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2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" platform cars.

2001 - 2007 V70
2004 - 2007 V70 R
2001 - 2007 XC-70
2001 - 2009 S60
2003 - 2007 S60 R

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RickHaleParker
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Fri Jul 10, 2020 12:58 pm

Not getting any definite answers on the number of spines and diameter. Looking like my only option is to shorten the XC90 shaft and fit a S60 outer CV joint on it.
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Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

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volvolugnut
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by volvolugnut » Wed Jul 15, 2020 4:51 pm

Do you have plan for shortening the axle? One method I would consider is cutting a section in the middle and having it inertia welded. If properly done, it is high strength.

volvolugnut
2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Wed Jul 15, 2020 5:22 pm

volvolugnut wrote:
Wed Jul 15, 2020 4:51 pm
Do you have plan for shortening the axle? One method I would consider is cutting a section in the middle and having it inertia welded. If properly done, it is high strength.
I doubt I could find a small machine shop to do a inertia weld.

Found a small welding / machine shop yesterday. They will not do welds on an axle but they can cut splines. Today I stripped the XC90 axle to the bare shaft. Tomorrow I'll take the bare shaft to the machine shop and see if they will cut it down and cut new splines.

Did figure out why I need to do this. On the XC90 4.4 Volvo changed the left inside splines size midyear 2007. If the donor 2007 XC90 had a lower chassis number the 2006-2007 S60R/V70R axles would of snapped right in. Midyear changes is the one thing Volvo is infamous for. They never did a P2 S60/V70 axle with the larger splines.
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

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volvolugnut
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volvolugnut

Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by volvolugnut » Wed Jul 15, 2020 6:42 pm

RickHaleParker wrote:
Wed Jul 15, 2020 5:22 pm

Found a small welding / machine shop yesterday. They will not do welds on an axle but they can cut splines.
That was my next idea. The inertia weld would need to be a specialty shop. I hope they can identify the spline dimensions from reverse engineering. Splines can be tricky things. I do miss working with large machine shops.

volvolugnut
2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

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RickHaleParker
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Wed Jul 15, 2020 7:05 pm

volvolugnut wrote:
Wed Jul 15, 2020 6:42 pm
I hope they can identify the spline dimensions from reverse engineering. Splines can be tricky things. I do miss working with large machine shops.
I checked the splines from the S60 outer CV against the XC90 outer CV. Internal: Same number, same diameter but slight different spline geometry. Think I will disassembly the XC90 outer CV and see if the internal hardware will transfer to the S60CV's outer case. That way I will be presenting them with only one geometry.

If the internal CV hardware will not transfer. I will need to have them transfer the spline geometry.
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

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volvolugnut
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by volvolugnut » Wed Jul 15, 2020 7:28 pm

Do you think it would be wise after they believe they have the spline identified to have a trial spline cut on a scrap bar and test fitted to the mating part? Do not want to find it does not fit and you need to buy another axle.

volvolugnut
2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

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RickHaleParker
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Wed Jul 15, 2020 10:10 pm

volvolugnut wrote:
Wed Jul 15, 2020 7:28 pm
Do you think it would be wise after they believe they have the spline identified to have a trial spline cut on a scrap bar and test fitted to the mating part? Do not want to find it does not fit and you need to buy another axle.
I'm going to leave that to the machinist. I will take the inner rings so he can test fit.

I can get the S60 inner ring started on the XC90 shaft but it is too tight. It takes a lot of force to get it started. Then again it is the same for the XC90 inner ring on the XC90 shaft. You are suppose be able to tap them on. I could be mistaking about the geometry. It could be that the splines need a good cleaning and polish.

There is another XC90 axle at the local PnP for $26.00 but it is the only one there.
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

User avatar
RickHaleParker
Posts: 4535
Joined: Mon May 25, 2015 2:30 pm
Year and Model: See Signature below.
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Thu Jul 16, 2020 4:32 pm

Took the shaft to the welding / machine shop and they referred me to another machine shop that was better equipped for cutting splines.

The second shop said they could do it but I was looking at 4 - 5 hours of labor at $85.00 per hour, $340 - $425. They ask me to leave it overnight. They are going to try to find a more cost effective solution. I doubt they will but I am going to let them try because I know the more one studies a problem the better the execution of the solution. The doubt is out of the way.

I could tell he was thinking shorten the slider near the other end. The slider compensates for the change in length when the suspension deflects. I not sure shortening the ability to change length is a good idea. The question is: for a given maximum deflection does the maximum change in length increase or decrease as the minimum length of the axle decreases.

In other words: with a opposite side of a right triangle being a constant, does the absolute difference in length between the hypotenuse and the adjacent increase or decrease and the adjacent decreases?
Last edited by RickHaleParker on Thu Jul 16, 2020 5:31 pm, edited 1 time in total.
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

User avatar
RickHaleParker
Posts: 4535
Joined: Mon May 25, 2015 2:30 pm
Year and Model: See Signature below.
Location: Kansas
Has thanked: 3 times
Been thanked: 579 times
United States of America
RickHaleParker

Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Thu Jul 16, 2020 5:17 pm

I always figured out the complicated first then the simple. Measure the slide travel on both shafts. If the difference is 1.5" or more we can cut from the slider rather then a end.
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

User avatar
volvolugnut
Posts: 882
Joined: Sun Jan 19, 2014 9:51 am
Year and Model: 2001 V70
Location: Midsouth USA
Has thanked: 51 times
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United States of America
volvolugnut

Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by volvolugnut » Thu Jul 16, 2020 6:47 pm

There must not be much difference in length to remove.

volvolugnut
2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

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