700/900 series locker into 200 series

[linuxman51]

This is a work in progress but this is what we've got so far. Both test vehicles are are 90+ 200 series cars, so YMMV.

Start with two lunatics (one's running the camera)

http://www.pbase.com/kdh51/image/71226577.jpg

pop the axles off (remember how the e-brakes come apart as this caused us some difficulty)

http://www.pbase.com/kdh51/image/71226578.jpg

You will also want to disconnect the shocks (unbolting from the top is easier) and panhard rod (18mm)

Remove diff cover (12mm)

http://www.pbase.com/kdh51/image/71226583.jpg

remove the chunk, make sure you dont mix up bolts and carrier retainers (or, and this is a better idea, have new diff bearings at the ready) swap ring gears and if needed, weld the tone ring from the old diff to the locker assuming (this produces interesting visual results, however the speedo will work fine, you will however need to space the sensor out approx 2-3mm to avoid hitting the ring)

http://www.pbase.com/kdh51/image/71226588.jpg

modified locker goodness (total lack of counter weight, and adjusted springs for quicker engagement)

http://www.pbase.com/kdh51/image/71226591.jpg

diff in the housing with 200 series ring gear

http://www.pbase.com/kdh51/image/71226600.jpg

Custom modified passenger side axle, not positive if this is required, chopsaw on the axle to shorten it by 4mm or so (but again, this might not be required, depending on year and wether or not you have abs, YMMV)

http://www.pbase.com/kdh51/image/71226601.jpg

and the glorious results:
http://www.pbase.com/kdh51/image/71280652.jpg


two days into the mod, the car still drives fine, no whine, no loud noises,etc, and it'll lay a mean pair of marks down the road if so desired.

Myth debunking:
700/900 series axles *will not* fit a 200 series rear end, too long by a good inch or two
More will be added as needed/discovered.

all of the pics from the first swap
http://www.pbase.com/kdh51/diff_swap&page=all

[740ATL]

hell f8n yeah!

I just dropped mine (g80) into mine two nights ago... I picked up a 92 240 rear with intentions of welding the spider gears, but I later decided against welding the spider gears as I lack a suitable welder.

With the G80 in place, both axles seemed to bolt right in, but you've got me nervous now... although seeing the whole thing's still sitting on the ground it ain't nothing but a thang to rip one out and cut it... although I suppose I should notice a 4mm gap on one side. (it's a 92 rear axle... )

did you guys in fact put new bearings in it? or are you/were you going to shim it?

Also... what'dya do to the spring? stretch it backwards? heat it?

Must be nice having a Tig welder in the shop... grumble grumble...

Damn... I may be spinning both wheels by the weekend!

[thelostartof]

hahaha this is what sam was ranting about


VERY nicely done boys .... very nice now take those unbalanced axles up to 120mph and hold it there, and then kiss the bearings good by maybe

otherwise pimp

[linuxman51]

only modified one axle...

[linuxman51]

hell f8n yeah!

I just dropped mine (g80) into mine two nights ago... I picked up a 92 240 rear with intentions of welding the spider gears, but I later decided against welding the spider gears as I lack a suitable welder.

With the G80 in place, both axles seemed to bolt right in, but you've got me nervous now... although seeing the whole thing's still sitting on the ground it ain't nothing but a thang to rip one out and cut it... although I suppose I should notice a 4mm gap on one side. (it's a 92 rear axle... )

did you guys in fact put new bearings in it? or are you/were you going to shim it?

Also... what'dya do to the spring? stretch it backwards? heat it?

Must be nice having a Tig welder in the shop... grumble grumble...

Damn... I may be spinning both wheels by the weekend!

on that one, no shimming, nothin, threw the g80 in with the bearings that were on it already. on the spring, not sure the exact process, but he made it weaker iirc.

[linuxman51]

updated the pictures a bit.

[740ATL]

on that one, no shimming, nothin, threw the g80 in with the bearings that were on it already. on the spring, not sure the exact process, but he made it weaker iirc.

