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  1. #61
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    Quote Originally Posted by oblark View Post
    And the last part of the gearbox puzzle arrived yesterday.

    Attachment 31496
    Is that a standard Petrol M66 AWD diff ? Supposedly from S60R M66C, right?

    From your story it becomes clear that the 45-spline-to-angle-gear petrol M66 diff paired with the D5 final gear ring without issues. Is it so?
    With all this effort you got M66 with wide diesel gears and 4:1 final drive + 45 spline output mounting the P80 angle gear without worries... Brilliant.

    Last thing - interestingly, if it is possible to interchange the XC final gear pair into AWD housing ?

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    Quote Originally Posted by Andzey View Post
    Is that a standard Petrol M66 AWD diff ? Supposedly from S60R M66C, right?

    From your story it becomes clear that the 45-spline-to-angle-gear petrol M66 diff paired with the D5 final gear ring without issues. Is it so?
    With all this effort you got M66 with wide diesel gears and 4:1 final drive + 45 spline output mounting the P80 angle gear without worries... Brilliant.

    Last thing - interestingly, if it is possible to interchange the XC final gear pair into AWD housing ?
    Not done it myself,but have chopped and changedgears in a M56, so I'd imaginethe m66 would be as easy to do..

    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
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  3. #63
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    Quote Originally Posted by oblark View Post
    Got the subframe and rear suspension parts back from the powder coaters. Made up a jig for the C70 soft top under floor brace ready for modify to fit the AWD centre brg support.
    Attachment 31547
    The U brace from C70 convertible is a nice upgrade, but isnt it interfering to AWD (angle gear) or downpipe?
    MAybe you know, if the C70 front subframe is wider or not? This would probably men longer driveshafts as well?

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    Stupid me, just read the whole topic again and there is clearly stated you use a S60R diff.

    The input shaft is probably the same both T5 D5 gearboxes - 23 splines?
    Most important - what flywheel/pressure plate/clutch disc combo do you guys prefer here in UK in those M66 swaps?
    As far as I've searched across, the favorite receipt on the other side of the pond is 850 SMF, 850R PP and Sachs sd-963 disc.

  5. #65
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    So now the AWD conversion is finished I was offered a S60R engine which had more cracks in the liners than crazy paving

    The engine was stripped down and a shopping list of parts was drawn up, A 850 block was sent off to the machine shop to be bored out from 81mm to 83mm. Once the block was bored out it was cleaned with Mr muscle to clean all the old oil off then it was time to rebuild the block.

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    The S60R head was dropped off today at the machine shop to be skimmed should be back so the engine can be finished off soon.

    1996 850 T5 AWD - 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, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

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    Why didn't you leave the bore with 81mm?

    V70 2.4T5 M66 Summum

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    Quote Originally Posted by Ric@rdo View Post
    Why didn't you leave the bore with 81mm?
    Could have just used the 850AWD block and just pop the S60R crank and pistons straight in afaik, but by boring out the block, Rob has started with a freshly honed set of bores, watching with interest what this setup makes power wise once finished.

    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

  9. #68
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    Quote Originally Posted by Ric@rdo View Post
    Why didn't you leave the bore with 81mm?
    I have yet to come across a 850 block that hasn't got badly worn cylinder bores.

    Quote Originally Posted by MoleT-5R View Post
    Could have just used the 850AWD block and just pop the S60R crank and pistons straight in afaik, but by boring out the block, Rob has started with a freshly honed set of bores, watching with interest what this setup makes power wise once finished.
    I've got a V70AWD 2.5lpt engine with 160k miles on it but the bores are more and likely worn so as you said boring out a 850 block I start off with a as good as new engine. I'm hoping to make around the 300-330bhp at the wheels which should be good for a chocolate AWD system

    1996 850 T5 AWD - 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, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  10. #69
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    Mine started to cook the clutch before hurting the AWD system. Thats just with a 19T, no tuning and unknown power.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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    Quote Originally Posted by oblark View Post
    I have yet to come across a 850 block that hasn't got badly worn cylinder bores.



    I've got a V70AWD 2.5lpt engine with 160k miles on it but the bores are more and likely worn so as you said boring out a 850 block I start off with a as good as new engine. I'm hoping to make around the 300-330bhp at the wheels which should be good for a chocolate AWD system
    I'm assuming that the P1 V70 AWD had the same B5254T4, as it's older sister the 850 AWD which I heard was a good engine for getting some good easy power out of and one may yet grace Gul's engine bay at some point in the future I hope.

