940 solid flywheel conversion?

Post 740493 by chazz.stockham on 2014-10-07 18:34:58

Hi my humble 940 2.3 turbo has come a long way, haven't posted on here in a while, got all my planed mods done and am now driving daily to prove reliability before i spend much more. I'm now at the stage where with my new found power my clutch is slipping on speedy pull aways and will even drop out for a brief second and make the hole car judder briefly on top end high boost driving so am sourcing a stage 2 clutch with pressure plate and release bearing but have recently learn the car has a dual mass flywheel. i understand there are other solid flywheels i believe are made by volvo i can use but Im not sure which one(s) i can use, i have a m90 gear box that should be 20 splines and take a 240mm clutch so need something that will work with this. dose anybody have any ideas or done a conversion like this? thanks in advance you lovely people

Post 740498 by Jamest5r on 2014-10-07 18:42:15

Ask Smithy he will know :)

Post 740555 by smithy on 2014-10-07 21:40:31

J[QUOTE=chazz.stockham;740493]Hi my humble 940 2.3 turbo has come a long way, haven't posted on here in a while, got all my planed mods done and am now driving daily to prove reliability before i spend much more. I'm now at the stage where with my new found power my clutch is slipping on speedy pull aways and will even drop out for a brief second and make the hole car judder briefly on top end high boost driving so am sourcing a stage 2 clutch with pressure plate and release bearing but have recently learn the car has a dual mass flywheel. i understand there are other solid flywheels i believe are made by volvo i can use but Im not sure which one(s) i can use, i have a m90 gear box that should be 20 splines and take a 240mm clutch so need something that will work with this. dose anybody have any ideas or done a conversion like this? thanks in advance you lovely people[/QUOTE] Ttv flywheel and 850r clutch best combo in my opinion.

Post 740622 by dionbullock on 2014-10-08 10:38:10

the 2.4td clutch kit is an easy upgrade for the lpt setup. Thats what ill be using in my 240 conversion

Post 740688 by smithy on 2014-10-08 14:18:34

[QUOTE=dionbullock;740622]the 2.4td clutch kit is an easy upgrade for the lpt setup. Thats what ill be using in my 240 conversion[/QUOTE] Yes but it is a 228mm clutch and dogfish flywheel .it all depends what power he is pushing and torque too .ive had both setups and killed the diesel clutch on the rollers lol.that was funny 300 bhp and good torque too .thats why I went for ttv flywheel and clutch .it all depends what setup he has .and future mods too .

Post 740700 by Ettienne on 2014-10-08 15:07:42

I may know someone breaking a r-98 940 turbo, he is doing an engine conversion. I'll post up if he goes ahead, sorry for hijack but peeps who would be interested are reading this. Oh just curious why has nobody fitted the audi 4.2 v8, it's a straight fit.

Post 740756 by dionbullock on 2014-10-08 19:16:10

[QUOTE=Ettienne;740700]I may know someone breaking a r-98 940 turbo, he is doing an engine conversion. I'll post up if he goes ahead, sorry for hijack but peeps who would be interested are reading this. Oh just curious why has nobody fitted the audi 4.2 v8, it's a straight fit. [/QUOTE] Do tell... Straight swap?

Post 740782 by smithy on 2014-10-08 19:42:24

They stick all kinds of v8s in 940 in the states .but in sweden mostly redblocks because they can get more power out of them and cheap to moddify too .

Post 740948 by dionbullock on 2014-10-09 09:46:50

[QUOTE=smithy;740782]They stick all kinds of v8s in 940 in the states .but in sweden mostly redblocks because they can get more power out of them and cheap to moddify too .[/QUOTE] Ah i was thinking into a 240, not much different i suppose? But like you say, same ish power from a turbo redblock with a lot less cost involved. only a lack of thumping v8 noise :(

Post 741348 by chazz.stockham on 2014-10-10 20:03:08

thank you for all your replies, Sorry for not replying sooner, i haven't been getting email updated as i should, excuse my ignorance but what is a Ttv flywheel and what vehicle would i try to source this from? and an 850r clutch is easy enough I'm guessing this takes 20 splines and is 240mm, so in theory i could use a upgraded clutch such as a black diamond stage 2, which is my intended clutch but would i but if i did do this would i buy it for the 940, 850 or to fit the Ttv flywheel or will they all be essentially the same? thanks again for the help, will try and keep you more updated with my work P.S. my goal is to in the end be aiming for around the 300hp mark as a daily driver as i do at the moment

Post 741380 by Jamest5r on 2014-10-10 21:38:19

Ttv is a.company that makes custom lightened fly wheels to suit, not that expensive.