My dial indicator may be here by the weekend... I suppose I could just throw the thing in the car, drive it, then check it once the indicator is here, but damn it's such a royal PITA to get those e-brake springs on and off...

lol... I like this one...
http://www.pbase.com/kdh51/image/71280652.jpg

PS... I'd love to see vidz of deathwagon V.2

[thelostartof]

but its not a wagon .. and deathsedan just doesn't sound right

[740ATL]

hmmm

sedan of death.

el muerte

death volvo

doesn't have the same ring...

[thelostartof]

nope

maybe we should just call it 'the 240'

but there are a lot of those .. hm i think we need to start a new thread FOR sam to find a new name for his car

[JohnMc]

I've got an LSD in the basement for the PV, but I've been too paranoid about gear clearances/shims/runout measurements/etc/etc to put it in so far. I keep thinking I should jsut take it to a rear-end shop for installation. Fore aft shimming of the pinion, side to side shimming of the carrier, it just sounds like the sort of thing I'd scrcew up.

[2manyturbos]

"VERY nicely done boys .... very nice now take those unbalanced axles up to 120mph and hold it there, and then kiss the bearings good by maybe"

Unbalanced axles? What am I missing here? If you are refering to cutting 1/4 inch off the end, it won't have any effect on the balance.

2manyturbos

[RoadRacer4Life]

the axels are not balanced from what i can tell so i seriously doubt its going to viberate at all at 120 and it dosent at 100 i can tell you for sure.. It does work great so far.. Its really more of a locker than LSD because it goes from open to locked in a split second and there is no in between.. My only conserns are shearing off the teeth on the spral flyweight thing like another tbricker did.. Success so far..
Sam

[945ti]

My only conserns are shearing off the teeth on the spral flyweight thing like another tbricker did.. Success so far..
Sam
what teef?
http://ct.pbase.com/g3/83/464483/2/54464582.Flyweightpic8.jpg
If you are a savage, you might break them. If you soften the spring on the back of the flyweights which you can just barely make out in that horrible photo and keep your lighter 240 on pavement, it will probably live. Mine is doing fine despite my repeated hammering.
Thanks for confirming what I suspected would work gents. Nicely done. I probably should have done this to my 245, but the welded was more fun on gravel anyway and I knew it wouldn't break.

[thelostartof]

"VERY nicely done boys .... very nice now take those unbalanced axles up to 120mph and hold it there, and then kiss the bearings good by maybe"

Unbalanced axles? What am I missing here? If you are refering to cutting 1/4 inch off the end, it won't have any effect on the balance.

2manyturbos



good to know .. someone had done that for one of our old wagons back in shop days(was some GM crap) and it chewed up about 3 bearings before we got the right axle for it and all of our issues went away

[suterman]

ive been wondering about this, ive got a 1041 in the garden and was thinking about trying to jam the gubbins into the 240 diff, well done

[RoadRacer4Life]

here is the link to the old locker mod thread..

G80 Locker Mod (http://forums.turbobricks.com/showthread.php?t=25829&highlight=locker+mod)

[qwkswede]

lol... I like this one...


PS... I'd love to see vidz of deathwagon V.2

Holy CRAPOLA!~ thats a big burnout for a Volvo.

[Nick]

So what cars did these G80's come in again?

[linuxman51]

So what cars did these G80's come in again?


generally speaking 90+ 700 and 900 series turbo cars.

[towerymt]

...but damn it's such a royal PITA to get those e-brake springs on and off...
Flat screwdriver through the hole in the hub flange, and use it to pry the spring up. Combined with needle nose vise grip pliers, they're not that hard. But I've done them a bunch of times.

[740ATL]

Flat screwdriver through the hole in the hub flange, and use it to pry the spring up. Combined with needle nose vise grip pliers, they're not that hard. But I've done them a bunch of times.

off is fairly easy... it's the on part that's the devil.

[volvorsport]

what we saying here ?

you need to shorten the 240 halfshafts to fit the G80 or the 7/900 ones

[MrSteve]

but its not a wagon .. and deathsedan just doesn't sound right

DeathKar

.

[thelostartof]

generally speaking 90+ 700 and 900 series turbo cars.

