lookforjoe Posted February 14, 2008 Report Share Posted February 14, 2008 OK I'm starting a new thread here, as the old one in maint got a little side tracked & hard to follow clearly. I just bought the following to convert my '98 V70 AWD XC to stick: '04 S60R M66 AWD with everything (mount brackets, levers,) '04 S60R flywheel w/clutch '00 Pedal cluster '00 shifter assy w/ cables 00' clutch master (w/ lines if he can locate them) New Spline Coupler Trans & BG seals as much hardware as they can bag for me that is relevant. T5M ECU is also needed, or a Manual tune from ARD/IPD/WothRLine, or TurboTunerUSB. OR use TunerPro Many, many thanks to 9480tx for the link to the reseller! That was about all I could come up with looking at the parts breakdowns, so the plan is to keep the AWD. I've bookmarked Mat B's excellent thread on FWD conversion, and I'm assuming much of the wiring issues will be the same - but I don't know about the CPS & tach sensors.... Anyone with direct experience or knowledge of issues that may come up, please LMK! EDIT: Just read through Project 6 that's one heck of an car! -many useful bits in there - but still need to know about any engine management issues... EDIT: NO issues with Bevel Gear / Rear diff ratios. As long as you use whatever existing AWD components are on your car as is, it's all good. Been driving it now for 7 years with no issues (that weren't my doing). EDIT: has pics of the casing mod to make subsequent left axle removal easier EDIT: wiring for '98 may differ from 850 - this what I noted from my conversion: For Reverse Use Pin 9 (Blue-Green +) & Pin 5 (Blue - feed to lights). There is more than one solid blue wire! Neutral Safety is the same, Blue & Blue -Yellow are bridged. For cruise control, remove Cruise Relay & snap off pin T3. Air Box inlet tube has to be 'dimpled" on the underside to clear shifter mechanism. EDIT: Auto AWD axles works fine, I have Manual M59 axles in mine, heavier duty outer axle shafts. 11/13 EDIT: Updated info at end of thread regarding trans mount, heim shifter bushings & filling trans. 05/10/14 EDIT: For Single Mass Flywheel conversions, you can use the Sachs SD693 disc (87-92 Ford Probe) with the 850 PP & flywheel (>see this thread for reference) 11/14 EDIT: Note: AWD requires Custom Trans Mount Bracket (use 9161101 rubber mount). Contact me if you want me to make you one Note: Modify shifter cable bracket on trans for 850 or 98-00 style cables. Not necessary if using C30/40/50 version shifter & trans. 9454743 Flywheel bolts for SMF x 10 9454744 Flywheel Bolts for DMF x 10 986321 PP hex head bolt x 6 Refer to Johann's thread for cable attachment pins & simple M66 cable bracket mod >post #1368 >Post #1371 10/14 Quote Link to comment Share on other sites More sharing options...
Big Will Posted February 15, 2008 Report Share Posted February 15, 2008 The username of the guy you're looking for is "Seamus" not Seagram. ;-) Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted February 15, 2008 Author Report Share Posted February 15, 2008 (Big Will @ Feb 15 2008, 12:56 PM) The username of the guy you're looking for is "Seamus" not Seagram. Ahhhhh... I'll PM him then I have found from 94850tx that there may be gear ratio issues - unfortunately Vadis has no info for '04 - but Car&drivers review of the '04 S60R listes the following specs.. Transmission: 6-speed manual Final-drive ratio: 3.77:1, electronic limited slip Gear ... Ratio ... Mph/1000 rpm ... Max. test speed I ... 3.38 ... 5.5 ... 36 mph (6500 rpm) II ... 2.05 ... 9.1 ... 59 mph (6500 rpm) III ... 1.43 ... 13.1 ... 85 mph (6500 rpm) IV ... 1.09 ... 17.1 ... 111 mph (6500 rpm) V ... 0.87 ... 21.5 ... 140 mph (6500 rpm) VI ... 0.70 ... 26.7 ... 148 mph (5550 rpm) ...which is a problem since my rear is 2.56:1 EDIT - rear & BG are 3.31:1 The 2002 Volvo S60 new car features manual list the AWD AOC cars as having 2.56:1 - which would be lovely if it's true.... Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted February 19, 2008 Author Report Share Posted February 19, 2008 (edited) Well, the S60R AWD has a 3.77:1 FDR I'll need a new Ring & Pinion for my rear which is curently 2.56:1, and the S60R angle drive to make this work. Anyone have any leads on shops that can make custom sets? There's no AWD x70 98-00 (stick or auto, same ring&pinion set) that uses anything other than 2.56:1 according to Vadis. I can't use the rear from a S60R - it's the newer AOC setup. Edited March 11, 2014 by lookforjoe Quote Link to comment Share on other sites More sharing options...
