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Thread: '95 960 t5

  1. #1
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    '95 960 t5

    Hi,

    I'm a long time lurker on VPCUK, but finally decided to join.
    My volvo journey started with a 97 854 t5 in 2006. Loved that car, did many things with it, but in 2013 got tired of the FWDness and bought a super cheap 2.5 manual 960 and put the 850's engine in it.
    Short list of the 850:
    -Konis/springs
    -the original 2.0 T5 gave up, so a 2.3 went in with NA cams
    -18T
    -customized RICA tune
    -SSW wheels
    -projector retrofitted headlights
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    Custom gauge pod. Unfortunately never finished it.


    And the last picture... still feeling sorry for this car..



    The 960.
    Always loved the 960... not in stock form.. they look kinda dumb... R bumper and a set of wheels + lowering and it is a completely different car..
    pics from the original AD:


    There was a time when I had 2 running volvos at the same time

    Which changed quickly to 1 running volvo.. this 2.5 straight 6 lump was slow and rather thirsty...

    Dummy engine in the 960

    Got to love the space you have in the 960


    Done(ish) version:

    Still a lot to do. Wiring is a mess, intake pipe is a joke... the stock 850 pipe it is.
    But it works and I'm having a lot of fun!

    Borrowed 18" pegs. This car swallows 18" wheels and still have the full turning radius



    Some lame attempt of a 3" sidepipe... I'm just too old for that...

    than made it less obnoxious
    http://www.youtube.com/watch?v=aZiqx...&feature=share


    So far the 960 mod list:
    - T5 swap, 2.3 + NA cams, otherwise bone stock.
    - resurfaced 850 clutch with kevlar
    - custom intake manifold
    - japanifold + custom 3" exhaust
    - 18T
    - VEMS, self tuned. Custom made wiring harness.

    This is where I keep the pics of the progress: http://s74.photobucket.com/user/hun_...?sort=3&page=1
    And this is the full build thread on turbobricks: http://forums.turbobricks.com/showth...=277359&page=1

    The plans:

    Engine:
    -try not to kill it... it runs at 1bar, kinda fast. Plan is to up it to 1.5.

    Suspension/brakes:
    - 850 D2 front coilovers (which is bolt-on, except the top mount), custom rear. Now I'm lowered on cut springs on the front, rear still has the stupid leaf spring setup. Have a mk1 IRS waiting to be swapped. Don't want to deal with the leafspring crap.
    - XC90 330discs + brembo 4 pots @ front. Not sure about the rears.

    Exterior:
    - x70 front bumper... if you have one for sale, let me know. The trashiest, the better. I'm gonna cut it up anyway.. shipping to Hungary is not a big deal..
    - modded 850 skirts
    - s70 rear bumper "skirt" added to the 960 bumper
    - do a projector retrofit

    Oh, a welded diff is also waiting for the abuse.. currently it is open diffed lame, but fun in the rain. And does awesome 1 wheel drive smoke shows on corner exits.

    Hope You liked it.
    Peter

  2. The Following 8 Users Say Thank You to Nari For This Useful Post:

    Biff (Sunday 28th September 2014),Doingitsideways (Sunday 16th March 2014),jamesy12345 (Monday 10th March 2014),jdavis (Thursday 6th November 2014),MoleT-5R (Thursday 22nd May 2014),Santa (Monday 10th March 2014),The Flying Moose (Tuesday 11th March 2014),Tomcat (Wednesday 18th June 2014)

  3. #2
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    Updatessss!

    We had to leave the old workshop, I was pretty sad at first, but got a better a place and we are on our own there, so all good now. Only downside is we don't have a lift anymore and have to buy a lot of equipment... oh well...

    Worked on the car a little as well.
    Re-routed the datacable from VEMS thur the firewall... it is a big improvement :roll:
    And wired in the rpm to signal to the tach, yay for having a working tach again.
    Got a set of OEM plugs, bye bye misfires :nod:
    Tidied up a wiring harness a bit, but I don't have a loom to make it pretty, so still WIP.
    Bought a set of COPs from a 2006 s80 2.5t. Have to redo the COP harness to make them work.


