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sventastic

Sventastic's 850R Daily Driver Project

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On 12/18/2017 at 4:07 PM, RedCar850R said:

Wow, thanks for some much needed inspiration. Btw, I've been driving for a few years now with only one e-code headlight glass

I replaced one side shortly after getting the car and forgot all about it. Didn't realize they were different until the foggy weather just recently

E-code side was definitely worse in the fog. I may have to change out for a pair of DOT ones...

That's odd the e-code was worse! I'm liking the DOT glass more and more now that I have brand-new bulbs, the cut-off is pretty sharp, especially on the driver's side

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Washed and waxed it, then installed new corner lamps, new fan-type windshield washer nozzles, S70 roof trim, and replaced the broken headlight washer arms with ones from my parts S70, and hooked up the hoses which had been dangling unused since I got the car

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Edited by sventastic
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Back to stock height for the rest of the winter :( Goodbye decent handling, hello comfort.

This swap definitely pointed out that my strut bearings on my set of struts with the IPD springs are completely shot. Despite a perfect alignment the car always pulled left, and the steering had a huge dead spot in the centre and would always feel like it lagged behind my actually inputs. With the front suspension from my S70, it drives perfectly straight and the steering is tight now, very happy with that!

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Edited by sventastic
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Finally installed my boost gauge after having it sit around for nearly a year. I bought a 3D printed vent gauge pod from a Turbobricks member several months ago and the timing finally worked out to get it installed.

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Wiring (red and green wire seen on left) tied into the dimmer wire for the radio so it dims properly with the rest of the dash

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Tied into the existing rubber vacuum hose behind the gauge cluster with barbed fittings and a new hose to the boost gauge. 

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Drilled through the plastic HVAC duct to route the vac hose and wires and snapped the 3D printed vent gauge pod into place

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Success!

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Lit up at night, it isn't quite as bright as I'd like, but it's still easily visible with the dimmer around 50%, although it doesn't show up well in photos

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Edited by sventastic
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Haven't been driving too much lately, but it was time for some fresh 5W40 Castrol Titanium synthetic and it's now 5k from the 250k milestone

Got around to filming my boost gauge in Mexico on an 80-120kph 2nd gear pull. She chooches pretty good but boost is inconsistent between 7-9.5psi... 

 

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With the car off:

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Edited by sventastic
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M56 swap finally happened! Along with a basically new 16T, blue injectors, Vast Tuning R M4.4 manual tune, R clutch, release bearing, clutch fork ball seat, hydraulic engine mounts, rear main seal, rad hoses and expansion tank, heater core junction, turbo oil return gasket, silicone vacuum hoses, and 215/45 Firestone Indy 500 tires.

All the goodies
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The first bit of progress on a Friday after work
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Day 2 was spent in frustration trying to break the axle nuts loose. Ended up buying a 36" 3/4 drive breaker bar to take care of that, after breaking a 24" bar. 
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Day 3 saw some better results!

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Day 4 after work the shiny new turbs got installed

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Day 5
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Day 6

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Engine back in 1 week after removal!

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And then, in week 2 things slowed down a fair bit. The pedals I got seemed to be from an earlier model year which used a different brake light sensor and bracket, and the shifter ball seat turned out to be broken. With Mark's help, I got 1996 pedals and another shifter assembly later that week. Got the engine bay mostly sorted during that time

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Replaced the e-brake handle with one that didn't look and feel like garbage

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By the end of week 3 it was all back together, and (much to my surprise), it started up on the first try! Unfortunately the heater core junction was leaking like crazy, so I ordered a new one of those. 

Got the new tires and air filter installed while I waited for the junction

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Once the new junction was installed, everything was good to go and it was time to drive the shite out of it. I put over 2000km on it in the first two weeks! I barely drive that much in two months typically. Got the new tune and blue injectors installed after the first 800km. 

Happy. As. A. Clam.

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:biggrin:

 

Edited by sventastic
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Next plans for this car are to finish up the little things... In terms of the manual swap I still need to wire up the reverse lights, install the manual throttle cable, and I've delayed cruise control for now since I rarely use it anyways. Beyond that, I bought an entire set of seats and a dash that are all in fantastic shape. The e-brake needs adjustment since it barely holds the car on a slight incline. Antenna mast needs replacement since it's been stuck halfway up for a year and a half now. Might switch out the BCS for the TCV from my '98 S70 T5. I seem to have a coolant leak which needs more investigation - appears it may be the hose that goes from the expansion tank around towards the hard line at the rear of the engine where it splits to feed the turbo. The upper torque bushing is disintegrating so I'd like to get a poly replacement. Any recommendations for that? 

Cosmetically, the grille needs a repaint, and the whole car needs a solid clay/polish/wax and interior detail. I'm considering going somewhat aggressive on the polish to cut down to a new layer and help slow down the oxidation. With how infrequently I polish the car (hasn't been done since Feb 2017), I think I can afford to be a bit aggressive to remove scratches. I may also remove the pinstripes (and I'd really like to remove the stupid IPD SR5T decal on the back), but I'm worried they'll leave a deeper red line behind unless I polish deep enough to match. The alcantara on the new driver's seat needs a lot of work to remove the pilling. I'm running out of weekends before I need to head back to school, so I likely won't get to all of this, I'll have to prioritize! 

Edited by sventastic

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Nice work! The manual swap is such a huge project but worth it!