Post 741406 by chazz.stockham on 2014-10-11 08:39:14

thanks again, i have had a look at there website and found what i think to be the rite flywheel http://ttvracing.com/product/volvo-b230-lite/?referrer=product-listing&iframe=true&width=80%&height=100%&type=flywheels&engine=volvo-b230&manufacturer=volcant see a price but have sent an enquiry form, looking at the details it takes (like standard) a 240mm clutch and is obviously 20 spline so in theory as long as i buy a clutch for a volvo with 20 spline 240mm it will fit, looking on a few websites prices range wildly even though they have the same splines and same diameter... surly one is the same as the next? or am i going overkill by looking at up-rated performance clutches baring in mind the hp i am ultimately amazing for and that its not going to be driven sensibly this is one of the best forums ive ever joined i really appreciate all the amazing help what a great community

Post 742606 by chazz.stockham on 2014-10-15 21:55:50

Ive had response from TTV and they have given me details of the flywheel i need to use the 850r clutch, Im told that i will 'need' to either space the pivot ball by 5mm or make a 20mm longer slave cylinder push rod, can anybody tell me how i would go about doing either of these, pictures would be very helpful, when looking for an 850r clutch provided its being sold to fit a 850r with 20 splines and a diameter of 240mm i should be fine correct? thanks in advance

Post 742620 by smithy on 2014-10-15 22:26:18

Best thing to do is extend the slave cylinder rod and even better make it adjustable .cut the rod in half and put a threaded bar in between the 2 ends .with 2 lock nuts

Post 742653 by chazz.stockham on 2014-10-16 07:19:40

excellent thank you, is this relatively easy or will there be any welding required to join the threaded rod, if you get time or have the facility to post a picture it would be much appreciated but if not no worried, the help has already been amazing, thanks again

Post 742784 by jks on 2014-10-16 17:13:11

I've got all the parts in the shed, il get pics for you..

Post 742955 by chazz.stockham on 2014-10-17 07:19:35

thanks a lot, really appreciate it cheers

Post 745004 by jks on 2014-10-27 21:50:37

Sorry, forgot to post pics of modified slave cylinder arm, here You go.. Sorry for crap phone pics, but it gives You idea..

Post 745423 by jks on 2014-10-29 16:30:53

Some of the stuff I've used, TTV flywheel with paddle, machined dogdish flywheel with 850R clutch, Depends what you after and how you drive it..

Post 745442 by Ettienne on 2014-10-29 17:34:28

Oh sorry yes apparently from what I've heard the audi lump meets straight up to the diesel box originally a vag box

Post 745572 by chazz.stockham on 2014-10-30 07:21:24

thanks all for your help, i should be picking my flywheel up this saturday from ttv, going for the m90 gearbox fitment flywheel that takes the 850r clutch, i'm really not keen to put a paddle clutch in, everyone i no that has had one or fitted one says there just awful for road use, i do intend to drive the car fairly hard but surly the 850r clutch should be quite a good match i should be putting my clutch and flywheel in on the 8th, will try and get on here and let you no how it goes, again, thanks for all the help

Post 745579 by jks on 2014-10-30 08:49:29

Good luck. Mine didn't take long to slip, but then Smithy's lasted years...car hasn't been on the road for year though..lol

Post 745614 by wiganer31 on 2014-10-30 14:35:14

good luck with this mate, i will be doing the same thing for about a 300hp setup in the next few week, although i will be using a dog dish flywheel because i already have one that was in my 360, let us know how you get on. i take it the 850r is the better of the standard clutches you can use? cheers

Post 745659 by chazz.stockham on 2014-10-30 22:08:45

just so i'm clear, by look of it, you took the rubber boot off that slave cylinder, unthreaded the standard pushrod and threaded in some threaded rod with an adjustable bit on the end, again cheers everyone

Post 746371 by jks on 2014-11-04 04:42:18

Cut the std rod in half, better to cut it towards fork end, so adjustable part will not rip the rubber boot at cylinder end. thread M6 bar in to it, with nuts to lock bar is place. fit and adjust to Your liking. If You need more pics, PM me Your email address and I'l take some.

