I have a '93 245 with an OEM roof rack - one of the very late model racks that BigDan indicated in an earlier thread was originally intended for the 700/900/V90 series. It has only 2 vertical support feet per side, with cross strips. No surprise, the well nuts are shot and need to be replaced. I want to replace the rubber gaskets that sit between the rack feet and the roof as well to ensure no water/rust down the road. My dealer has the well nuts but says the roof rack installation kits, that would included the gaskets, for the 200s are no longer available. Any one know if the kits for a 700/900/V90 would include similar shaped gaskets? Any alternative suggestions on where I can purchase substitute gaskets? Sure would appreciate any help.


Incidentally, I have read all the threads and acknowledge the opinions about the poor quality of the OEM racks vs. Thule clamp ons but I plan to paint and reinstall mine:
I have never had a problem with OEM rack and have hauled lots of lumber, 120lb Gheeno boat, etc.
No signs of rust on top or on the headliner
I like the look of the rack and don't like the look of the iPd plugs.
I don't want to mess with trying to blend/match the paint under the rack fee if I remove it.

JPB

Steve,

That's exactly the kind of suggestion/solution I was looking for. Thanks.

I haven't pulled the roof rack yet to see the pattern of the gaskets, but I have two other questions. How did you apply the silicone - a think layer spread evenly across the entire bottom of the gasket (the bottom being the side applied to the roof) or just around the outer edge of the gasket? Just regular 100% silicone sealant or something special to adhere to the rubber gasket? Sure appreciate your help.

Jim

If it's any help, I did this remove/reinstall on my '82 245. I was on the trail of rust streaks and could tell that the gaskets were all split with age. Pulled the rack and found that all the mount screws were in good shape and solidly mounted to the roof surface. There were traces of rust around each of the screws/mounts where they were cut into the sheet metal of the roof. I reduced the rust with a dremel tool and sanding disk then primed and painted the spots. Luckily, all the rust was superficial and lay withing the border of the rubber seals which rest between the rack and the roof. The gaskets were all shot, but one or two were in good enough shape to use as a pattern to make new gaskets. I cut the new gaskets using my pattern and an X-acto knife from the thin rubber membrane used in covering flat roofs, obtained from a roofing supply house in the smallest quantity they've ever sold. I also put a layer of silicone sealer between the new gaskets and the roof, as I do not like the idea of rust falling in from above. In the end, it looked like a pretty good fix.

Hope this helps!

Steve.

I have an 85 245 with a roof rack that I bought from a backyard mechanic. He let me know when I was buying it that he had tried to work on the rack but found that nuts/brackets that the rack bolts screws into fell into the space under the roof. The one corner he started on had to be reattached with sheet metal screws. Instead of relying on the rack I have since picked up a set of Yakima roof racks that clamp on.

Just a warning - you might be in for more work that its worth..... I have never taken off the inside roof covering, so I am not sure what I would find. I probably would visit a junk yard that has lots of Volvos to see what's hidden first.

michael

I've said this before - I assume it's the same in the USA - but here in Europe the dealers sometimes say a part is no longer available because it's not listed by their local distributor.

The factories still hold many of the parts, which can be 'special ordered'. Try contacting Volvo US, or even Gothenburg, as it's only rubber gaskets, which can be posted quite easily.