Hi,

I've just finished repairing the module from my '96 850, and electronics is
also my business.  Have a look at
http://www.matthewsvolvosite.com/chat/phpBB2/viewtopic.php?p=46827#46827 if
you already haven't.

Removing the module on my car (right hand drive non-turbo) took less than
15minutes. Access was good.   I also had a set of Torx sockets.  Removing
the 4 "one-way" spring clips on the module case was not too difficult, but
opening the case took me at least an hour.  I was trying to not damage it.
I used a piece of flat spring steel about 2mm wide, bent at 90degrees to
scrape as much silicone as I could from the groove, then some brute force
and leverage.

Inside the PCB is coated with a thick silicone-like conformal coating.  I
had to peel it off the socket pins to get a good look at them.  The pins for
the two pin connector were obviously fractured (after the coating was
removed).  I cleaned the coating from all of the connector pins desoldered
and then resoldered them, although I think only the two big ones needed it.
I used clear nail polish to reseal the PCB, and a neutral cure silicone
sealant (made by Selleys) to reseal the casing, used sparingly.  Then after
the case was back together I ran a bead around the gap, and smeared with my
finger and wiped the excess with a rag dipped in mineral turpentine, to
neaten it up.  I put it back on the car almost straight away, but left it
overnigh before starting.  Although the tube says 72 hours to completely
cure, a big blob I had left over seemed "solid" overnight.

Unit has worked fine ever since (about 5 days so far).

regards
Barry