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1973 Volvo 1800ES | The story of Robyn's old Volvo… "The Sexy Swede"

A Quiet Year

It’s been a very quiet year for the ES.  In the spring, a rare occurence happened.  The forecast for the Carlisle Import show was four days of sunshine, so I opted to take advantage of the rare chance to take the Spitfire out there without being a drowned rat for four days.

I think perhaps that may have angered the ES, however.  For Father’s Day, the weather was nice so I drove the ES out to PA to have breakfast with my parents.  On the drive out, there were a few times where I was driving along and the car would suddenly and briefly lose power.  Best way to describe it was as if someone had flicked the overdrive switch off and then back on.  Having had an issue with the overdrive doing that before (thanks to a loose wire), I thought nothing of it and made a note to check the wiring when I got home.  On the way home, the problem became more frequent.

Once home, a quick check ruled out the wiring, but the transmission fluid was a little low.  Thinking that might be the culprit, it got topped off and then the car sat.  It was another disgustingly hot and humid summer this year, so I was less than excited about driving a car with no air conditioning.  Again, this may have further angered the car. It did make the trip out to Macungie for Das Awkscht Fescht and the stumbling continued.  Back to the drawing board.

Labor Day weekend is the traditional week-long vacation up in Watkins Glen, ending with the Vintage Festival.  I’ve been taking the ES up there for 5-6 years now.  A few weeks before vacation I decided to get the car out and drive it to see how it was.  The problem seemed to be getting worse.  It was no longer a brief hesitation, it was now a prolonged stumbling, mainly while trying to get moving in 1st and 2nd gears.  It made getting through intersections “interesting”.  A quick once over in the engine bay and it appeared that the manifold pressure sensor had a leak as it would not hold a vacuum.  Swapping in a spare one seemed to solve the problem, but only briefly, so a rebuilt sensor was ordered ($$$ – ouch) and the wait began as it was coming from California.  While waiting for that, I decided to give the car another go in case the stumble on the brief test drive was just a fluke, so I drove the car to work one day.  At lunch I had to run to the post office to pick up the new sensor.  I got there fine and made the mistake of thinking that everything was OK after all.  As I pulled out of the parking lot, however, the problem returned with a vengeance.  I could barely get the car moving and decided to limp it back home and take a different car back to work.  As I rolled into the driveway, the car stalled.  I got it to start again and made it into the garage.

With the new sensor on hand I thought surely things were turning a corner.  Well, they were, but it was the wrong corner.  After installing the new sensor, the car will no longer even start.  Time ran out, and for the first time in years, I had to leave the ES home and go to the VINTAGE Festival in a boring “newer” car.

The last shot at getting the car out to some kind of event this year will be the Lincoln Club show at Peddler’s Village the last Sunday in October.  Fingers crossed, but it’s not looking good right now.  The problem hasn’t even been diagnosed yet, let alone fixed.

Major update…

I had decided long ago that this page deserved some more attention, but with the previous format, it had become cumbersome and time consuming to make an update, so I decided to redo the entire page in a blog format, using WordPress.

This should allow me to make more frequent posts and should also make it easier for people navigate the blog and search for information.

All the old content has been moved over to this new format so nothing has been lost.  It just looks different.

Thanks for checking out the page.  Enjoy!

Long overdue…


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Well, it’s been far too long since I updated this site so here goes… Actually since the transmission swap was completed there hasn’t been a whole lot that has been done.

