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Volvo 850, S / V / C70 Mechanical Ignition Switch R&R
Tools needed:
1. Dremel or similar rotary tool with a thin cutoff wheel
2. Flat head screwdriver
3. Small torx bit set
Steps:
1. Start by removing the shroud that sits just behind the steering wheel. It is fastened from the bottom using three torx fasteners. The top portion is held to the lower instrument cluster surround by tabs, but is easy to remove withouth tools. Remove both top and bottom portions and place out of the way.
2. Remove both the control stalks from the upper column assembly (turn signal stalk on left side, wiper on right side). These are fastened using 3 torx fasteners. Once the fasteners have been removed, unplug both stalks from their respective connectors, located on the upper column.
3. There will be one other torx fastener that attaches the airbag electrical connect ring to the top of the ignition switch. This can be difficult to remove unless you have short torx bits. With some work you will be able to remove this fastener.
4. At this point, you should have a clear view of the upper portion of the ignition switch assembly. On the left and right hand side of the upper portion, you will notice what look like odd looking rivets. These are actually the fasteners that hold the upper portion of the switch to the lower portion. Volvo utilized “break-off” head fasteners in the installation of this piece. The new kit you receive will come with the fasteners and you will understand what I mean when I say “break-off” heads. Basically they work by snapping off when you tighten the fasteners to a certain point (quite a bit of force I would guess). I will refer to these as break-off stubs
NOTE: (Not recommended for high crime areas): when reassembling the switch, it is not necessary to break these heads off, just make sure they are tight, as they use locktite (the blue stuff on the threads) to keep them from moving.
5. On the left side of the ignition switch housing is the electrical portion of the ignition switch, covered by a black shroud. Remove this shroud, and then remove the two torx fasteners holding the switch to the housing. Be careful when removing the wiring holder, so that none of the wires move out of position, and if they do, make absolutely cetain they go back in the same position that they came from.
6. Going back to the break-off stubs, using a Dremel or similar rotary tool with a thin cutoff wheel, very carefully cut a slot in the top of the break-off stubs. What this will accomplish is to create a groove that should allow you to remove the break-off stub with a flat-head screwdriver. Make sure the groove is plenty deep, and you should have not problems with this.
If, however, this does not work, find the seam where the top meets the bottom section and cut with the dremel along the seam, where the bolt would run down. You will start by cutting into aluminum, but should soon get to the bolts, cut all the way through the bolts on both sides, and then the top and bottom should come apart
7. Once the fasteners have been removed, there is a cable that is inserted in the back bottom portion of the ignition switch. Place the key in the switch, and turn to approximately position 1, and this cable should come free. If not, try slight movements of the key to just before position 1 to just after position 1. While doing this, pull gently on the cable, and it will come out.
8. Re-assembly is the reverse of removal.
NOTE: The above instructions are based on a 1998 V70, and each step may not be exact for every year and model.
Part cost: Approx $110 U.S. (Call dealership with your VIN to order for your car)
Time: Approx 1.5-2 hours
Estimated Savings: $120 U.S.
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