YouTube video about the process:
Old tutorial:
Watch both!
When you order, send me a message about the type and the colour of your car.
Volvo P80 load cover repair kit
In the package:
2 end pieces, which fixes the spring problem
3 T-parts which closes the rod and keeps the end pieces in place. If you have the original ones, use them, they are better but they many times break or get lost through the fixing attempts.
2 M3 screws to fix the !!remanufactured!! T-parts in the rod. If you have the original part, you can use that.
You can contact me here, online support is included in English and every language Google translate knows
Quick tutorial:
But watch the videos!!!
There is a faster version, I will show that, but this is the sure version.
Load cover repair kit tutorial Volvo P80 estate
Get your broken load cover
You know it’s broken from the lack of the rolling back and the end parts coming off. Sometimes only one side is broken and it still works. It won’t work long. I promise. The other side is also going to break.
Take off the end part on one side
And on the other
You can see the repair part on the picture prepared. Check if it’s the correct side. It has to slip in the end part with the tube outside. Sometimes it doesn’t fit perfectly, cause there are a little bit different end parts with the fckn same part number. Don’t worry. It will still work.
Starting on one side, take off the 3 screws, one here
Two here
Then pull out the end part
Like this
Take off this insulation, you will need it later.
Break off the left of the inside part of the endpart. Terrible design Goteborg. You should be ashamed.
Do the same on the other side.
There is a pin in the T-part in the middle. You have to hit it in VERY gently. Get a flat screwdriver or something like that and a cute hammer like mine and start to hit it inside gently. When you feel the resistance decreasing, do it even more gently. Then it falls in the spring rod(the long metal stuff in the middle) If you did it gently enough, it didn’t fall far, and you can get it back easily later. You will need it.
Woah! It fell in. Good job!
Carefully get the T-part out. It might resist a bit, bit it will come out and probably fly somewhere, so keep your eye on it. This is the other very important part.
I am a lucky man. It didn’t fly anywhere.
Now get these off from the end of the spring rod. You will need them later.
Try to get the tiny middle part of the T-part back by shaking the whole stuff upside down. If you were gentle enough at the hammer part, it will fall out from the spring rod. If you weren’t it stays in. 3rd option. When you pulled out the T part, it flew somewhere in the room. Good luck for the search! This happened to me in this case, but I found it.
Same on the other side. I was lucky here.
Now you got the the half of your work. Everything what needs to be taken apart is taken apart. Now comes the reverse part.
If you weren’t lucky with the tiny middle part of the T part, and it’s still inside the spring rod, there comes the 2nd option of the getting it back. Go to the lucky side of the spring rod take it in your mouth and blow in it. The tiny part might fly off on the unlucky side. If it doesn’t blow harder and harder until you faint. Then let it go. You can replace it with a tiny screw.
The reason you had to take both side apart is, sometimes both tiny parts get stuck. Blow one side. Blow the other side. Good job!
Now reverse!
Put this back. Watch out for the linings! It can slip in badly. It has to match the aluminium cover perfectly!
Put one screw it, so it holds it in place.
Put back the two plastic things and the spring on the spring rod.
These. There might be a washer at one end. Don’t worry, put it back. The direction doesn’t matter.
Now put the repair part on it. DOUBLE CHECK IF IT’S THE RIGHT SIDE! If you fck it up you can start it over.
Put the T-part in. You might need some help from the other end of the load cover to push the spring rod, so it comes out properly and you can put the parts on it.
Gentle hammering again.
Put the middle part of the T-part in and a bit more of gentle hammering. This tiny piece holds the T-part in the spring rod and holds the whole shit together. If you lost it, you can replace it with a tiny screw. It will do the same job, but don’t choose to big screw. You need 4mm max.
It’s in. This side is done. It holds.
Other side!
Now you do the whole stuff on the other side. Watch out for the direction of the repair part! It has to be the same as the first side. If you miss it, you can start it over.
Both sides are done. Now put back the remaining 4 screws.
2 on both sides. You can put them in earlier, but I usually fck up something and have to start it again, so I have to take out 4 screws less.
Now comes the painful part. You have to be VERY careful! This is the part why I wear gloves(glove).
You have to roll it up in the direction I precisely drew on the picture. It pulls in the cover UNDER. You can do it in the other direction, but it won’t work, because the spring inside is designed for the other direcion.
So just roll and roll and roll.
If you do it correctly, the cover starts to come in into the housing. When it came in, you roll 3-5 more, depending on your taste of stiffness and you do this:
You put one side of the end part on it carefully. If you miss it, it will roll back like hell hit your hand and cut it. (Gloves!)
Carefully!
Almost!
Good!
Now do the other side. No more danger of rolling back. One side holds it in place.
Good
Great success!