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

[RickHaleParker]

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.

[volvolugnut]

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

[RickHaleParker]

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.

[volvolugnut]

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

[RickHaleParker]

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.

[volvolugnut]

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

[RickHaleParker]

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.

[RickHaleParker]

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?

[RickHaleParker]

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.

[volvolugnut]

There must not be much difference in length to remove.

volvolugnut