  • We did finally get around to getting the sun visors rebuilt.  Actually Ian gave them to me as a Christmas gift and I installed them this winter.  It’s been so long since I had them in the car, that I had forgotten how nice it is to have them.  The visors were rebuilt by Vinyl Specialties (http://www.autosunvisors.com/)
  • Last fall the car developed a deep rumble that only seemed to occur up at highway speeds.  Spring came and the rumble was still there, making me a bit nervous about taking the car too far from home.   A quick post on the 1800list brought a few suggestions, and the problem turned out to be low fluid level in the differential.  Ian topped that off and the rumbling sound is now gone.
  • This past fall, I also had a small bit of rust repair done by Dave Colvin of Bluestone Auto Body.  There was a quarter sized area of bubbled paint on the driver’s side rocker just ahead of the door opening.  We had run into Dave at a car show out in York, PA.  While admiring his beautiful 122, we discovered that he had painted it himself, and that in fact, he had his own shop.  After some more chatting, I felt like he was the right one to take the car to.  His work was obviously good, and he is a Volvo enthusiast so I felt the car would be in good hands.  We took the car out in early November and picked it up a week later.  I could not be happier with the results.  Once he cut out the rust on the exterior of the car, Dave discovered some rust on the inner rocker, so that was repaired as well.  With the rust repaired, he coated the inside of the rockers on both sides of the car to help prevent future rust from forming.  Finally, he repainted and blended the repaired area.  The final result is perfect.  You can’t tell which areas have been repainted.  I can’t say enough good things about Dave’s work, and I will definitely be taking the car back out to him whenever that time comes again.  Unfortunately, Dave does not have a website, but if anyone is interested in getting some work done, his number is (717)-600-8533.
  • One of the most exciting things that has happened, though, has been the installation of a stereo in the car… finally.  The stereo I had posted pictures of earlier on this site is now installed in my Spitfire.  I decided that there was just no good way to install that in the ES without cutting the dashboard, which I did not want to do.  A local club member had suggested sending my original Volvo stereo out to be rebuilt… replacing the old internals with modern digital tuning and an auxiliary input.  It was a great idea, but the price was a bit more than I wanted to spend.  Then another club member suggested a hideaway type of system that his brother had installed in his Oldsmobile.  I can’t remember the name of the system right now, but again, to get all the bits I wanted for my car, the price climbed up a bit higher than I wanted to pay for a car that isn’t driven regularly.
  • Finally, the perfect solution fell in my lap when I wasn’t looking.  One of my Spitfire club members had purchased a retro style stereo for his car, which turned out not to fit.  The dimensions made it sound like it would fit in the car and he was offering it for a slight discount since there was a small scratch on the face, and I decided for that price, it was worth a shot.  This stereo LOOKS just like an old car stereo, complete with the old analog style tuning display, but behind that display is an LCD display that lights up when the stereo is on.  The unit also offers:
  • 240 watts
  • Digital tuning
  • RCA aux. inputs for iPod/mp3/satellite
  • USB input
  • CD DIN plug for CD changer
  • 4 channel RCA pre-outs
  • Separate bass & treble, front/rear fader
  • Digital clock
  • 18 FM & 12 AM pre-sets
  • Selectable USA and Euro tuner
  • Power antenna lead
  • Two year warranty
  • RCA to 3.5 cable included.
  • Best of all was the installation.  Not only did it fit in the car, but Ian was able to reuse the faceplate and knobs from my Volvo stereo which makes the new one really blend in well.  At quick glance, you might not even notice that it’s not the original stereo.  This stereo can be purchased from Woody’s Custom Shop.  They offer several different versions of the stereo, some intended specifically for certain cars.  The one I got is titled as being for a Triumph TR6 and is currently selling for $239 plus shipping.  Here is a link directly to the page:   http://tinyurl.com/npr9qw.  They also offer a less expensive version for $179, but it is only 200 watts and you lose the USB input.


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To sum up…

I put this video together that covers the entire transmission swap and engine bay restoration process.

The GREAT Transmission Swap:

 

 

 

 

 

It lives!!!


