Couple of issues, May just be me being fussy...

[cherry1809]

Car doesn't seem to have much pull from the off. It's (More than) fine when the turbo spools right up, But it doesn't seem as quick low down as my previous manual T5. Turbo not cutting in as quick sort of thing. I know it's a tad bigger turbo but, Will it make that much difference?

Got a noise that I thought was boost leak when I first picked it up, But pretty sure it's gearbox related. Quiet as a mouse slowing down, But at certain revs pulling away it makes a sort of, Rattle.
Stops after the revs build up a bit past around 2k.
If it's a gearbox out job, I may as well play with the 6 speed idea, flywheel, Clutch etc.

[nobananas]

If it's a 16t that you've now got I believe it is the case that it won't spool as quickly as the 15g. Not sure what you're rattle is but if you go the 6 speed route you may find it a lot of work for little gain. Top gear is much the same ratio as the standard T5 box but it has lower gears further down the box (like a T5 needs a lower 1st gear !) so you won't get a lower RPM cruising speed which would be nice. My mates Mondeo 2.0 TDCi pulls about 1500 rpm in top gear in sixth, now that would be useful in a T5 !

[p fandango]

i looked at a 6-speed box myself (i even bought one) but its not worth messing with. 6th on the M66 is the same ratio as 5th on the M56H. It'd need a custom rear gearbox mount making & a S60R clutch

[cherry1809]

I was thinking it may help the issue of high boost/Low rev = Bent rods.

[cherry1809]

The noise it makes from the gearbox is the same as you get when the release bearing is on it's way out. Thought that only made a noise at idle in neutral though???
Where should the gauge needle sit at full boost too?

[The Flying Moose]

The noise it makes from the gearbox is the same as you get when the release bearing is on it's way out. Thought that only made a noise at idle in neutral though???
Where should the gauge needle sit at full boost too?

I have exactly the same problem on the noise front only happens when accelerating in first and sencond and at low revs, also makes a noise similar to a loose exhaust heat shield. Mine too makes the noise when idling but more so when the clutch pedal is pressed down. I have been reliably informed today by Burton and Wilson Volvo specialists it is the clutch release bearing.

[cherry1809]

I thought that at first, But mine makes no noise at idle whether the clutch is in or out. Wierd.

[leet5r]

could be a cracked manifold , mine had a rattle type sound and changed loads of bits to cure it, and turns out mine was the manifold

[cherry1809]

could be a cracked manifold , mine had a rattle type sound and changed loads of bits to cure it, and turns out mine was the manifold

Odd.
I'll have to get little Bruv to sit on the front panel while I drive up the road.

[leet5r]

lol , if i turned the boost down th below 10 it would not do it.
i checked mine by accident when i was changen a turbo and found it to have 5 nuts missin , so when i removed it for closer inspection there was 3 big cracks in , so now its got a s60r manifold and a 16t turbo on

[woz]

...
Where should the gauge needle sit at full boost too?

As standard about 80% of the way across the white bit. If you have a RICA or other boost enhancing mods, then you can se it off the scale. I do quite frequently. (When road conditions and speed limits allow!!!!)

p.s my daughter had a similar rattle - was a loose baffle in the exhaust. Thats cheap!!

If your noise changes with anything to do with the clutch pedal - then suspect the release bearing or pressure plate springs. But these old girls can go on for miles with a shagged clutch. I think mine was making a funny whoopy noise on take-up when I bought it at 167k. 5 years later an odd vibration started when idling - new clutch time at 220k - I believe it was teh original clutch!! Three brkone springs and bits loose all over but plenty of wear left in those (bits of) friction linings that were still attached.

Good luck.

ps if you do need a new clutch make sure you get OEM spec not a cheapy from a clutch franchise - the labour costs the same but cheap parts are a false economy.
Woz

[cherry1809]

Could be the baffle, As pushing the clutch in and out makes no difference to the noise as it only makes it whilst driving.
If I change the clutch for anything it'll be an uprated item.

[brett craig]

Could be the baffle, As pushing the clutch in and out makes no difference to the noise as it only makes it whilst driving.
If I change the clutch for anything it'll be an uprated item.

could also be the cat internals failing, they tend to rattle once the core is gone, theres also around 3 different heatshields under the car from front to back to look at, my release bearings on the way out as it rattles when the pedal is " up ".

gearbox internals i'm not to sure but i think its been brought up on here before regarding layshaft bearings and selector problems.

cat could explain noise and performance problems though !

is yours the 16T ? i found going from a 15g to 16t quite different, they dont spool up as fast and seem low on power but its normal, i fitted r.i.p kit and exhaust and the problem was gone, 100 % improvment.

[cherry1809]

It's a P reg so would have thought a 16T.
Cat should be fine as it's done it since I bought it (Hasn't got any worse) And it recently went through mot (March I think)
Will check around the front at the weekend as it sounds like it's coming from there.
As soon as work picks up again I'll carry on and get the exhaust/filter and remap sorted out. Might be losing our Saturdays any minute, As work are making more cut backs