ClubVolvo Exclusive! Broken M46!

[916volvosport]

hahaha.. it's 3rd gear.. check it out..

http://members.aol.com/juzuni/m46a.jpg

http://members.aol.com/juzuni/m46b.jpg

http://members.aol.com/juzuni/m46c.jpg

ouch!

yes, that's my tranny. that's my 3rd gear. here's what i got:

81 242t
completely rebuilt b21ft (all new, .020 overbore, polished crank, t-cam)
junkyard intercooler kit
late model intake and exhaust manifold
mitsu td04h-13c turbo @ 12.5 psi
2.5" exhaust (magnaflow muffler)
91 octane gas
new bushings all around
28mm front sway bar :D / 25mm rear sway bar
stock rims w/ 205 55 15 dunlop sp5000b
m46 tranny
centerforce dual friction clutch setup (modified pressure plate, dual fiction clutch disc, shaved early flywheel)
uniden radar detector
jvc el-cameleon kd-lx3
jbl 4" component fronts
two 10" subs in custom bandpass box in rear trunk shelf

stuff to do:
seal rear deck (to seal trunk)
convert to late model p/s and a/c (i have the parts off a '91 245)

plans:
getrag 265 tranny w/ custom adapter to m46 bellhousing (yes, there's more to it)
t-5 turbo mated to late exhaust mani
10 gallon fuel cell in trunk for race gas hooked up to -->
haltech f-5 aic controlled by injectors on volvo fuel rail w/ aftermartket injectors (i have the haltech already)
lsd
gm 100 amp alternator

-patrick gallaher / sac, cali

[Hank Scorpio]

HOLY SHI* PAT!!

Just got back in town! love it, guess you really did take 3rd out pretty well!

ROFL

[916volvosport]

Originally posted by EgS60racer
HOLY SHI* PAT!!

Just got back in town! love it, guess you really did take 3rd out pretty well!

ROFL

i wonder who's next (besides me!).. and nobody better gank my pictures.. damnit.. those are original!!

[dl242gt]

Hi Pat,
About 3 years ago I blew up third gear in my 84 242ti. I was downshifing to third for an on ramp to the interstate. I downshifted
and heard a horrible crunch. Then nothing in third. It was like I had neutral for third. I drove home just fine though. I still had 1,2,4 and
even OD. They are tough even blown up. I bought a junkyard trans for $150. It even had a working OD. The car has been great ever since.

Dave 82 242ti 278k mi., 84 242ti 172k mi.

[wills]

My manual tranny days are over. So far the autos are in the six digits with no problems

[916volvosport]

Originally posted by wills
My manual tranny days are over. So far the autos are in the six digits with no problems

:apoke: take that.. who said it's about mileage? come on now. manual trannies aren't that hard to swap out.

[dl242gt]

I only drive manual Volvos. The manual transmissions are tough and long lasting. The automatics are fine. Just not OK for me to
drive. I do all my own work at home and prefer to shift. If Volvo
brings the newer cars over with a manual trans and all wheel
drive like they are supposed to with the S60R I'd be interested
in checking one out. But I'm staying with my old cars for the near
future. Thankfully, they have kept their turbos on the market.
Boost is fun.

Dave 82 242ti 278k mi., 84 242ti 172k mi. and others

[Hank Scorpio]

You can get 5spd t5 s60's right now, though they aren't awd.

[dl242gt]

Yeah,
Those 5spd T5 models sound nice. I'm just not the new car buying kind of person. I have too many other project cars that I prefer to put my money into. Actually, if I was really into the new car market I'd probably seriously consider a WRX. I do try to keep up with what's new, I've just never been into buying.

Did you get those damn freeze plugs to stop coming out?

Dave 82 242ti 278k mi.

[Hank Scorpio]

Sure did! Popped em all back out, got new ones, put sealer on them, drove em till they were flat or just a bit more convex, then jbwelded over them!

They are sticking now!