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  • Ian put the output flange on from his car and as ready to install the narrower driveshaft we got from John Adamchak.  We thought we were finally going to make progress but the driveshaft, or at least the front half of it, proved to be about 1/2″ too short.  Aarrgghh!!!  Finally, Ian pulled the driveshaft from his car and we used that.  The length is perfect and I FINALLY have a driveshaft.
  • Got the new gas tank installed.  It went in nicely apart from the fact that the holes for the fuel sender screws were unexpectedly in metric.
  • I installed the new coolant decal and air filter housing decal from VP Autoparts.
  • Ian finished hooking up all the remaining hoses, wires, and components.  The engine bay looks absolutely amazing.  It’s been a long process and I thought we were insane at several points along the way, but the end result just looks so great.
  • I decided that the hood was going to have to wait.  I still can’t decide if I want to pull off the existing insulation to respray or if I’ll just mask around it and paint.  If I do remove it, which will be a nightmare, I can’t decide if I want to go with the silver insulation again or a more stock color black.  I’ve decide to hold off on that project until I can make up my mind.
  • On 5/3, we finally fired the car up.  Well, we tried to fire the car up.  The starter would not engage.  Ian pulled it out and tested it, reinstalled it, and tightened up the connections but still… nothing.  We had read that the solenoid can sometimes stick and that a little tap with a hammer can loosen it up.  We gave this extremely technical solution and shot and sure enough, the car turned over.  Took a few attempts to get it started but finally the engine came to life again.
  • Happiness was short lived.  We noted that the idle was extremely high and the car was running lean again (red hot exhaust manifold).  Fuel pressure tested OK.  We decided to try to richen the car up by adjusting the ECU, at least as a temporary fix and figured that the car should be OK to make the 2 mile trip the next day for it’s scheduled front end alignment.
  • The drive to the shop the next day was “interesting”.  Despite the ECU adjustment, the car was still running lean.  About 1/2 mile from the house the transmission, began making a really loud, constant, whining sound and the car backfired a couple times, something it had never done before.
  • We picked it up the next day after the alignment and an emissions test to see just how lean it’s running.  The test showed a CO level of 0.1% where normal level should be between 1% and 1.5%.  Eeek!  And that was with the ECU turned to full rich.   We drove it home, with the tranny whining all the way, and resigned ourselves to the fact that there was no way we were going to make it to the scheduled car show in two days.  The show was the goal we had set for ourselves back in November and was supposed to be the big unveiling of the new manual transmission.  I was disappointed but realized it was best not to push things and cause more damage.
  • Ian got on the phone with John Adamchak, who had helped us out with driveshaft parts and advice when we had run into trouble a few weeks before.  John graciously offered to pay us a house call and take a look at the car.  I was ecstatic.  I still didn’t think the car would be ready for the next day, but at least we’d be on track to maybe make it out to Carlisle on the 20th.
  • John came over in the afternoon and after about an hour or so, they determined that the MAP sensor, which had been fine before, would no longer hold a vacuum and was probably the source of our problems.  Fortunately, we not only had a spare, but it was in good condition and held a vacuum well.  Ian replaced the old sensor, and that made a big improvement.  A bit of fiddling with the timing and idle adjustment and the car was running better than it had before.
  • The high idle turned out to be the throttle cable which had been adjusted incorrectly and wasn’t allowing the throttle to release completely.
  • So I now had a running engine but there was still the matter of a transmission that sounded like it was ready to self-destruct.
  • Ian and John went for a little test drive to see if John could diagnose the noise.  When they returned, Ian said the noise had decreased but was still there.  John felt that though we had filled the fluid to it’s maximum level, it would take time for the oil to get worked up through the whole transmission.  He recommended driving it a bit more to see if the noise went away.  Sounds like a good excuse for a trip to the Dairy Queen if you ask me!!!
  • Later that evening we got in the car for the 15 mile trip to the DQ.  The engine was purring away and sure enough, the transmission noise was all but gone.  But a new quirk appeared.  The car was occasionally bogging down, and almost stalling.  Then power would return and we’d continue on our way.  Very strange.  It gets stranger… As we kept driving, I noticed that this phenomenon only occurred when we turned right.  The harder the right hand turn the worse the power loss, until on one extremely sharp turn, the engine stalled completely.
  • Once again, despair returned.  We were so close to being able to attend the show but the Swedish car gods were doing their best to thwart us!
  • After returning home, Ian opened the hood and did a little poking around.  The fix was simple.  A couple wires from the distributor that run over to the firewall, near the steering column, were getting caught up by the steering column and shorting out, causing the car to lose power.  A simple reroute of the wires and the problem was solved.
  • With that last hurdle, we realized we could make it to the show the next day!  We quickly reinstalled the center console, and heater ducts, which were the last remaining bits of the interior left to go back in.  The car was done!  It was hard to believe after so many months, that I actually had a whole car again.  With no time left for the Zaino treatment I had planned, I gave the car a quick detailing with some Z8 and she was ready to go.
  • The next day was spectacular.  The weather was perfect and we were meeting up with several friends, both Volvo and MINI, to attend the car show.  We hadn’t told anyone the car was roadworthy so it was a surprise when we showed up in the morning.
  • But the biggest surprise came later in the day, when the Sexy Swede won first place in the “Pre-1979 Import class”!  The judges said I should give the other Volvo owners classes on how to detail an engine bay.  If only they knew…