    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
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  12. #71
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    I picked the cylinder head from the machine shop, had to have 4 thou skimmed off of it to make it flat.

    Then it was just a case of fitting the head, tighten it down, fit the cams and the cam cover.

    Last job was to fit my custom VVT delete pulleys and time it up.

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    1996 850 T5 AWD - 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, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

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  14. #72
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    Quote Originally Posted by oblark View Post
    I picked the cylinder head from the machine shop, had to have 4 thou skimmed off of it to make it flat.

    Then it was just a case of fitting the head, tighten it down, fit the cams and the cam cover.

    Last job was to fit my custom VVT delete pulleys and time it up.

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    I see you've returned to the original style inlet manifold Rob, does this have any gains over the ME7 one you've used in earlier in the project threads..??

    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

  15. #73
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    Quote Originally Posted by MoleT-5R View Post
    I see you've returned to the original style inlet manifold Rob, does this have any gains over the ME7 one you've used in earlier in the project threads..??
    I wasn't 100% happy with the throttle linkage when using the me7 inlet manifold and plus the intercooler to throttle body pipe kept blowing off the throttle body.

    So I've gone back to more "reliable" set up

    1996 850 T5 AWD - 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, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

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  17. #74
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    So as I've gone for a S60R head it means I have to use the P2 ME7 cam belt cover which in turns opens up another load of problem to overcome

    As the 850 aux belt tensioner won't fit due to the fact the cam cover is in the way I've had to use the P80 ME7 power steering pump, alternator and bracket.

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    As you can't get a non A/C belt for the ME7 engine and I've removed the A/C from the 850, so I'm going to have to design and manufacture a idler pulley to sit where the A/C compressor was.

    I've also found out that P80 ME7 power steering lines are like hen's teeth.

    As the engine is 80% S60R I thought it'd be right to fit some blue engine covers

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    1996 850 T5 AWD - 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, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  18. #75
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    Always the way, nothing ever goes the way you plan it
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  19. #76
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    I'm sure you'll find an easy way around your issues, could you find a serpentine belt from another vehicle that will give you the length you require..??

    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

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    Quote Originally Posted by MoleT-5R View Post
    I'm sure you'll find an easy way around your issues, could you find a serpentine belt from another vehicle that will give you the length you require..??
    The problem is the P80 pre ME7 the alternator rotates clockwise and the P80 ME7 alternator rotates anti-clockwise.

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    The ME7 alternator has a one way clutch in the pulley, it only engages in a anti-clockwise rotation, it feel wheels clockwise.

    1996 850 T5 AWD - 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, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  21. #78
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    Rob, if you can confirm belt width, number of ridges and proposed length, I might be able to help, assuming you can fit a pre me7 alternator to get over your clockwise anti-clockwise issue??

    Would the belt be the same as pre me7, just a different length??
    If so I can use one of mine as a sample

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    Picked these up from the machine shop on Friday, the large one is for is to replace the heavy crank pulley. The other on is for the idler pulley just waiting for the bearing, shaft and the 2 brackets.

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    I did this little upgrade today, replaced the front and rear fog light switches for a all in one 960 switch. All I had to do was remove pins 1 & 6 from the front fog light switch (need to cut the pins out of the plug) and fit them into the rear fog light switch plug.

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    Finally got around to loading the extended load and boost threshold software on to the car. when boost pressure is below a set threshold the TCV is not pulsed and map set point calculations are not made, when the boost pressure is reached the TCV set point is activated. When you step on the loud pedal the turbo is up to speed and boosting you don't have to wait for the turbo to speed up and to produce boost.

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    1996 850 T5 AWD - 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, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

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  24. #80
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    Up date time

    Over the Easter weekend and this weekend quite a few jobs were done on the car.

    Firstly the old struts were changed for some nice new ones.

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    A x70 headlight relay was fitted, the reason for swapping it from the 850 one is because if you flash the headlights before locking the car, once the car locks the headlights come on for 20 seconds.

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    Lastly the last parts arrived for the idler wheel and I finally got hold of some ME7 power steering lines.

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    1996 850 T5 AWD - 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, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

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