[dl242gt]

That's good to hear.
Those damn things were really a pain. I saw your post about your
car shutting down on you. It may be the fuel pump relay. If there is anything I can help with like info let me know. I drive the same year 2 dr. turbo. Happy rolling!

Dave 82 242ti 278k mi.

[300+]

Wills,

Be careful... mine went out at 146,000...oh yeah about 110 racing a Vette.

[Hank Scorpio]

Originally posted by dlot
That's good to hear.
Those damn things were really a pain. I saw your post about your
car shutting down on you. It may be the fuel pump relay. If there is anything I can help with like info let me know. I drive the same year 2 dr. turbo. Happy rolling!

Dave 82 242ti 278k mi.

ya, thats exactly what I'm thinking. Almost 99 percent sure thats what it is, too bad it didn't do it early enough in the week to get a new one here. Guess, I could go to a dealer though :(

Ya, they are the biggest pita ever! Think the next one I do, I'll just throw the entire block up on the press and use a press to really get them in there nice and flat!

Got any pics of your 242? We should start the "Turbo Comando Bumpers" Club! lol

[dl242gt]

I do love the commando bumpers. However, I like the idea of saving 35lbs off my car even better. Eventually I'll be changing my
car over to the newer bumpers. It's weight off the ends of the car
for better handling. Try resoldering the relay. You can pull it apart
and check it for cracks in the solder. Many times just soldering the relay will fix it. Although over the years I have had wierd ones that just croak. Ever closer. You just have to take it one step at a time. I'm refurbishing a 82 245T for a friend and as we goto each step of bringing the car back we find more to do. But we are close to having it on the road. Well, time to go do some Volvo stuff.


Dave 82 242ti 278k mi.

PS I have a couple of pics that I put in the picture thread. Check it out. It's from a couple of years ago but they look pretty good.
Would have nice to have better scenery.

[wills]

Wills,Be careful... mine went out at 146,000...oh yeah about 110 racing a Vette.


Looks like I have plenty of time, only have 50K on R car. Also change ATF yearly with synthetic.

[Hank Scorpio]

Dave, exactly what I was thinking. Course, if I have traction problems, that extra 30 pounds hanging out over the tail wouldn't be so bad?! :)

I'm trying to get off my arse and head down there right now and get started on fixing it. Hopefully I can get something done today!

Doug

[dl242gt]

Hey Wills,
There's a guy in South NJ who has a worked 850R. The thing is a monster. I believe he has an auto tranny worked over by this place called Stand 10 or something. He claimed to run 22psi boost
and said he makes 400hp on a dyno. His name is Emile Gontowsky. There used to be a web page from him but I haven't checked in quite a while. I'm sure with yours running synthetics you'll get a good life out of it. I understand they are GM manufactured trannys. Happy rolling.

Dave 82 242ti 278k mi.

[Hank Scorpio]

Level 10 perhaps? I think thats the name, they make automatic upgrades for just about everything out there!

[300+]

It's actually a Toyota transmission.

If you want 400 hp... I can do that too. Bring a gunny sack of twentys and give me about 3 months.

We'll start of with a set of Carillo rods and maybe a billet crank. Then we can make some hp!

[300+]

By the way Doug go with the plastic bumpers and put a bag of sand in the trunk...

[Hank Scorpio]

Originally posted by 300+
It's actually a Toyota transmission.

If you want 400 hp... I can do that too. Bring a gunny sack of twentys and give me about 3 months.

We'll start of with a set of Carillo rods and maybe a billet crank. Then we can make some hp!

lol, I know I used to do that with my old firebird. Was mostly looking for an excuse to be lazy

:embarrasm

[300+]

Here is a picture of my 240 converted from the heavy aluminum bumpers to the plastic bumper. I removed the 5 mph shocks and made a bracket that moved the bumper about 1" closer to the car. if you'll notice there is no trim moulding. I wiped the bumper clean and you couldn't see it so I am using the picture with it dirty. The car has been in my shop for about 2 1/2 years now and it's time to get a move on it. I have been collecting parts for it and I have just about everything I need to get it on the road again. When I get the area around it cleaned I will get some more pictures.

