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Hi Tom,
I agree with what Bob has posted and much of my posting repeats his advice. Tips on repair rather than replace maybe helpful.
I had the same problem with my 93 945. The following are the steps I followed-
1.Remove bottom section of the rear seat behind the one you wish to repair.In the wagon it simply clips out.This gives better access and enables front seat to recline further.
2.Recline the front seat as far back as it will go. This will reveal 3 wire hog ties. Cut these with a pair of pliers. Replace them with plastic ties when it is reassemble time.
3.Return seat to the upright position.
4.Remove the lumbar support knob by turning it anti clockwise. You will feel it turn more freely when it disengages from the internal thread. By pulling it firmly it will now come away.Also remove the trim bezel. It simply pulls away. The larger knob, the rake adjustment knob does not need to come out.
5.In the bottom edge of the front and rear faces of the seat cover where the rings were, you will see two metal rods going the width of the seat inside a pocket.Remove these rods.
6.Tilt the seat to enable the front section of the seat cover to be pulled through to the front.
7.Now commence pulling the seat cover up as though you were removing an article of clothing over your head. A little way up you will feel some resistance. Tilt the seat as far forward as you can and by getting down in the rear passenger footwell you should be able to see a strap on each side attached to the frame. Unhook these and it will enable the seat cover to be pulled up high enough to reveal the lumbar assembly.
8.Disconnect the strap that stetches across the back of the padding. When tensioned it shapes the seat. This is done by putting pressure on the two clips.
9.Move to the outside of the seat again.Get your torx screwdriver from the Volvo tool set.Three screws can be found rearward from the knob you have removed.They hold the lumbar assembly in place. To access them you will need to gently push padding out of the way and maybe slide the seat to
give room to work.
10. Remove the mechanism from its internal location.The problem will now be obvious and most likely be a break in the plastic bolt like fixture.It has a hollow rectangular head. Mine was broken through this head.This head has a pin passing through it.
11.You now have two options- buy a new mechanism for $20US,
-or repair by placing a 10mm bolt through the centre of the adjuster to tie it together and strengthen it.
12.To repair you will need - a 75mm x 10mm cup head bolt,
- an electric drill,
-drill bits from 11mm downward,
-hacksaw or grinder and file,
- and a small nail or pin.
13.Remove the pin that passes through the head of the plastic bolt by tapping with a rod of smaller diameter.This enables the broken bolt to be removed.
14.Drill an 11mm hole through the centre of the hollow rectangular section of the plastic bolt.It needs only be wide enough to enable the 10mm bolt to snuggly slide through the centre.The head of the bolt should be at the rectangular end.
15.Fit the broken section back together and carefully align the drill so it passes through the plastic casing, then the bolt and then through the plastic casing on the other side.This is to enable the pin you removed to locate in its original place and at the same time pass through the bolt.
16.Once again check that the plastic bolt is together as it should be.Drill a hole the diameter of the small nail or pin you plan to use, through the non threaded end section of the plastic bolt.This hole must go through the plastic,steel bolt and plastic to enable the pin to locate snuggly.It keeps the plastic bolt together and enables it to be wound in and out without breaking.
17.Cut bolt so that it finishes flush with the plastic end.File pin so that it also is flush.The cup head at the other end doesn't have to finish flush.
18.Reassemble.
This has worked effectively for me and I believe it to be stronger than the original plastic. Success may depend on the nature of your break.
Take care,
John H from DOWNUNDER
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