Post 748550 by wiganer31 on 2014-11-19 12:46:48

sorry to jump in on someone elses thread but while everyones on about it and it saves another thread about this, dose anyone have the part number for for the best clutch setup to use with a dog dish flywheel+m90 box? i know it needs to be 20 splines and 228 mm? but what bearing should be used? i was looking at this on volvo forums, was going to go for option 2 but the part numbers dont seem to work and dosent say anything about the release bearing? copied from volvo forums "And there are two easy clutch options: (All parts are interchangeable between the two options) Option #1: Standard 940TDi clutch setup. Good for ~400NM. Clutch disc 940TDi, organic, 20 splines, 228mm, Sachs p/n: 1862 468 031 Pressure plate, stock, 228mm, Sachs p/n: 3082 204 033 Option #2: Custom clutch setup. Good for a little over 450NM. Clutch disc 850GLT, organic, 20 splines, 228mm, Sachs p/n: 1862 314 032 Pressure plate, strengthened/performance, 228mm, Sachs p/n: 3082 999 763 If you want even more clamping force, use the pressure plate I mentioned above together with one of the following clutches: Clutch disc 850GLT, organic race, 20 splines, 228mm, Sachs p/n: 1864 999 996 (Will hold a little over 510NM) Clutch disc 850GLT, sintered, 20 splines, 228mm, Sachs p/n: 1864 999 993 (Will hold a little over 580NM)" can anyone help please? sorry again for the hijack just got a little confused now and really need to order my clutch asap cheers

Post 748559 by smithy on 2014-11-19 14:26:50

It's a td clutch mate off the turbo intercooler diesel but the one fitted with the m90.what power u running

Post 748581 by chazz.stockham on 2014-11-19 17:28:31

I've now done this and when i did it i ran into the problem of release bearings, i used the cage from my old spent 940 release bearing and fitted it to the brand new 850R bearing making one good releasing bearing out of two, all you need is a small flat blade screwdriver, its easy, you just have to be careful not to over-stretch the metal straps on the cage of the release bearing when removing it. you will also defiantly make the pushrod 20mm longer, i tried my standard one just out of interest and it wouldn't completely disengage the clutch properly so i couldn't get it in gear, made a brand new adjustable pushrod and set it to exactly 20mm more than standard (100mm in total) and it works like a dream good luck, hope this helps

Post 748650 by wiganer31 on 2014-11-19 22:49:52

[QUOTE=smithy;748559]It's a td clutch mate off the turbo intercooler diesel but the one fitted with the m90.what power u running[/QUOTE] the clutch i need is a td one? i was gonna go for the stronger option because i dont wanna have to do the clutch again for a while, im aiming for about 300hp with a 16/19t and supporting mods, engines in bits atm while i do the head, timing belt kit, clutch/flywheel etc, will be put back together in the next few days but just need the clutch before it goes back in cheers

Post 748651 by wiganer31 on 2014-11-19 22:51:01

[QUOTE=chazz.stockham;748581]I've now done this and when i did it i ran into the problem of release bearings, i used the cage from my old spent 940 release bearing and fitted it to the brand new 850R bearing making one good releasing bearing out of two, all you need is a small flat blade screwdriver, its easy, you just have to be careful not to over-stretch the metal straps on the cage of the release bearing when removing it. you will also defiantly make the pushrod 20mm longer, i tried my standard one just out of interest and it wouldn't completely disengage the clutch properly so i couldn't get it in gear, made a brand new adjustable pushrod and set it to exactly 20mm more than standard (100mm in total) and it works like a dream good luck, hope this helps[/QUOTE] cheers mate that helps alot, so is the push rod threaded inside? cheers

Post 753295 by 7mgtesup on 2014-12-26 20:39:56

I run the TTV flywheel and 850R clutch combo, it started to slip after about 2000 miles. No Idea what power or torque but it seemed to happen after a couple of accidental 30psi spikes on my GT3082. Had been running at 20psi for about a year (2000 miles) good enough for 0-100 in 12 seconds so I'm guessing 300ish HP.

Post 753611 by reijo5 on 2014-12-28 20:05:29

hi how much are the ttv flywheels for the 850r clutch please ?

Post 755999 by pwalker on 2015-01-14 17:48:21

I enquires a bit ago I think they were something like £270-300. Hopefully getting one myself in the next month or two, does anyone know how much lighter the ttv flywheels are? I'd there much difference in Rev response?