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

[RickHaleParker]

There must not be much difference in length to remove.

Using the wheel track width of a XC90 64.3" and the wheel track width of a S60 61.5", (64.3" - 61.5") / 2 = 1.4". Can we take the 1.4" from the slider? The length changes as the wheel goes up and down.

[volvolugnut]

What is the full stroke length of the shock? I would assume about 2/3 of total shock stroke is possible from static position with weight on the wheel.
How much is the slider travel?
This does not look promising to work out with 1.4 inches needed.
Answer these questions and I can do the trigonometry calculation (I think I still can).
volvolugnut

[RickHaleParker]

Answer these questions and I can do the trigonometry calculation (I think I still can).

I can do the trigonometry if I have the data but don't need to now.
Gave the machine shop:
1. A disassembled XC90 Axle.
2. A assembled XC90 Axle.
3. A assembled S60 axle.

They will take the two assembled axles compress them and measure the minimum length on both. The difference between the two is what they will take off the disassembled XC90 Axle. This will ensure the adjacent side of the right angle is not too long. They will cut from the end not the slider, then cut new splines.

[volvolugnut]

This plan sounds good. Keep plugging holes and the project moving forward. I will be watching for updates.
volvolugnut

[RickHaleParker]

This plan sounds good. Keep plugging holes and the project moving forward. I will be watching for updates.
volvolugnut

I did figure out how to calculate everything I was wanting to know from four measurements.

Axle 1 maximum length, minimum length.
Axle 2 maximum length, minimum length.

[RickHaleParker]

I will be watching for updates.

Got the axle back today. The machine shop said the spines are not as tight as they would like. It fits, no slack or slop but it slides on you don't need to tap it on when the spring clip is not installed. My guess is: the Machinist did not take thermal expansion in to account when he was grinding the splines.

Got to wait for some new CV band clamps to come in before I can reassemble it. Per VIDA, the inner CV is suppose to be unserviceable. You cannot buy a new inner boot. I went through a bunch of CV boots trying to find a 95mm large end and 50mm small end ... nothing. Glad I did not cut the boot off. Same story with the clamps. Could not 95mm & 50 mm clamps. Order some universals, the smalls cover 20mm-50mm and the large cover 50-120mm.

Got the XC90 Air box cut down so it fits. Need to order some sheets of ABS plastic to re-plate the bottom of the Air box.

Got the radiator fans installed. Cannot use the S60 fan control module it is pretty much integrated to the fan motor. It controls six windings. Hoping I can use a simple fan relay instead.

[bmdubya1198]

Should have no problem running a standard fan control. It should be perfectly capable of cooling, just might have some codes in VIDA.

[RickHaleParker]

Should have no problem running a standard fan control. It should be perfectly capable of cooling, just might have some codes in VIDA.

Ah shoot! The control signal for the Fan Control Module is Pulse Width Modulation (PWM) not voltage controlled. A Electromechanical relay is out of the equation.

It looks like the twin fan FCM from a S60, V70 or S80 will work. It uses the same signal from the ECM and it is setup to control two fans rather them one big one. I can buy a aftermarket unit for $20.00.

[RickHaleParker]

Modified AC lines.

Modified radiator fans..

Modified Air box.

Modified drive shaft.

[volvolugnut]

This project keeps moving forward!

volvolugnut