BC-Racing Coilover installation (Front axle)

On older Volvo models, the front shock absorber is installed inside a tube that is a fixed part of the wishbone. Converting to coilovers requires cutting the original tube and welding a new threaded sleeve onto the hub.

This is not just a "bolt it on" kit. You will need: Basic tools: Socket set, wrenches, adjustable pliers. Specialized tools: Spring compressors, bench vise, angle grinder (disc grinder). Welding: A reliable welding machine (MIG/MAG or TIG) and welding skills. Heating: A blowtorch may be needed to loosen seized tube nuts.

Raise the car on a lift, remove the wheels and disconnect the brake calipers (and their brackets) and brake discs. Disconnect the track rod end and lower ball joint. ABS sensor: Do not try to disconnect the sensor from the strut yourself (it almost always breaks), instead disconnect the sensor connector from the engine bay/inner fender side. Open the shock upper end nuts from the engine bay and lower the entire strut to the floor.

Once the strut is removed and the old tube is cut out, position the new coilover tube/sleeve on the hub. Use a bench vise to hold it straight. Weld the sleeve with a MIG or TIG welder, ensuring full-length penetration welds on all sides for strength.

After welding is complete and cooled, reinstall the lower ball joint and track rod end. Ensure all fasteners are torqued to Volvo specifications.

Place the coilover unit inside the new welded sleeve. Use the provided brackets and fasteners to secure it. Adjust the ride height using the adjustable perch on the coilover body.

Before lowering the car, verify all welds look solid, all fasteners are tight, and the suspension moves freely through its range. Test drive at low speed to check alignment and handling before normal driving.