2001 S40 - Key Shell
 

re: 2001 S40 155,000 miles

Greetings,

The shell / case on my ignition key is falling apart after 25 years.

#1 Can I buy one of the new fancy switch blade + remote fob for my 2001 ?

#2 Are there after market shells - best price so far is $45 including shipping

Manythanks,

Tom

Any use?
https://www.ebay.co.uk/itm/391912737...Bk9SR8jRjujjYw
Bob.

2001 S40 Key shell
 

Hey Bob,

Thanks for the suggestion. I'm in the USA and called the dealer - they said no to both the key shell and the key fob / shell you mentioned.

FWIW - my key does not have the straight line on the key, but more like a wavy line / zig zag.

Update: Blank Key = $45
Software and Programming ~ $155 = ~ $200
The fancy dealer in our area is charging $179 per hour :shocked::shocked:
They have 50+ employees at this location

Thanks,

Tom

Thanks for the reply:~
Typical ripoff prices from Volvo dealers for these keys.
-------------------------- " -----------------------

On my '97 V70 the keys are very similar- if you want to reinforce the worn part then it can be done: clean the area as best you can- obtain a short piece of copper tube (brake pipe sizes are good) that fits between the opening.. split the same tube lengthwise and roughen the inner bore.

Fix the above into place with J.B.Weld- and then close the tube as necessary.
The weld will initially slump a little so hold in place with tape whilst it starts to set- once it reaches the putty stage remove the tape & mould into shape.
(Allow it to fully cure)

You should end up with a much stronger key body.. Good Luck.
Bob.

Another option could be this? https://www.ebay.co.uk/itm/233875435302 If you can get a key blank as pictured-with a removable tab then the original chip could be removed from the key and exchanged etc.
This type of flat bladed key can be cut by some outlets, the key will require the chip to start the car.

Hey Bob,

Many thanks for your attention to my issue.

Right now I am searching for a silicon slip-on cover or
some type of case. **

I am only driving this car about 3,000 miles per year, will keep it until one of us dies. I still have the other key.

The car really is in very good shape, considering I have added several thousand in new or replacement parts over the past 8 years.

I’ll update with my final solution. Best to you.

Tom

** Your fix is a great idea. At age 72 I’m just fat lazy and spoiled. Certain projects I am not very good at and have minimal tools / workspace. Apologies for the ramble.

Final: Money is not the issue, I’m just a skin-flint. My mother told me our family invented the copper wire = two cousins fighting over a penny 😉

Key Shell prototype#1
 

Hi Guys -

I asked my wife - she sews a lot, here is the first prototype.
The fabric is called Duck cloth, a soft version of canvas.
She sewed a button hole for the key, and I attached an eyelet grommit for my carabiner.

Cheers,

Tom

Hello, this is my first post here, I had the same problem, here in Uruguay it is impossible to get a shell or key, so I bought one on AliExpress, then I had to go to a locksmith. He copied the key and transferred the chip from the original key to the new one, although to do that he had to destroy what was left of the original key, in the end this is the result.

https://www.aliexpress.us/item/32568...yAdapt=glo2usa

Nice S40 Key case
 

Hey Tomas -

Looks like you had the "switchblade" model of the Volvo key case.

You did very well re your fix - congratulations.

I'll check with a locksmith when life slows down. I actually have three keys for my Volvo.

If you run into any issues with your car, send me a message - I have made lots of repairs for stuff over the 24 years owning the car.

Cheers,

Tom in USA

Here, in another thread about key shells , is what i did with mine , https://www.volvoforums.org.uk/showt...37#post2543937