    Started to assemble the MK1 IRS. First time ever I have to put together a rear diff, and to get the diff sit correctly in the housing is more difficult than I thought. I'm still not convinced it is sitting right...
    Decided to mod the trailing arms a little and use universal GAZ shocks with spherical bushing top and bottom. So the lower mounting points are about the get a treatment.. :nod:



    Switched to e85. Smells so gooood. But I still have the itty-bitty 315cc injectors... they are not happy. And the stock 960 fuel pump got a bit tired, above 4500rpm on any boost level AFR went waaaay too lean. A friend came up with a smoking deal for a AEM pump, so I jumped on it.

    F*ck You volvo for putting the fuel pump there...

    this was the 2nd time I had to fiddle with the pump and still hate it. I miss the 850's folding seats..

    anyway, here is the AEM pump installed in the stock carrier:


    Had to mod the stopping tabs a little, other than that it was a straight swap.


    And a little comparison:


    Thats all for now..

    oh, I got an awesome birthday cake from my friends:
    945 T6 in progress

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    Wobbly Dave (Thursday 22nd May 2014)

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    welcome to vpcuk love the car have read up on these else where tho vs?
    1995 854 t5r

  6. #4
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    aiming for the 13's again...
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    Nice work, bet it's fun with the welded diff

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
    Previous Volvo's 1987 745 gle 1989 745 GL 1995 855 Olive GLE 2001 V70 p2
    My Ebay Items http://www.ebay.co.uk/sch/moleadrian...p2047675.l2562

  7. #5
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    Update!
    Car does sound like this...


    The car was doing fine lately. Took it to the local annual Volvo meeting, 80% of the people didn't even realise what it was. One dude assumed the VEMS was a DVD player and went looking for a LCD screen..

    So I did this:




    THE END

    Not really...
    960 goes to a new owner with a spare T6, and gets some new fancy stuff...


    And this is where the T5&m90 going next:








    Wohoooo, I have a wagon finally!
    945 T6 in progress

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    artfulflounder (Wednesday 18th June 2014),Jamest5r (Wednesday 18th June 2014),jdavis (Wednesday 18th June 2014)

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    Yay.... dont forget to keep us updated.

    I for one would love to see your progress

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    Nari (Wednesday 18th June 2014)

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    making progress... of destroying the tire.. just one.. open diff...



    http://i74.photobucket.com/albums/i2...psdba5701e.gif
    945 T6 in progress

  12. #8
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    5 pot heart of a Volvo
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    Should of put it in a 740

  13. #9
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    Nah, I like 9 series better.
    945 T6 in progress

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    leet5r (Monday 2nd February 2015)

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    The 945 T5.


    I want to make this car a lot more organized than the 960. I want it to as a DD and I want to trust it...
    So I sold the VEMS. I was sick and tired of the coldstart issues on e85. On regular gas it was a bit better, but it left me stranded so many times.
    I bought the Motronic 4.4 COP conversion pack (it is just a bin file and a "manual" to what to do with the ECU) from Aaron (tightmopedman9). I'll do the Ostrich conversion later.
    The front facing custom intake has to go as well. That gave me to many problems, too. Went through about 6 machine shops to get mating surface flat, but it never happened. I got incredibly high qoutes for the job so I decided to do it manually... imagine how flat that was........
    Not to mention that this intake manifold wasn't engineered in any way. It was copied from a SR20Det manifold. Powerband shifted a bit.

    Current specs are:
    - '94 2.3 T5
    - '93 NA Cams
    - Motronic 4.4 converted for coil on plug.
    - 4.4 harness
    - Green (440cc) injectors
    - td04-18T turbo
    - M90 with welded stop ring. LINK
    - SM flywheel, resurfaced 850 disk, stock t5 PP.

