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My kid's 940 cruise control died and I traced it to a broken wire in the turn signal stalk. The Volvo manual instructs you to remove the air bag and steering wheel to replace the stalks, a nightmare if there ever was one. After looking carefully at the assembly, here's an easier way to do it:
1. Buy a small Torx T-25 bit and, using a very hard hacksaw blade (I used a diamond-coated blade for tile) cut the shank end down to just fit inside a narrow 1/4 inch box-end or ignition wrench. Tape or glue the bit into the wrench.
2. Disconnect the battery to disable the air bags. Remove the top and bottom covers of the stalk assemblies by removing the four screws forward of the steering wheel. The bottom cover takes some maneuvering to clear the stalks. Remove the driver kick panel, the knee bolster cover, and the knee bolster under the steering wheel.
3. Using your special tool, remove the two screws holding the stalk to the steering wheel assembly. Your tool will be just short enough to fit between the stalk screw and the back of the steering wheel. Use a magnet to remove the screws so you don't drop them into the assembly.
4. Disconnect the electrical connector at the front of the stalk and then, in the case of the turn signal stalk, disconnect the cruise control wire under the dash. Snake this up so it can be pulled out.
5. Pull the stalk out and replace the new one in inverse order.
6. Torque the knee bolster screws to 5.8 ft-lb and button it up.
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