[300+]

Notice too, no emblems, no lock...

[Hank Scorpio]

Ya, the shock absorbers are why I haven't switched bumpers yet! Couldn't figure out for a while how to get em out! I do like the way that looks though w/ out the molding!

Doug

[dl242gt]

Thanks for the info guys. I didn't know it was a toyota tranny. That's actually even better than GM. I understand the AW70 and AW71 trannies were toyota also.

That's a very nice clean look with the bumper closer to the body. Probably saves another 10lbs without the bumper shocks. I'm going to go with the bumpers but I want to keep the shocks. I want just that bit of safety. 300+ how did you setup the side supports for the side extensions on the bumper?

My next mod is to install a cam and install the LH style intake. I just installed the 3 inch MVP exhaust. I bought one of the last ones. It really added a lot of power over the whole rpm range of the motor. Very impressive. Sure sits low under my car though. Also going to add the terminal 11 trick. I got one of the Saab adjustable overboost switches. For an original motor with 278k mi. that's about as far as I want to take it. It should last awhile longer. I want to see how long it'll last making that much more power.

Dave 82 242ti 278k mi.

[Hank Scorpio]

Love the exhaust dontcha? Mine does hang a little low though, think I can get it shoved up a bit higher though.

Doug

[300+]

I am thinking of maybe exiting the exhaust on the right just in front of the tire. Maybe modify the floor so it has more ground clearance...nyuk nyuk nyuk.

[Hank Scorpio]

Originally posted by 300+
I am thinking of maybe exiting the exhaust on the right just in front of the tire. Maybe modify the floor so it has more ground clearance...nyuk nyuk nyuk.

LOL, I would love to see that!

Doug

[dl242gt]

Hi there folks,
Yes, that system is truly a wonderful product. Made a noticeable difference in the performance of the motor. Seth at MVP told me that the motor could run 2 psi more boost than stock. I already had my motor around 12 psi and now it seems to boost up to the fuel cutout. I wound out third getting onto the highway going home tonight and BAM! hit the cutout. Man, that sucks when your
trying to wind it up. I'm going to adjust the boost a bit lower next chance I get. Hopefully, that won't happen again. Once I get done fixing some cars for other folks I'm going to install a cam.
Happy rolling guys!

Dave 82 242ti 278k mi.

[Hank Scorpio]

Awsome bud!

word for the wise, plan on a CBV or a BOV for going beyond 12 psi, or plan on a dead turbo.

Doug

[dl242gt]

Hi Doug,
I installed one shortly after I installed a new higher output turbo.
That was at 213k miles. I used the plastic Bosch one used by Porsche. I didn't make a bend in the pipe before it returns the air
and it causes a nice gunshot type boom out the exhaust when it blows off the air. I just got some copper pipe elbows and I'm going to redo the way the pipe is run. That should take care of it.
Always something new to learn.

Dave 82 242ti 278k mi.

[Hank Scorpio]

Sweet man! A buddy of mine knows the Kragens part number for a molded hose that fits perfect aparently. PM if you want me to find out what number it is.

doug

[dl242gt]

Originally posted by 300+
I am thinking of maybe exiting the exhaust on the right just in front of the tire. Maybe modify the floor so it has more ground clearance...nyuk nyuk nyuk.

Check out the Nascar boys for your side outlet. I believe they are now using oval shaped exhaust pipe which should fit under the car a little easier. Looks like a really nice job on the bumper. Did you use the stock Volvo side supports?

Dave 82 242ti 278k mi.

[300+]

Dave,

Yes I did use the stock side supports as they are designed for the bumper to slide forward in an impact. No modification was necessary to the side mounts. It really fits nice without the trim.