Big Will Posted February 19, 2008 Report Share Posted February 19, 2008 Ahh wow very interesting. So the rear differential is turning out to be a problem with using the M66 is that what you're saying? The rear diff's final drive ratio is 2.56:1 ? Maybe look to the 940. I know they used a similar rear diff as the 98-00 AWD cars. I have no idea what the ratio is but maybe it's closer to what you're looking for?WWSD? "What would Seamus do?" Quote Link to comment Share on other sites More sharing options...
socal850tuner Posted February 19, 2008 Report Share Posted February 19, 2008 I would actually contact a off-road or rock crawler shop. They know there stuff about 4wd and might be able to help find you some compatible gears. Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted February 20, 2008 Author Report Share Posted February 20, 2008 So far what I've come up with is that all the multilink RWD models (760/780/960) had a 3.73:1 rear R&P in a variety of applications - but that doesn't help.I'm going to give a call & see if they can help.... Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted February 21, 2008 Author Report Share Posted February 21, 2008 Great news! I spoke to Seamus - a most helpful guy - and he clarified several points, not the least of which is that the M66 AWD trans works just fine with the stock AWD angle gear & rear diff - there is no need to replace any of those components. His has 40K on it since the swap with no issues. pic of the l/s rear fabricated mount bracket, that allows the use of the existing mount: First mockup revised final design He also confirmed that the stock driveshafts will work, although it would be better to get a r/s Manual AWD driveshaft - so I'll be tracking one of those down.. Like Matt B, he says the stick ECU is a must. Other tidbits include the need to modify the underside of the airbox inlet & duct hose to clear the M66 linkage, and the need for higher temp brake fluid as a result of the internal slave cylinder. If all goes well, I'll have all the parts in the next week or so, then I can get set to put it all together Quote Link to comment Share on other sites More sharing options...
Y2kV70R Posted February 22, 2008 Report Share Posted February 22, 2008 You have me on the edge of my seat..... My '00 R is screaming for a six speed. If you don't mind me asking what kind of $$ are we talking? Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted February 23, 2008 Author Report Share Posted February 23, 2008 (edited) You have me on the edge of my seat..... My '00 R is screaming for a six speed. If you don't mind me asking what kind of $$ are we talking?1650 in used parts - another 320 wholesale for the Volvo S60R clutch kit & new output & angle drive seals..I do all the work myself, so I have no idea what a shop would charge, but I'd have to estimate well over a thousand in labor.I'm putting it in tomorrow - so I'll post back - I'll try to (photo) document at least the important aspects of the install... Edited February 23, 2008 by lookforjoe Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted February 26, 2008 Author Report Share Posted February 26, 2008 The trans is in - had a few glitches with the shifter cable brackets - one cable popped out last night when I was parking - had to get it back in on the street; and getting the clutch bled. It is a nice setup, pulls very nicely, can't wait to get the proper remap for the manual/16t. At 70 mph, it runs @ 2600 rpm. I haven't had it over 110 yet, I still need the fabricate the left rear mount bracket- the trans is sitting on a rubber block against the frame until I can get back to it tomorrow afternoon.I also need to replace the handbrake cables & shoes - ran out of time As Seamus had said, the AWD functions perfectly.I'll post a few pics later for anyone interested. Quote Link to comment Share on other sites More sharing options...
Big Will Posted February 26, 2008 Report Share Posted February 26, 2008 (edited) Hey Congrats on getting it up and running!The M66 in my S40 runs about 3000 rpm at 80 mph in 6th gear so 2600 at 70 seems about right. Which shifter did you use? One from an R or from an S40? (Not a big fan of the moonball from the R personally).Did you change out the angle gear oil while you were under there and had things taken apart? Edited February 26, 2008 by Big Will Quote Link to comment Share on other sites More sharing options...
Mogatu'r Posted February 26, 2008 Report Share Posted February 26, 2008 big man. Just throw a Manual ECU and you're set, unlike the 99+, I wish mine was that easy :( Quote Link to comment Share on other sites More sharing options...
NEU Posted February 26, 2008 Report Share Posted February 26, 2008 I'll post a few pics later for anyone interested.Hells Yeah!!! Let us see what you did... Did your GI Joes help with the install? :lol: Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted February 26, 2008 Author Report Share Posted February 26, 2008 Hells Yeah!!! Let us see what you did... Did your GI Joes help with the install? No Joes this time - I just didn't have enough time to play around on this job. :( Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.