M66D and focus RS MK2 revo knuckle swap

[MetalmanC30RS]

this is left field and I've run the searches out.  Always admired the RS MK2, discovered they are basically a c30 with a different suspension, fell into an RS MK2 front suspension to swap (sounds crazy, but after research can confirm it's actually a bolt in swap...).  Found out along the way it requires an unobtainium quaife diff swap as well because the RS axles are required for the new geometry and the splines are HUGE and the quaife is the only thing off the shelf that fits, but quaife only supplied to ford and sold out after the initial batch.  Lucked out getting a diff, inside a complete RS sourced M66 with a cracked case from being dropped.

SO, the question.

Ive been looking for an M66 to rebuild and swap the case from, found a deal on an M66D from a d5, but it's a 2014, car is a 2011, think RS trans is an 09

1.  Can anyone confirm what changed with the newer m66 because the parts searches say there was a vin cutoff and my 2011 c30 was apparently on the earlier side of it, because the RS is cracked I would need the 2014 m66d case to be compatible.

2.  I don't know what the ratios on the RS M66 are, I like the m66d tall 6th for the highway and have always felt the c30 ratios were silly tight, but does anyone know if I will have issues with the swapping the final drive ratio between cases or gear sets?  I'm not sure if I will have issues with the diff/carrier and the different ratios, seems like it's not a big deal but I never hear of anyone doing much inside the transmissions.

3.  Anyone have a good source for rebuild kits?

[lookforjoe]

How far did you get with this?

If you swap FD for a different ratio (ring gear) then the mainshaft  has to go with it. Never heard of vin cutoffs for M66 (FWD?) - was that searching in the Volvo catalog? Any specifics?

You can swap entire gear sets & shafts - ppl have put AWD sets in FWD cases, and vice-versa. I kept the AWD M66 gear set when I did my C30 AWD conversion, 6th becomes a great (higher speed) highway cruising gear. Why do you need the Diesel casing? Because the price is right, or that's all you can locate? Vandsautodismantlers has had the best pricing here in the US.

 There are no rebuild kits per se - you can get seals & bearings based on the number/markings on the bearings easily enough. There is a site that offers 'kits' for $$$$ (search on Swedespeed, it's linked in the R 2004 Forum - unless you have broken synchos, I'd just do seals & be done.