White 940 2.5TDI wagon

[DET17]

I know that VW knows how to build the small diesels..... while they are nearly everywhere in Europa, we don't see them that much in the States.

OK, sounds like your modern 2.5TDI will "bolt right up" to the M90.... I thought the diesel engines that Volvo used in RWD vehicles had a custom bell housing pattern; I didn't realize they copied the original Volvo petrol engine pattern. Very interesting!

Good luck with the final drive axle assembly.... sounds like a solid choice using a proven professional source. That work is tricky all around.... I've done several of them and it is definitely an iterative procedure to get the R&P pattern just right whilst also establishing pre-load on the carrier bearings. One needs special tools, a press for carrier bearings/shims "on and off and on and off" to get things right.

I'll be following your progress on your diesel Vaggen..... I think my German friends called them a KOMBI.

 

[petiww]

I know that VW knows how to build the small diesels..... while they are nearly everywhere in Europa, we don't see them that much in the States.

OK, sounds like your modern 2.5TDI will "bolt right up" to the M90.... I thought the diesel engines that Volvo used in RWD vehicles had a custom bell housing pattern; I didn't realize they copied the original Volvo petrol engine pattern. Very interesting!

Good luck with the final drive axle assembly.... sounds like a solid choice using a proven professional source. That work is tricky all around.... I've done several of them and it is definitely an iterative procedure to get the R&P pattern just right whilst also establishing pre-load on the carrier bearings. One needs special tools, a press for carrier bearings/shims "on and off and on and off" to get things right.

I'll be following your progress on your diesel Vaggen..... I think my German friends called them a KOMBI.

To be honest I don't get it why little diesel economical cars were not pushed in the States. Have you heard about the Lupo 3L?

About the bellhousings, your previous assumption is correct that diesel RWDs have a custom bellhousing pattern, different than the redblock or whiteblock. It is the Audi/VW earlier 5/6cylinder petrol and diesel engine bellhousing. The 2.5TDI uses this too. Thats why the diesel M90 is rare aswell. I have a little secret desire to put an Audi S2 engine into a Volvo.

If i had the time and plans to do more than just one r&p install, I'd actually invest in the tooling and would gladly learn it too. The real tricky ones are the FWD Audi gearboxes!

Kombi haha, well, we also use this word for cars like this.

 

[petiww]

Hooray, after almost a year, the 740 Dana 30 axle got the 3,08 ring&pinion

Ratio install was not as straightforward as it seemed:
- Pinion is not a crush sleeve type
- Volvo metric flange nut did not fit as this has an imperial thread
- Differential carrier break is no joke - Volvo only used the 3,73&up design in all the factory axles. 1031 uses this exact carrier all the way down to 3,31, if i'm not mistaken. Well, this r&p being a true Dana30 3,08, it uses the 3,54&down design, which design in fact offsets the ring gear to the left about ~3,5mm. This meant the carrier had to be turned to shift it to the left. 2mm was removed.

Carrier_on_lathe by Péter Gede, on Flickr

Fortunately there is still no clearance issue here:
Clearance2 by Péter Gede, on Flickr

And the set up, finished art. I'm really glad i let a professional do the job:
Dana30_3,08_Installed by Péter Gede, on Flickr

Now i only need some time to test fit the halfshafts (hopefully no modification needed on the left side), set the speed sensor depth, seal the axle up and install. Can't wait to break it in!

 

[DET17]

Now that's some determination to get a 3.08 final ratio into a 740! Well done, your pro clearly knows what he's doing.

The lowest (numerically) ratio I've heard of in the States would have been used in the diesel 7 series..... and those are fairly rare here! Our best chance for a "desert gear" here is to find an early 960 which has something near the 3.31 I believe.