- 1 Volvo has never made an XC or off-road version of the Volvo 940. All the more reason for LucaCarMods to make one.
- 1.1 How will we lift the Volvo 940?
- 1.2 Volvo 940-235/75/15 off-road tires, front struts 75mm lengthen and insert spring spacers
- 1.3 Front Side increase 75mm
- 1.4 Anti Roll bar spacers
- 1.5 Adjusting Bumpers and spraying sills
- 2 The end result
Volvo has never made an XC or off-road version of the Volvo 940. All the more reason for LucaCarMods to make one.
As you may know, LucaCarMods.com offers BC-Racing coilovers for the Volvo 940 but until recently no “Volvo 940 Lift Kits“. As a winter project we are going to lift the suspension on a Volvo 940 approximately 10-15 centimeters to give the 940 a tough off-road look.
How will we lift the Volvo 940?
When lifting a car there are three options that are often used:
- Bodylift/subframe Lift
With a bodylift you put spacers between the cab and the frame of the car. You often see this with pick-up trucks or other vehicles with a ladder frame. The subframe lift is possible with many more cars. Here you place spacers between the front and rear subframe and the car. This ensures that the suspension is lower compared to the chassis. Both methods do not give extra suspension travel. You increase the cars ride height only.
- Long Travel Suspension
These are sets that you will often encounter on rally cars and better offroad vehicles. The shock absorbers and springs of these sets are longer and provide a longer travel path. Increasing the car in this way also actually improved the driving behavior when off-road use.
- Larger tires, extending the struts /spring spacers
The most simple and budget-friendly way to increase a Volvo 940 is to place spacers between the rear springs, lengthen the front struts and mount larger tires for better looks and extra height.
Volvo 940-235/75/15 off-road tires, front struts 75mm lengthen and insert spring spacers
Large Toyo Open Country A/T 235/75/15 tires!
Let’s start at the beginning. The Volvo 940 has the standard tyre sizes 195/65/15 or 205/60/15 which are perfectly good for normal use However, we are going to increase the Volvo 940 considerably, to do this we also are installing larger All Terain tyres from Toyo. To be precise the 235/75/15 Toyo Open Country A/T; These have a very sporty look but the profile is relatively quiet on the highway and ensures enough grip.
Larger tyres better complement the wheel arches and ensure that the first few centimeters of extra ground clearance are already won.
The image below shows the difference in tyre size. The 235/75/15 tyres are a total of approximately 10cm higher than the original tyre size. This results in a gain of 5cm extra ground clearance.
Now you will probably think; 5cm that’s easy to win, I only mount larger tires. Because the tyres are a lot larger than the original (and we want the Volvo 940 even higher), space will have to be made in the wheel tubs so that the Toyo Open Country A/T tires do not start rubbing.
Front Side increase 75mm
To achieve a total of approximately 125mm increase and to ensure that the tyres are not rubbing, the front struts will need to be extended between 60 and 75mm. The tyres won’t rub against the strut anymore.
After disassembling the struts, the coil spring and shock absorber should be removed.
After removing the spring, you will see a locking ring that leaves the shock absorber in place. Spray it generously with WD-40 or any other pentrating oil to your liking, leave it for about 10 minutes before you try break the ring loose. The ring can be very tight, the use of a good hamer is advisable.
After the shock absorber is removed from the strut, the grinding/sawing work can begin. This is also ‘ the point of no return ‘. We cut the strut at exactly 27 cm from the stub axle housing measured, this distance gives you enough space to be able to weld without the spring dish in the way. An additional advantage is; The higher you cut and weld the less the material will warp over the entire length.
After marking the 27cm distance, a long line can be placed perpendicular to the marking so that the position of the spring dish remains exactly the same as the fusee. Measure everything twice to be sure. Then place a hose clamp around the strut so you know for sure that the cut will be as good as 100 straight
After cutting the strut we make the strut completely clean in the weld area and as you can see below also a V-groove at the part which will be welded. This is an absolute MUST!! This ensures that the weld 100 gets penetration with the correct settings on the welding machine. If you do not do this then there is a weld ON the material which is a lot weaker than a weld that is 100 through.
With a center plug we ensure that all parts are perfectly aligned while attaching the 75mm additional length that will be added to this strut.
A piece of 75mm strut tube is added between the cut parts. This also gives the 75mm extra ride height to the Volvo 940. With the center plug all parts are well aligned, you can place the first tack welds. Note that also the position of the spring dish and the stub axle housing relative to each other remain the same, this is easy to check with the markings made on both parts.
Here you can see well that there is a deep V-groove which allows the weld to flow deeply into the material. First, we fix everything with 4 tack welds, also make sure that the center plug can still move smoothly through the entire strut. If so then the everything can be welded.
After welding, it can might happen that you have had very good penetration and the weld on the inside has become slightly too thick causing the shock absorber to not go in smoothly. This is easy to fix with a die grinder.
Because the shock absorber tube 75mm has become longer, you will need to drop a 75mm spacer in the strut tube to support the shock absorber. If you do not do this there will be no damping the first 75mm of travel.
See below the end result of the 75mm extended Volvo 940 struts.
Increase back with spacers
The rear of a Volvo 940 is very easy to do with the LCM Volvo 940 3 inch lift spacers! These are spacers which need to be mounted between the springs and the chassis. You assemble it by putting a jack under the axle so that when the shock absorber and spring are loosened there won’t be any stress on the brake hoses.
After the taking out the lower shock absorber bolt and the removing the spring the LCM Volvo 940 3 inch Lift spacer can be placed. You bolt it in the same spot where previously the spring was mounted against the chassis. Then place the spring back and bolt it to the spacer. Caution: Always make sure that the tension on the brake hoses is minimal.
With the Volvo 940 lift kit, you use the original shock absorbers to ensure that the rear axle can not lower further than standard. The maximum outspring of the rear axle with standard shock absorbers is a safe margin for the brake hoses. When placing longer shock absorbers can cause the tearing of brake hoses! Always use the original and check if there is enough slack on the brake hose.
Below we see a picture of the design the 75mm/3 inch spacers which are supplied in the kit.
When making this post, we used a test spacer, which is purely for the sizing and testing of the kit.
Anti Roll bar spacers
Adjusting Bumpers and spraying sills
The lift of the Volvo 940 is now actually ready. However, there are a number of things we carry out to give the Volvo a more aggressive look! First of all you win a lot in terms of looks and height when removing the front bumper lip and spraying front bumpers black. We sprayed the front bumper with a stone coating black which looks very tough and makes the Volvo 940 look a lot higher.
With this 940, the sills have some spots or they are dented. We also coated the sills so that they look neat again and the car looks higher.
Finally, the choice was made to also cut the rear bumper in half so that the back looks much higher. This is of course optional but we find the result very successful. The Volvo 940 really looks like an Off Road vehicle.