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apeacock

Peacocks Wagon Build

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Getting closer and closer to putting in this m66. Flywheel was resurfaced this morning. Looks great, not a spec of rust on the whole thing! 

Clutch is on the way. 

Going to have to layout everything as connected as possible to see what small pieces I may still need.

Is there any way to see if I should replace my collar gear without getting it apart? I was thinking I could just order one from FCP and if It's not needed return it. 

20160216_174240.jpg

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Collar gear? Do you mean the spline coupler / collar?

You should definitely replace that if it is original. 

 

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8 hours ago, lookforjoe said:

Collar gear? Do you mean the spline coupler / collar?

You should definitely replace that if it is original. 

 

Yes that one, I believe it's original seems to function perfectly but I guess for the expense it might as well be replaced. 

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4 hours ago, apeacock said:

Yes that one, I believe it's original seems to function perfectly but I guess for the expense it might as well be replaced. 

Could get that upgraded one, and never have to worry about it again. Forget who is manufacturing it though.

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Just now, Tommy. said:

Could get that upgraded one, and never have to worry about it again. Forget who is manufacturing it though.

I believe PDV Motorsport and they were out of stock when I looked a few days ago. Correct me if I'm wrong but doesn't it serve as a wear point so the rest of the awd system avoids damage? 

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Just now, apeacock said:

I believe PDV Motorsport and they were out of stock when I looked a few days ago. Correct me if I'm wrong but doesn't it serve as a wear point so the rest of the awd system avoids damage? 

I would not know the answer to that question sorry... Yes that's them. It would make sense though with the physical strains being put on the AWD system that upgrading that could in turn put more stress on things that weren't meant to be stressed. Best to ask Andy or H I would say. I know Andy has it and I thought H had it before the XR demise.

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3 minutes ago, Tommy. said:

I would not know the answer to that question sorry... Yes that's them. It would make sense though with the physical strains being put on the AWD system that upgrading that could in turn put more stress on things that weren't meant to be stressed. Best to ask Andy or H I would say. I know Andy has it and I thought H had it before the XR demise.

I'll have to see what they say if they don't chime in here. Reminds me to double check the splines on the actual m66 I have sitting in the garage. 

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The collar gear / spline coupler is sort of a wear point. On paper it is much cheaper and easier to replace it rather than a gearbox / angle gear. For this reason it was made to be softer than the two splined shafts it connects. However early versions were made to of to soft metal resulting in premature failure of the part. Volvo did a bit of redesigning and made a better, i.e. harder, version. Which still wears like pretty much every drivetrain component does.

Now in case of any kind of collar gear failure one of two things will happen: Collar gear fails and needs to be replaced OR collar gear fails and damages other components. The second option seems to happen far more often than the first one. Makes sense as the collar will be spinning and "grinding" away at the splined shaft it no longer is securely connected to. Just wear on the collar gear alone can lead to damage to the gearbox / angle gear as the worn splines allow for movement that shouldn't happen.

PDV says they have made their part harder than Volvos redesigned part but less hard than the splined shafts. To me this seems like the most logical thing to do and something that Volvo should have done in the first place. I don't think that a harder collar gear places additional stress on the drivetrain. Should be fine to use it.

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5 hours ago, Blockpartie said:

The collar gear / spline coupler is sort of a wear point. On paper it is much cheaper and easier to replace it rather than a gearbox / angle gear. For this reason it was made to be softer than the two splined shafts it connects. However early versions were made to of to soft metal resulting in premature failure of the part. Volvo did a bit of redesigning and made a better, i.e. harder, version. Which still wears like pretty much every drivetrain component does.

Now in case of any kind of collar gear failure one of two things will happen: Collar gear fails and needs to be replaced OR collar gear fails and damages other components. The second option seems to happen far more often than the first one. Makes sense as the collar will be spinning and "grinding" away at the splined shaft it no longer is securely connected to. Just wear on the collar gear alone can lead to damage to the gearbox / angle gear as the worn splines allow for movement that shouldn't happen.

PDV says they have made their part harder than Volvos redesigned part but less hard than the splined shafts. To me this seems like the most logical thing to do and something that Volvo should have done in the first place. I don't think that a harder collar gear places additional stress on the drivetrain. Should be fine to use it.

Thanks! Now if they only had them in stock!

 

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Blockpartie covered it nicely.

I do have the PDV collar on my M66 AWD trans. Once you install that sucka it's NEVER coming off (in one piece). I personally have never seen the diff splines wear on an M66. I'm sure it's possible. I've seen auto trans diff splines wear though. Typically, the splines wear on the AG input shaft and in the collar. The splines become pointed instead of squared off -

This is what you want them to look like

x70AWDcomponents0010.jpg

This is what they usually look like on the AG side

x70AWDcomponents0009.jpg

 

Just get the new Volvo Number, you should be fine if the splines on the AG and M66 look like my first pic. 

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57 minutes ago, lookforjoe said:

Blockpartie covered it nicely.

I do have the PDV collar on my M66 AWD trans. Once you install that sucka it's NEVER coming off (in one piece). I personally have never seen the diff splines wear on an M66. I'm sure it's possible. I've seen auto trans diff splines wear though. Typically, the splines wear on the AG input shaft and in the collar. The splines become pointed instead of squared off -

This is what you want them to look like

This is what they usually look like on the AG side

Just get the new Volvo Number, you should be fine if the splines on the AG and M66 look like my first pic. 

Tanks a lot for the pictures! I'll pick up a kit before I take it all apart. 

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1 hour ago, lookforjoe said:

Blockpartie covered it nicely.

I do have the PDV collar on my M66 AWD trans. Once you install that sucka it's NEVER coming off (in one piece).

Just get the new Volvo Number, you should be fine if the splines on the AG and M66 look like my first pic. 

Just wanted to agree with Hussein here.  The PDV gear goes on tight, because it was manufactured for a tighter fit than the OEM gear to help reduce the chance of wear on the collar gear.  It took some serious effort to get it onto my M66.  I wish I could offer some more feedback on the actual gear itself, because my wagon has been FWD since before I M66 swapped my car :sad:

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Size difference on the OEM 850R clutch and the Sachs SD693 is really noticeable. 

LNXosptm.jpg

Full assembly looks awesome and with the very clean flywheel is basically all brand new. 

gLR8J9Mm.jpg

Finally had a break in the weather to get the R out from under the covers and install the do88 radiator. Performing the fan reposition at this stage as well, my room is cut short because the intercooler came with bent side wings. 
tYajzw8m.jpg
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kyYtq9um.jpg

Ran out of light before I could finish! 

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Not mine but good example of the way the wings get bent on the intercoolers, really makes the install a lot hard then it needs to be. 
pxJjdz7l.jpg
Had the space to tweak the Snabb rip kit so it fit a little better. I was getting a lot of rubbing in the bottom section. This was a kit from the pre order so maybe theve changed a bit since then. 
NBRWXpSl.jpg
Considering some sort of heat wrap on the intercooler pipe down there. 

Gratuitous Swede picture
l17AXGbl.jpg


Much stronger mounts with the all aluminum design. I had to cut a slice out of the fixed washer to bolt it up at all though. The offset on the intercooler and new raditor push the whole thing closer to the engine. 
ni6CTyUl.jpg

Rather then using the slide on grab tab style mounts I opted for washers and locking 10mm nuts. You can see the nut on the reflection. 
QQqpzjfl.jpg

 

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Nice!

Did you let DO88 know about the shipping damage? They obviously need to revise their packing since this is a recurring  issue

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