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  1. #1
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    Project 850 T5 AWD

    After fitting a T5 engine in a 240 I thought I needed a more challenging project.

    So I brought a 97 V70 awd with a full service history and 150k miles from a guy who had owned it for 8 years and only driven it around north london.

    So over last weekend the running gear was removed and the shell scrapped.

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    Once the engine/gearbox was set up the standard downpipe was removed and a 3" stainless one was tack welded together.

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    As for the engine I got a 850 block bored out to 83mm making it a 2.4. It was rebuilt with a ME7 pistons, crank aump and a S^)R head with my VVT delete pulleys.

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    1996 850 - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, custom built inlet manifold, 3" downpipe with 200 cell cat, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, white injectors, 3 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers

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  3. #2
    Gearbox Killer
    aiming for the 13's again...
    MoleT-5R's Avatar
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    Nice project Rob, as always I will be avidly watching the progress of your latest phase of the 850's progress. I like the 2.4 850 block mods and look forward to seeing what she makes on the rollers when completed, keep up the good work mate.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD and 1999 V70R 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

  4. #3
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    Dangerous Dave's Avatar
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    Nice project, looking forward to future updates

    You got any mods planned for the AWD system?
    1996 Olive Green 850 AWD - Follow the project here
    1996 Nautic Blue 850 AWD - The daily, bring on the snow
    1997 Grey V70 T5 - On loan

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  6. #4
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    They work well, Adam from Wales did it on his 854R. Iirc volvo have now ran out of some of the rear suspension mounting brackets, they are easy to remove from a donor. I think Shem got a couple of sets when he did his shell and didn't use them all.

  7. #5
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    Quote Originally Posted by Dangerous Dave View Post
    Nice project, looking forward to future updates

    You got any mods planned for the AWD system?
    The only mods I'm going to do is to upgrade the solid discs to the XC90 discs & calipers.

    I've done a quick mock up and discovered the discs fit, the calipers fit BUT the calipers won't fit when the discs are fitted.

    Looks like a bracket is needed.

    1996 850 - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, custom built inlet manifold, 3" downpipe with 200 cell cat, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, white injectors, 3 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers

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  9. #6
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    Quote Originally Posted by oblark View Post
    The only mods I'm going to do is to upgrade the solid discs to the XC90 discs & calipers.

    I've done a quick mock up and discovered the discs fit, the calipers fit BUT the calipers won't fit when the discs are fitted.

    Looks like a bracket is needed.
    Hmmm interesting.

    Think I need to look at my AWD system as I think it is slipping at some stage.
    1996 Olive Green 850 AWD - Follow the project here
    1996 Nautic Blue 850 AWD - The daily, bring on the snow
    1997 Grey V70 T5 - On loan

  10. #7
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    The donor car had a vibration that came from the centre tunnel, on closer investigation it was found that the centre bearing was a little dry but the centre UJ was seized these causing the vibration. Got a new brg on order along with a complete UJ, all should be here for the weekend.

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    1996 850 - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, custom built inlet manifold, 3" downpipe with 200 cell cat, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, white injectors, 3 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers

  11. #8
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    Nice, good thing that they use available parts as getting those things from Volvo would mean a whole new prop (if you can still get them that is).

    BTW where did you get the bits from?
    Last edited by Dangerous Dave; Thursday 9th March 2017 at 22:00.
    1996 Olive Green 850 AWD - Follow the project here
    1996 Nautic Blue 850 AWD - The daily, bring on the snow
    1997 Grey V70 T5 - On loan

  12. #9
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    All the parts have turned up so I can now rebuild the propshaft.

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    1996 850 - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, custom built inlet manifold, 3" downpipe with 200 cell cat, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, white injectors, 3 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers

  13. #10
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    Got the internal reinforcing plate welded in for the torque tube fixing point. Also found 7.42 between the sound proofing and the floor plan under the drivers seat. Looks like it's been there a few years.

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    Some before and after photos of the angle gear.

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    1996 850 - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, custom built inlet manifold, 3" downpipe with 200 cell cat, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, white injectors, 3 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers

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    Under the seat treasure! Looking good Rob.

  16. #12
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    Quote Originally Posted by oblark View Post
    Some before and after photos of the angle gear.

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    did you strip and rebuild it with new seal etc Rob ?

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD and 1999 V70R 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

  17. #13
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    Nope, just cleaned it.

    But I will be changing all the oil seals and changing the oil.

    1996 850 - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, custom built inlet manifold, 3" downpipe with 200 cell cat, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, white injectors, 3 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers

  18. #14
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    May be worth taking it apart and cleaning the crud out of it, mine had done 160k and had a very thick layer of sludge around the whole inside, took me ages to scrape it all out. Plus there is ports off the main reservoir that splash oil through to the outer bearing on the output shaft. Quite an odd design really.





    The only issue is tightening the output shaft nut, it has to be done to a specific torque as there is a crush ring on the shaft.
    Last edited by Dangerous Dave; Thursday 23rd March 2017 at 10:42.
    1996 Olive Green 850 AWD - Follow the project here
    1996 Nautic Blue 850 AWD - The daily, bring on the snow
    1997 Grey V70 T5 - On loan

  19. #15
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    Picked up a xc70 m66 gearbox during the week and discovered today that a early p1 angle gear doesn't fit a m66 gearbox. Also found out the the p1 collar is obsolete.

    Need to look into what the s60r angle gear ratio.

    1996 850 - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, custom built inlet manifold, 3" downpipe with 200 cell cat, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, white injectors, 3 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers

  20. #16
    New Identity
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    I'm guessing they have different hole centres?

    Whichever angle gear you get you'll need the rear diff off the same model to match
    1996 Olive Green 850 AWD - Follow the project here
    1996 Nautic Blue 850 AWD - The daily, bring on the snow
    1997 Grey V70 T5 - On loan

  21. #17
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    The hole pattern is the same it's the splinde shaft, the early p1 shaft is 4mm smaller diameter than the P2

    My current angle gear/diff is a 3.31 which looks to be same as the s60r.

    1996 850 - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, custom built inlet manifold, 3" downpipe with 200 cell cat, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, white injectors, 3 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers

  22. #18
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    Good info

    I guess a P2 collar won't fit into the hole on a P1 angle gear? (thinking machine down a P1 collar to fit inside a machined P2 collar for the angle gear side). And I guess S60R angle gears aren't cheap?
    1996 Olive Green 850 AWD - Follow the project here
    1996 Nautic Blue 850 AWD - The daily, bring on the snow
    1997 Grey V70 T5 - On loan

  23. #19
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    Picked up a M66 diesel xc 70 gearbox during the week and thats when the fun started. After searching the good old internet I couldn't find nothing to comfirm whether the diesel collar was the same as the petrol collar. Well I can confirm that the diesel collar has 47 splines and the petrol collar has 45 splines. So I'm going to see if i can get a custom collar made with 47 splines at 1 end and 45 at the other end.
    I can also confirm the S60R angle has a ratio of 2.56 - 1 and fits the M58 gearbox.

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    A P1 v70 awd angle gear compared with a P2 S60R angle gear.

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    So after the fun and games with angle collars I fabricated the new M66 gearbox mount.

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    1996 850 - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, custom built inlet manifold, 3" downpipe with 200 cell cat, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, white injectors, 3 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers

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