This is the view with the panel still held on by wires, the door opener and the locking lever.



To remove the panel, you will need to disconnect the green and the grey connectors, the metal wire and the locking lever.



Here's a close up of the door opening wire with a hammer on the end - the plastic cover comes off with little effort.







With the panel fully removed, you need to pull out the black plastic cover on top of the speaker to be able to retrieve the door stop.

The door stop is held in place at three points:

one T40 bolt to the body of the car



and two 10mm nuts to the door



Undo these and you will be able to remove the door stop through the hole left by the black plastic cover.

Slotting the new* check strap in is the opposite of removal - do the 10mm nuts first, then the T40 bolt (with a drop of thread lock).

You could use a bit of help holding the panel and aligning the clips, but it's doable by one person as well, just a bit more fiddly.

You need to hold the panel against the door, plug the 2 electric connectors, the wire hammer with the plastic cover and finally slot in the locking lever. With all of these done, align the panel to the pins on the door and give the panel a few firm wacks/thuds in key points.

Install the tweeter cover, then screw in the 2x T25 bolts behind the handle and install the silver handle trim - and that's it!

Thanks again to everyone on this great forum, hope this is helpful to someone at some point, I'll try to post any other work/repairs I do as well in the future.

PS: I have noticed the speaker seems to be 'riveted' into place - how would I go about changing it for a better/newer one? I don't have premium sound and was thinking about at least upgrading the speakers, starting with the front ones, if at all possible.

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Last edited by theseriojca; Jan 26th, 2020 at 01:02. Reason: spelling
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Old Jan 28th, 2020, 05:10   #2
aslan
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Very useful guide!

Not that I need to replace mine but the photos of the door strap was very informative and useful. It's great to see how the mechanism works since everything is concealed inside the door.

I regularly lubricate the strap but have always wondered if I'm applying the lube properly as I can't see what I'm lubricating inside. I see you only have a picture of the strap from one direction. From your observation, is one fine only lubricating the surface of the strap facing you? Or should you lubricate both the front and back surface of the strap?
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Old Jan 28th, 2020, 22:55   #3
theseriojca
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It's difficult to explain how it actually works - inside it has two rollers that are attached to a twisted C-shape metal clip that provides the 'springiness' and a little give. As the door opens and closes, the wavy metal bar slides/rolls between the two spring loaded rollers and provides that 'step' for every position of the door.

The rollers are plastic and the metal bar has a plastic cover as well, so not sure if it needs all that much lubricant - just enough to stop it from squeaking, I guess?
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Old Jan 30th, 2020, 12:25   #4
oragex
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Interesting information. Got my doors also slammed by gusts of wind, but not to the point of breaking the stop - I'll be more careful from now on.

For the speaker, it's not that easy to remove. Those are hard metal rivets, takes a quality drill and you'll need to go at an angle because at some point the rivet will start spinning. Reason for rivets is safety, the speakers are heavy and can fly in a crash. Need to put back solid pins or rivets solid fit so it doesn't rattle. Behind the speaker there's a white sealing tape - has to go back in place because it seals the cabin from rain dripping inside the doors from outside window strips. But if you have the HU-613 or HU-650, just swap the head unit with the 800 series - find one from the same year and undo the battery while swapping. The high end speakers don't add much unless you crank the volume real high
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Old Feb 1st, 2020, 17:31   #5
Bits
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Default Door stay repair

Just repaired the non-working drivers door catch.:regular_smile

I mistakenly thought it was either worn out or broken so I ordered a new one from Volvo for £38 this morning.
Managed to repair the existing one. The spring and one of the rollers was found in the bottom of the door.
I managed to put it back together with the help of the photos in this thread - many thanks.

Need to call Volvo Monday to cancel the order.

Mark.
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check strap, door card, door panel, stopper


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