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6 hours ago, gmsgltr said:

Nice work! The manual swap is such a huge project but worth it!

Thanks, best thing I've ever done to the car by a long shot! It was pretty cool to have the engine out just sitting on a pallet to work on. Changing the rear main seal was a bit harrowing, but no leaks yet! All told, it was 4 weeks beginning to end, but thankfully I bike to work :)

The manual transmission brings such a giant change to the car's character, the 4 speed auto is an absolute dog in comparison with its asinine gear ratios. 8 years with that transmission was more than enough! 

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im not a fan of the m56h ratios that much either now that i've driven some newer slick 6speeds but i agree with you still - its the best mod for our cars (or the porsche bbk which is still my favorite)

bike to work everyday! man that is awesome. i dream of that for me someday!

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4 weeks isn't bad at all!

I've actually always thought the 4spd was a pretty decent transmission. Stomping the pedal at 25 or 50 was always brutal, and I'm still not good enough at driving manual to replicate how that felt. My one complaint with the m56 is how high it revs when coasting on the highway over 55, it makes me want another gear.

Question.... do you have any gear rattle?

 

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9 hours ago, gmsgltr said:

im not a fan of the m56h ratios that much either now that i've driven some newer slick 6speeds but i agree with you still - its the best mod for our cars (or the porsche bbk which is still my favorite)

bike to work everyday! man that is awesome. i dream of that for me someday!

Which ratios do you not agree with as much now? I think I'll be in the honeymoon phase for awhile with it...

Man those Porsche brakes must be amazing. That seems like a pretty epic upgrade. I love the look of your car, it's too nice and not fair haha. What suspension and intercooler are you running? Front-mount looks so mean. 

Yeah it's great! 10km each way and it's just as fast as driving due to traffic. This job is only for the summer though, back to school in the fall. 

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37 minutes ago, Brad850 said:

4 weeks isn't bad at all!

I've actually always thought the 4spd was a pretty decent transmission. Stomping the pedal at 25 or 50 was always brutal, and I'm still not good enough at driving manual to replicate how that felt. My one complaint with the m56 is how high it revs when coasting on the highway over 55, it makes me want another gear.

Question.... do you have any gear rattle?

 

Yeah it wasn't too bad looking back, but in the moment it felt like a long time (of course)... I just wanted to start driving it, hence why I skipped the reverse lights and throttle cable for now...:laugh: Including the turbo swap, seals, mounts, everything else I replaced, and everything I did two or three times like installing the shifter and pedals, it was roughly 75 hours of work. 

The 4 speed is pretty bulletproof and good for highway cruising, but I just hated first and second gear ratios so so much. Made it impossible to have fun around town. My 850R with the automatic was also a complete dog compared to my S70 T5 - stomping second gear was noticeably slower. That may have been down to boost leaks which I've now inadvertently fixed! I haven't noticed too much difference in rpm on the highway, maybe 200rpm? An rpm calculator says the AW42 should be at 2150rpm at 100km/h, and the M56 at 2350rpm

I'm not sure I know what you mean by gear rattle so I'd have to say no, I haven't noticed any rattles? I do notice a clacking noise when slowly going over big speedbumps in first gear, must be pressure plate/clutch/flywheel because it doesn't make the noise when the clutch pedal is depressed

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I think I know what you're experiencing with the low-speed clacking noise while in gear. I went from a dual-mass flywheel to single-mass (like you have) several years ago and started experiencing that. All mounts and bushings were/are fresh and tight, but could not eliminate it. Kind of like a "trailer-hitch" effect, is I believe how lookforjoe described it, with a metallic clink. I finally discovered that there is just a small amount of rotational slack in the axle itself. Not sure if it's where the splines meet the gearbox, or if it's internal in the m56h itself. Either way, it's not going away. My m56h was already rebuilt two years ago, so it's just a part of life. I believe in my case the dual-mass flywheel was absorbing that slack; it only became noticeable when I converted to a SMFW.

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On 7/14/2018 at 6:46 AM, washdup said:

I think I know what you're experiencing with the low-speed clacking noise while in gear. I went from a dual-mass flywheel to single-mass (like you have) several years ago and started experiencing that. All mounts and bushings were/are fresh and tight, but could not eliminate it. Kind of like a "trailer-hitch" effect, is I believe how lookforjoe described it, with a metallic clink. I finally discovered that there is just a small amount of rotational slack in the axle itself. Not sure if it's where the splines meet the gearbox, or if it's internal in the m56h itself. Either way, it's not going away. My m56h was already rebuilt two years ago, so it's just a part of life. I believe in my case the dual-mass flywheel was absorbing that slack; it only became noticeable when I converted to a SMFW.

Yeah I agree, must be some kind of slop in the drivetrain. The same noise can be created by tapping the clutch pedal at slower speeds to engage and disengage the drivetrain so it could be internal or within the diff/axle connections. To your point about the DMF to SMF - my M56H has an external slave which means it would have originally had a SMF, right? I don't believe the combination of external slave cylinder and SMF was ever available?

 

Something that has been a nuisance since finishing the swap is that my clutch engagement point is only 3-4" off the floor, it feels like about 1/4 of the pedal travel. Sometimes when starting the car cold, the engagement point is basically 1" off the floor until I pump the clutch pedal 5-10 times. When I bled the clutch, there were no air bubbles by the time I was done, but I'd assume these symptoms would point to the clutch not being bled properly? 

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