Yes the NASCAR oval was what I had in mind. The only thing I am concerned about is the noise level. I geuss I am getting old, I like the quiet stealthy approach to performance. My 240 had no cat and the muffler was hollowed out. This provided nice flow and deadened the sound just enough, but coming out the side might make it too loud. We'll see when I get that far. That part of the project is quite aways away.

[Kevinator87'240]

I'm sorry this was another useless post.

:)

[Hank Scorpio]

Awww, thats what I thought you said. Lets please try to keep these sort of relevant.

[dl242gt]

Originally posted by 300+
Dave,

Yes I did use the stock side supports as they are designed for the bumper to slide forward in an impact. No modification was necessary to the side mounts. It really fits nice without the trim.

Yes the NASCAR oval was what I had in mind. The only thing I am concerned about is the noise level. I geuss I am getting old, I like the quiet stealthy approach to performance. My 240 had no cat and the muffler was hollowed out. This provided nice flow and deadened the sound just enough, but coming out the side might make it too loud. We'll see when I get that far. That part of the project is quite aways away.

Hi 300+
Thanks, for the additional info. I'm hoping to do the bumper conversion after the winter. I'm going to concentrate on mechancial stuff and taking care of the rust that came back after 4 years. Since you want the high flow but without the noise I can suggest my experience. Before I installed my MVP exhaust I went through using a few different mufflers.

1. Setup was a glass pack with a Pacesetter resonator tip. It made a bit of noise but the edge was smoothed by the resonator tip. This was stock pipe size with the muffler removed and the glasspack and tip installed in the rear. This was the loudest.
2. Flowmaster Delta 40 series oval 2.5" muffler with 2.5" pipe cat back pipes.
This also used a resonator tip. Also made a bit of noise. I thought that this flowed well especially top end. Not too loud but not quiet either. After about 1.5years the internal metal baffles on the Flowmaster broke loose and made a horrible rattle. I had to dump it.
3. Flowmaster replaced with Ultra Flow 2.5" stainless muffler. This made quiet power. A nice sound with the resonator tip. This was the best setup so far. A smooth quiet performance sound. Not obnoxious at all. Using a resonator tip smooths out the system sound. Takes away any raspy edge but doesn't mess with the airflow.

I'd like to add a resonated tip to the MVP system. It's hard to find a tip like that to fit upto 3" pipe. The tips I'm referring to are the type with the glass pack built in around the inside. Like the Pacesetter brand and 3ARacing brand. I bought the Flowmaster, the Ultra Flow and the Pacesetter tips from Summit Racing. The
MVP system reminds me of the sound from the Flowmaster. It is
deeper though. With only the muffler I like the sound but a resonator would definitely smooth it out just that bit more. Plus it adds a nice look to the end of the exhaust. Hope this helps you out some. Wish you well with the car.
Best regards,
Dave 82 242ti 278k mi.

[Hank Scorpio]

I also have the mvp system, the muffler is a Magnaflow muffler and I am very happy with mine. Quiet when your off the throttle, and not even that loud at WOT.

doug

[dl242gt]

Hi Doug,
I find that without the resonator I get a bit of a resonance between 2-3k rpm. That's why I like the tip so much. It takes away the droning resonance. Overall, though the system is quieter than I expected for such a large system. It rocks, one
of the best performance mods the car's had.

Dave 82 242ti 278k mi.

[Hank Scorpio]

I agree, mine seems to be loud around 2k also. I kind of like it that way! :)

Hands down though, an awsome exhaust system.

[916volvosport]

heh.. those were those m46 days, i tell ya

[1stRaven]

ahhh, mine came with a m46. I'm now enjoying the m90 days!

[BB-Q]

ahhh, mine came with a m46. I'm now enjoying the m90 days!

Me too.:-D

What the hell caused the resurrection of a 4 year old thread?!

[the poi]

I think he was jsut reminiscing.

[Morley]

Ze Volvo boxes made in Ze Germany iz much besser.