Step 1:  Remove engine from car
Step 2:  Completely disassemble front suspension/braking system
Step 3:   Well you get the idea…

  • Most likely, that’s the only trophy she’ll ever win, because there’s no way the engine bay will ever stay as clean as it was the morning we pulled out of the garage for the first time.
  • So here ends the “Great Transmission Swap”.  It’s been a long and sometimes maddening experience, that Ian claims he’ll never attempt again (no matter how much I tell him we could clean up the Spitfire’s engine bay).  Ian’s mechanical skills and my obsessive cleaning/detailing compulsion worked well to get through the project, but we can’t take all the credit.  We had a lot of help along the way and I’d like to take the time to thank everyone who helped in one way or another.  We couldn’t have done it without you all:
  1. Nancy Graziano – for finding the engine hoist her neighbor was throwing away and dragging it home on one of the hottest, most humid days of 2005.  It served us well.  (see Nancy, I didn’t forget you this time!)
  2. Paul Graziano – for helping us with the engine removal, and install and for pointing us in the direction of John Adamchak.
  3. Manny Lopez – for painting the engine bay for me and sparing me from having to do it myself.
  4. Scott and Jay – for helping us with the engine removal, and install.
  5. George Mitchels – for helping us with the engine removal (I think he was a bit too eager for that part), and for providing us with an endless supply of latex gloves, which I went through like crazy during the parts cleaning/painting process.
  6. John Adamchak – for helping us out with driveshaft parts and advice and most importantly for the house call that allowed us to get the Swede out on the road for the car show!
  7. Dick Sampson – for donating a beautifully made wooden shift knob to the Swede when she had none to call her own.
  8. To anyone else I may have inadvertently forgotten.


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And closer still…

  • It’s been almost a month since the engine went back in and it still has yet to start again.  We ran into a problem with the driveshaft.  I was not aware that Volvo had used two different diameter driveshafts over the years and naturally, the one that I bought last year is the wrong one.   The fatter driveshaft mates up to the overdrive but not the rear differential.  The thinner driveshaft mates up to the rear differential but, you guessed it, not the overdrive.
  • After doing some research and talking to a few experts, we’ve learned that the J-type overdrive was produced with two different size output flanges.  One for the fatter driveshaft (for the older higher horsepower 1800’s) and one for the narrower driveshaft (for the later, lower compression 1800’s).  To get the car back on the road in time for the first show, Ian is going to pull the output flange off one of his currently dead ES’s and put it on my car.  Then we can look for a replacement for him later.  He should be able to get the flange off his car and hopefully on mine before this weekend ends.
  • Once the driveshaft problem is solved, he can reinstall the transmission mount and then proceed to finish up the engine.  He held off reinstalling the intake and exhaust manifolds because the transmission mount is not in place.  We were afraid with the engine at that angle, it might be possible to scratch my freshly painted engine bay.
  • I just finished up getting the heater box, brake booster, air filter housing, and charcoal canister cleaned up, treated with POR-15 and painted semi-gloss black.  In a few days they’ll be thoroughly dry and ready to go back in the car.  With the heater back in, we can button up the interior.
  • Later today, I’ll be getting some green paint on the hood hinges and hood hold down mechanism.  All that will be left to do is respray the underside of the hood.  I’ll need to remove the hood insulation that I had installed last year first.  Not something I’m looking forward to.
  • I had planned to get my gas tank renewed, but we opted instead to buy a new tank.  Ian was not sure how well they were going to be able to repair my apparently leaky pick-up tube, plus they said it could take up to 2 weeks to return the tank to me.  That would be cutting it really close to the May 7th show.  Ian’s frustration level at this point is high and he said it was worth it to him to kick in the extra $200 just to get a brand new tank.  In fact, the UPS man should be dropping the tank off today.  I’ve already got a new fuel filter ready to go.  It will be so nice to be able to drive more than 100 miles on a tank of gas!
  • I just called VP Autoparts and ordered the remaining engine bay decals that I need to replace so they should be here sometime next week.