91+

90's while most i've driven seem to love to spin both and act like they have the locker have all been open rears. tho ithink someone might of mentioned the 90+ cars all have longer splines or something odd like that as a locker from a 91' would not fit right in poi's 89' wagon

[MrSteve]

I don't see any mention of this step in the instructions :-P

http://ct.pbase.com/g6/11/359711/2/71226602.mWHXuMKt.jpg

[shaved240]

what do the ring gears look like, and what is the purpose of the tone ring?

[blkaplan]

what do the ring gears look like, and what is the purpose of the tone ring?

The tone ring feeds the speed sensor, ie your speedometer

[linuxman51]

91+

90's while most i've driven seem to love to spin both and act like they have the locker have all been open rears. tho ithink someone might of mentioned the 90+ cars all have longer splines or something odd like that as a locker from a 91' would not fit right in poi's 89' wagon

the one in sam's 240 came out of a 90 740 turbo in the jy.

[linuxman51]

I don't see any mention of this step in the instructions :-P

http://ct.pbase.com/g6/11/359711/2/71226602.mWHXuMKt.jpg

cut a 2x4 to get the shocks bolted back up. it was funny cause it filled the shop up with smoke.

[740ATL]

Well... the 84 rear end definitely needs a shorter passenger axle... After cramming in the locker, I shoved (it was more like a gentle shove) the passenger axle in and it looked a tad too long... bolted it in and it froze. Damn...

Luckily I had a complete rear end from a 92 240 sitting about 5 feet away... yanked the passenger axle, compared the 84 and 92 side by side, the 92 is 4-6mm shorter. Shoved it in, bolted it up, spins fine.

While I didn't measure the backlash, it felt identical to the open diff that was in there. I realize that my finger calipers aren't calibrated to thousandths of an inch, but it felt similar... so I'm going with it.

However, I didn't weld on a new tone ring... I cut away 3 out of every 4 teeth... gives me 12.... I'm going to use the differential cover from the 92... we shall see. The car didn't come with an electronic speedo to begin with, and now with the getrag, there is no provision for one so this should be interesting.

And suprisingly, I got the e-brake springs back on in under 20 minutes. Only 3 incidences of power words required.

I can't wait to go out and lay a patch.

In the car... http://www.pbase.com/740atl/image/71778500
http://www.pbase.com/740atl/image/71778500.jpg

anaerobic sealant http://www.pbase.com/740atl/image/71778502
http://www.pbase.com/740atl/image/71778502.jpg

cover. http://www.pbase.com/740atl/image/71778504
http://www.pbase.com/740atl/image/71778504.jpg

[945ti]

Well... the 84 rear end definitely needs a shorter passenger axle... After cramming in the locker, I shoved (it was more like a gentle shove) the passenger axle in and it looked a tad too long... bolted it in and it froze. Damn...

Luckily I had a complete rear end from a 92 240 sitting about 5 feet away... yanked the passenger axle, compared the 84 and 92 side by side, the 92 is 4-6mm shorter. Shoved it in, bolted it up, spins fine.

While I didn't measure the backlash, it felt identical to the open diff that was in there. I realize that my finger calipers aren't calibrated to thousandths of an inch, but it felt similar... so I'm going with it.

However, I didn't weld on a new tone ring... I cut away 3 out of every 4 teeth... gives me 12.... I'm going to use the differential cover from the 92... we shall see. The car didn't come with an electronic speedo to begin with, and now with the getrag, there is no provision for one so this should be interesting.

And suprisingly, I got the e-brake springs back on in under 20 minutes. Only 3 incidences of power words required.

I can't wait to go out and lay a patch.

Thanks for confirming that it works! Good work! I probably won't toss a G80 in a 240, but good to know my suspicions about the late axles weren't insane. Rock on!

[TURBO_Volvo_Dan!!]

so, i have a 91 740se as my parts car, and it has a locker, so i am goin to put it in my 240, could i use the smaller axel off the 740? or should i cut the 240 one?.
thanks

[740ATL]

If you have a 240, you're going to use your 240 axles as the 740 units will be too short to begin with.

What year 240 do you have? If it's before 90 or so, you will need to cut the passenger side axle by about 4-6mm. (I don't know the year where they changed lengths....) I know for sure that a 92 240 had the shorter passenger side rear axle...)

So... either grab a passenger rear from a 92-93, or cut the one you have.

Mike