94 850 door stay sheet metal breaking?

That's the approved way to fix it, but try this:

Yeah I got this too - have to say this is a truly APPALLING build quality issue and what makes it worse is that my 1996 model also suffers from it - so several years later and they still have the same problem - should have been ironed out by '96......

Am very happy with the car apart from this but there is absolutely no excuse for a poorly designed door hinge....this is basic stuff.....

I dropped by a dealer today, and they said to stop by either of the local bldy shops they use, as they're VERY familiar with the issue. He impllied that they can weld & reinforce it without removing the door. Didn't have time to get a quote then, I'll check them out tomorrow. It may be that the big hole for the wiring weakened the area, because my crack ran between the two holes. I'm at 194,000 miles now, longest ever for any car I've owned without major issues. Or, maybe not, since I seem to have a rear main seal leak... Waiting to see how the new body style Subarus look (the current ones are just too ugly for me )-)

AWD, not bad, but the wheel arches look awfully high, as ifthey jacked the suspension up to SUV height.. I may have to wait torthe WRX version.. (No more Volvos for me, because the service manuals aren't available, and I can't be be sure if I'm buying a Volvo, Ford, or Mazda.)

To reply, please remove one letter from each side of "@" Spammers are VERMIN. Please kill them all.

I just gave a '90 Legacy away. The brakes and most everything under the car had rusted out. The tailgate rusted out and had to be replaced. I replaced the automatic transmission but couldn't replace all the metal that was rusting out.. It was a real rustbucket. Never again.

I drive my 850 180,000 miles and they still look like new. I didn't even get 110,000 miles out of the Legacy.

Service Manuals 1-800-25-Volvo

My '92 850 had the same known problem by Volvo who fixed mine free of charge. Every time I opened or shut the drivers door there was a loud clacking sound. The door was pulled, welded and resprayed.