 

Closer and closer…


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  • Well, the front crossmember, suspension, steering and some brake parts got a coat of POR-15 and then a topcoat of POR-15’s semi-gloss chassis paint. Looking really nice now (and I hope it stays that way).
  • In between coats of paint on those parts I was out in the garage trying to shine up the engine bay a bit.  Some rubbing compound and finally wax did bring up the shine a bit more.  Before waxing though I carefully installed my new emissions decal in the same location as the original.  I still need to order a new coolant decal but haven’t gotten around to it yet.
  • I also installed a new hood seal while it was still easy to get in the engine bay. 
  • With the waxing finished I declared the engine bay “finished” and we started putting parts back in (woohoo).
  • Ian partially reassembled the front crossmember and then mounted it to the car with shiny new hardware.  After that he finished reassembling the suspension. 
  • The steering box went back in, along with the tie rods.
  • While Ian was working on all that, I was installing the new door seals that I had purchased.  My old ones were intact, but they were very dried out.  The new ones went in fairly simply with a little patience and made a nice difference in how the door closes.  Much more solid feel than with the old seals.
  • The morning of the big install day, we were up early and out in the garage.  Ian installed many of the new stainless steel solid brake lines along with the fuel lines.  He finished up reassembling the front hubs/brakes so we could get the wheels on the car and get it down off the dolly it’s been resting on since November.  He wanted the front end of the car down as low as possible for the installation.
  • Our help arrived that morning and after finishing up the brake lines, it was finally time for the engine to go back in.  It took a total of about 3 hours to get the engine back in.  Much of that time was spent fighting to get the engine mounts into position, until someone finally realized it would be easier to mount the mounts to the car and then slide the engine in between them.  Live and learn.  All went well with the exception of some scratches on my freshly painted firewall.  I’ll need to touch that up before we’re through
  • We wrapped up around 8:30 that night, went out to dinner, came home and passed out.  It was a long day.
  • We’re currently in the process of reinstalling all the wiring, and the remaining parts that had been removed to allow for the bay to be painted.  
  • On Sunday, I finally worked up the courage to drill the hole in my dashboard for the overdrive light.  I had been avoiding it for fear of not getting the hole properly lined up and having to live with it, but once again, everything went well and I now have an overdrive light.  Of course, it’s not wired up and neither is the overdrive switch…
  • I still have some painting left to do.  The heater box, brake booster, and air cleaner housing are all going to get painted a nice semi-gloss black.  I also need to paint a few bits that hold the hood closed green.  And finally, since the engine bay is now looking so nice, I’ve decided that I’ll “need” to repaint the underside of my hood.  The little patches of black from my POR-15’ing last year are really going to look terrible now that everything else looks so nice.  It will mean investing in a new set of hood insulation pads but in the end I think it will be worth it.
  • The next deadline we are working toward is May 7th, which is the date of the first car show that I’m signed up for.  Barring any unforeseen problems, I think we should be in pretty good shape.


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Moving forward, finally!!!


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  • After three and a half months of doing nothing but disassembling and stripping bits of the car, today we finally took a step in the other direction…. The engine bay has been painted.  Woohoo!!!  I think this car might actually come back together someday.
  • The credit goes to our friend Manny, who came down today and ended up painting the bay himself.  I was a nervous wreck about getting in there with the spray paint myself.  Fortunately, Manny has had lots of practice on his own car so he jumped right in.  I can’t thank him enough!
  • I’ve now decided that since the engine bay looks so nice, I’ll really need to touch up the underside of the hood.  Those little black patches of POR-15 where I touched up the rusty areas, just aren’t going to cut it anymore.  That’s a relatively “easy” painting project so I’ll tackle that myself when time permits.  It’s not something that needs to be done before our 3/25 engine install deadline.
  • Ian picked up the first batch of parts from the media blaster and all I can say is “Wow”!!!  I swear they look like they were painted but it’s just the bare metal.  They look brand new.   Everything looks so nice, in fact, that we decided to bite the bullet and spend the money to get the rest of the suspension odds and ends cleaned up.  I was thinking I’d clean some myself to save some money but there’s no way I could ever come close to getting anything that clean.  I should be starting on painting the clean parts tonight but we’ve decided to go out to dinner to celebrate my engine bay being painted.
  • Ian bought a $3 fin comb and finally got a chance to comb the fins on my radiator.  What an amazing job it did.  The radiator looks good as new.  No more dented areas.


