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I started to do this but didn't really succeed in doing a short cut.
I got the old bellows out by removing the intake grill and short duct as a start. This allowed me to see the thing and gain access to the nuts and clip on the door shaft. (Also the lower dash panel of course.)
After I got the nuts and the clip off, I cut a slot using aviation snips to give the actuating shaft room to drop down without the room to move the bellows back far enough to clear.
With the thread cutting nuts off and the slot I was able to clear the mounting stud toward the center of the car and the actuating shaft but the outer stud broke when I used too much force.
I tried shortening the mounting studs and pre-threading the studs before reassembly but ended up breaking the outer stud on the new bellows. I jammed some foam in behind it to make it work-- sort of. I have another new bellows to try when the spirit moves me. Next time I plan to alter the slot so it reaches the outer stud hole and try it that way.
Hang onto those thread cutting nuts! I lost one and the parts manager had to call the Volvo parts specialist to get the part number and they cost about $6.00 each!
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'96 965, 16' wheels, Michelin Pilot Sports, rear 18mm bar + Koni, 201 HP cams, 128K. Put 200K on '85 745 TD.
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