Hi.....we bought a used 1996 850 GLT sedan and love it. But the door stays on both front doors have broken their door post
mounting and they now make a horrendous clicking sound when opening and closing the doors. Our mechanic had never
seen this before on any 850 or other Volvos. Since then 2-3 other 850's that he has sold have come back with the same problem.

It appears that the small piece that the door stay is bolted to is only tack welded to the door post. When this weld breaks the
door stay won't function as designed and make a loud click.

He thinks that it must be welded to the the door post and the post repainted. A friend who owns a body shop has done this
to several Volvo's.

Rumor has it that there is a replacment part or kit that fixes this without welding but we cannot find any such thing.

Anyone else having problems with this? Got details on how to fix it, other than welding it?

Seems like a poor design...there is simply too much torgue produced by the door stays to have the bracket hold in place with
only one tack weld.

Thanks.