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Project Replace Everything - 242TIC

After a worrying first start that was a failure because of a bad remanned Bosch starter, the swap was a success. Still not very drivable because the new exhaust barely fits in the center. Rear fits perfectly, but the middle hits the floor no matter how low I let it hang. Clutch cable needs to be adjusted and then it’s good to go.
 
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The car is finally dependable enough to have made one of my dream trips, which was to drive up Mt Washington. The car covered 920 miles over the weekend, and was accompanied by my friends WRX, 2019 Miata 30th AE, and a 1996 Miata M edition. Car drove well all weekend, minus a momentary glitch with the OD solenoid.

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Now that the trip is over, Im finally doing the coils. I ended up ordering new spring perches for the rear, as my originals were not pretty. Other new parts and new hardware as well. Im also gonna slap on my stainless brake lines, as the fronts were replaced in 2007 and the rears are still the original hoses. Superpro poly bushings in the front arms and powder coated rear arms.

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looks like you went with a BNE coilover setup...do you mind sharing your specs (spring rate F/R, length, etc)?

I believe they?re 275lb front 150lb rear with the Koni sport dampeners. 10 inch front springs and 11 inch rear. I took a drive after I did the rears and it?s a better ride than what my Bilstein HDs offered.
 
Been a while & have plenty to update on. Been through a few other Volvos since 2021. My primary daily, 93 Regina, it gave up right after I hit 300,000. Mystery issue that I couldn't figure out for about 9 months, which led me to replacing it with a 98 V70 XC (hated that car). Turns out that a bolt fell out of the rear main seal housing, and ground up my flex plate. Back to daily driving and at 315k miles now, have had it going on 7 years. I sold the XC as soon as another 940 popped up, enter my 95 turbo sedan.

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I really love the 95. Such a smooth car. I rebuilt the 13c, added an OBX catback, MBC, headunit, speakers, new shift knob, Geminis, and a hood bra to hide my ugly hood dent. Tons of maintenance as well, your standard stage 0. I parked it the last few winters since the 93 is back on the road. Drove the 95 from NY to Georgia summer 2025, then from NY to Acadia Maine in the fall. Flawless every time.

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My 242 had its first break down as well. Blue gates timing belt sheered all its teeth off doing 80 in MA turnpike traffic in the left lane. Not a great feeling pushing it out of the left lane with traffic whizzing by. Had to abandon the car for 3 days in a parking lot while I went further north to the Poland Springs national Volvo meet. Got a "new" square tooth belt for 5 bucks at the swap meet.

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The same fall, the 242 ended up getting featured in a movie (Legend of Jose Mundo).
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242 is now under the knife. Pics to come. What started as a turbo swap turned into a head gasket and finding out my head wasn't sealing on 3 cylinders. Doing lots more work in the bay at the moment.
 
Holy 4.5 year update! Welcome back, so the old reliable Rex/Regina wagon is still rocking? I'm reviving a 90 745, gotta love the Vaggens.
 
You're the only other person I've seen who had a bolt fall out of the rear main housing and mangle their flex plate.
Oddly enough mine was also a 93 Regina wagon with about 300K on it.
 
Holy 4.5 year update! Welcome back, so the old reliable Rex/Regina wagon is still rocking? I'm reviving a 90 745, gotta love the Vaggens.
It’s always been extremely reliable for me. Not without glitches, I’ve fried a few intake sensors (blue and black one IDK the official name). Still my daily but the NY winters are starting to show. I think I’ve got some time left, just found my first hole in the battery tray
 
You're the only other person I've seen who had a bolt fall out of the rear main housing and mangle their flex plate.
Oddly enough mine was also a 93 Regina wagon with about 300K on it.
Someone else told me to check for it days after it happened. I thought it was ridiculous so I blew it off. Should’ve listened!

Looking back, I can pinpoint when it happened. I had this awful metallic bouncing noise coming from the trans tunnel and I thought my trans was about to blow. Then silence. Fast forward a few months I was driving the car hard to work out a moisture in the dist cap related misfire. I hit some railroad tracks fast and the car got a little light. Bolt must’ve floated up into the flexplate. The car would start and run, but would’nt rev past 1k.
 
Way cool. Was it a background car?
Yes, in a few scenes. Theres a movie trailer out now, and you can see me driving behind the main car. It was a street parked background car in the pic that I posted for another scene too. It’s set in 1984, which would’ve made it brand new for the movie.

Highlight of the entire experience was that I got to drive the Yellow Cab for a scene.
 
Scrubbed the block for a few weeks straight to get it clean enough for some POR15 engine paint.

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Couldn't salvage the old gasket for the mechanical fuel pump block off plate / CPR mounting plate. Cut a new one from some Felpro gasket sheets I had lying around.

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Also finally swapping to later battery cables. I've been through a few batterys over the past two years. The ones I keep getting from auto stores are covered in dust and dead at purchase. I figure this will give me access to a wider selection. Had to change the heat shrink colors so they correspond with + and -

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Powder makes everything better. I've read that the OE early turbo intake is really one of the worst flowing available to the red block tractor engines. If one must have originality, so be it. However if MO POWAH is the goal, there are better alternatives.
 
Powder makes everything better. I've read that the OE early turbo intake is really one of the worst flowing available to the red block tractor engines. If one must have originality, so be it. However if MO POWAH is the goal, there are better alternatives.

Yep it definitely is the worst. However, I didn’t have complaints and I was happy with the car where it’s at. A lot of originality is the goal with this one.
 
Yep it definitely is the worst. However, I didn’t have complaints and I was happy with the car where it’s at. A lot of originality is the goal with this one.
If you decide to run the B21 K-Junk style intake, I've got about 3 of them? Always loved the look of that flat top plenum that easily holds a couple beers!
 
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