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The madness continues…


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  • The primer arrived the day after I ordered it along with a gallon of POR-15’s Marine Clean.  Unfortunately, I had to work much of this past weekend so I didn’t get as far as I had hoped.
  • While doing some final disassembly, Ian discovered an old mouse nest in one of my defroster ducts.  Explains why we never got much airflow out of there!
  • On Sunday afternoon, I got into the engine bay (literally) and managed to get the whole thing scraped clean and sanded.
  • Today after work, I got back in there and went over the whole thing with my Marine Clean solution and an old toothbrush.  It’s amazing how big an improvement just a really good cleaning has made.  Of course, there are still the little rust areas that need attention so my work is far from finished.
  • When I got out of the engine bay tonight after my cleaning, I looked back at my car and a chill went down my spine.  What the heck are we doing???  My car has no engine, no suspension, no steering, no front brakes, no brake lines, no fuel lines…. I must be insane!!!  There are Volvo parts all over my garage and house.  Heck, I’ve got the hood comfortably residing up on my guest bed, where it’s been since November.  It’s hard to imagine everything ever coming back together so I guess I’ll take it one day at a time.
  • Ian had removed the heater core/blower from the car in order for me to clean the engine bay.  While I was cleaning tonight, he decided to tackle that.  Turns out it needed some attention.  It’s now in pieces (Yikes, more pieces) on my workbench.  We’re ordering a new gasket kit for the whole assembly and it sure needed it apparently.  The controls have always been pretty sticky and now we know why.  Parts of the blower assembly that are supposed to open were seized shut!  Fortunately, the whole assembly can go back in the car AFTER the engine is back in place.  That means, I don’t have to tackle getting that whole thing cleaned and painted before our 3/25 deadline (which feels like it’s tomorrow).
  • When I get done with this write-up tonight, I’ll be placing an order for all the remaining bits (we think) we’ll need to complete the engine assembly:  clutch fork boot, heater assembly gasket kit, coolant overflow bottle (my old one is opaque and you can’t see the fluid level), rubber hood buttons, defrost air ducts, new paper air ducts for the heating system, speedometer cable (mine has a slight kink and it’s easier to replace now than later), and a new hood gasket.
  • Tomorrow night, its back out to the garage to go over the whole engine bay with Metal Ready to neutralize any rust and prepare any painted surfaces to receive POR-15 paint.  If everything dries out quickly enough, I should be able to get the POR-15 on tomorrow night as well.  If not, that will be Wednesday’s project.
  • By Friday at the latest, I should be able to apply the self-etching primer to allow the POR-15 to receive the green paint.
  • They are forecasting really nice weather this weekend (fingers crossed) so I should be able to get some green paint in the engine bay this weekend.  I plan to do some wet sanding between coats so I may or may not get all the green done this weekend.


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A Quick Update…

  • We got started disassembling and cleaning the front suspension.  It quickly became apparent that getting off the old undercoating, no matter how bad it’s condition, was going to be a nightmare.  And I have been working a lot of overtime the last couple weeks to meet an approaching deadline at work.  We pretty quickly decided that it was worth spending the money to have everything professionally cleaned and media blasted.
  • Ian dropped all the parts off on Tuesday and for a quoted price of $150, we should be getting back a whole pile of nice clean parts that can then get a coat of POR-15 and a top coat of semi-gloss black.  It’s money well spent as far as I’m concerned.
  • I ordered all the primer, and paint today for the engine bay respray.  My plan is to get in the engine bay this weekend and really start cleaning things up in preparation for a coat of POR-15.