    Pics!

    Disassembling the M90:



    That is a rather worn 3rd gear You see there

    Unforetunately this transmission is really tired The 940 came with a m90h2, which is in a really great shape, but I sold it already.

    In the beginning I wasn't sure what kind of EMS I'm going run. First bet was the 4.3 Motro with front mount distributor. But it is ugly and rather sketchy, so I never got further than this:



    Bye bye b200ft


    I tore down the whole front-end to clean it up a bit. 17 years + 400.000kms worth of oil, dirt everywhere.



    Sunday evening clean-up

    It is not showroom clean, but You can see the difference. I run out of patience to be honest..

    945 T6 in progress

  16. #11
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    Assembled the m90, mated it with the T5 and in it goes!

    Yay, it is in! (wait for it...)

    And I have to pull it out (yeah, that's what she said, I know), because I left out a go******n fu**ing piece of s**t bearing. Fu*k me. I was so mad when I found out this "little" mistake...


    It took less the 2 hours to pull the engine, disassemble the tranny and refit everything. I made a timelapse, too. Youtube upload is in progress.

    This is where I'm at now.
    I still need to install the ancillaries, some plumbing, wiring and refit everything. And it is done. :roll:
    945 T6 in progress

  17. #12
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    Look! A video:
    945 T6 in progress

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    Doingitsideways (Thursday 6th November 2014)

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    bored of thinking!!

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    brill pal, i cant think of a better combo, get an R bumper on the front and will be what the 850R should have always been

  20. #14
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    Nah, I'm keeping stock. I even leave the trailer hitch on
    Sleeper status
    945 T6 in progress

  21. #15
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    bored of thinking!!

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    ahhh i see, nice and descret fair play to ya.

    there will be some raised eyebrows when that thing goes flying past lol.

    ive always wanted to do this conversion it to a 740/940 wagon if my money allowed

  22. #16
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    Done... kind of

    so I had a not so brilliant idea about using the 6cylinder intake manifold and not the ME7 one, because:
    1. I don't have to worry about IAC placement
    2. Throttle linkage is bolt on
    3. IC piping is piece of cake.

    DON'T EVEN THINK ABOUT USING THAT INTAKE. It was a huge mistake...
    Its bulky, ugly, iac interferes with the master cylinder, and the bottom is waaaaay too close to the positive terminal of the starter.
    I have to redo the intake side withthe ME7 manifold.

    Original 6cyl fuel rail

    Made it shorter

    Cut a runner off and welded it shut


    Wiring, yay!




    And the final result, it is fairly tidy, I still have to make an ECU box. Now it just sits next to the air filter.


    945 T6 in progress

  23. #17
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    Lashing it up with binding
    twine.
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    Awesome bit of work there.. You make it look very easy.

  24. #18
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    Good stuff, well done something a bit more unusual and some cracking work!

  25. #19
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    228k and still not broke it!

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    Brilliant! Fantastic work

    But I noticed one mistake you made there...

    You've put the steering wheel and pedals on the wrong side of the car
    19t, greens, 3" inlet, 3" downpipe with race cat, V70R catback, autotech map...

    310.2bhp / 333ft/lb

    2016 Swedish Day UK "Best Modified Swede"

  26. #20
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    So a friend had this (MK1 960, non-leaf springed IRS)


    Harvested some parts

    Bought a locker live-axle... well... it was a mistake, IRS and non-irs lockers are different

    Pulled the live axle



    Fastforward some cutting, swearing, hammer bashing, smore more swearing...

    Almost there


    Believe me when I say: DO NOT TRY THIS. It was supposed to be an easy swap, some welding and drilling and done.
    Nope, nope, nope. Pre v90 wagons never came with IRS, floorpan is different than the sedans.
    I still have a lot of cutting and drilling to do. It sits on its place now, but some screws are missing.

    And it is a b*tch to install the shocks/springs...
    945 T6 in progress


 

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