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-   -   760 5 cylinder...scratching a 10 year itch (https://forums.turbobricks.com/showthread.php?t=341191)

940 16 valve 04-13-2018 08:17 PM

760 5 cylinder...scratching a 10 year itch
An updated pic of how she sits now:

As of right now (Sept 2020) she's running and just needs some final items.

Specs list:
2006 B5254T2 - stock
Mitsu 16T turbo
Motronic 4.4 modified to run COP (Thanks to VAST tuning for that!)
T5 Transmission, Southbend Clutch disc (Organic), 850R pressure plate.
Ebay intercooler (It says JDM on top for extra points)
Koni's all around, cut IPD springs up front (ugh) Eibach 11" 275lb coils in back.

Some history is in my old thread... http://forums.turbobricks.com/showthread.php?t=243308

I've had a lot of fun, and learned a lot turbocharging my beloved 940. 3 years ago I moved back home after finishing school, started a practice, bought a house. Now I have a space to work on my projects!
This is probably the best pic I have of the space. After me and a buddy picked up a tire machine.
I purchased a 89' 760 with the intention of taking the doors which were in better shape for my 940. Then I started dreaming about swapping the IRS, but I also really like the updated dash of the 760, the long hood. The more I thought about it the 760 was in better shape too.
As much as I love my 940, with the turbo and the T5 transmission it's a blast to drive, but it's just not refined. About 10 years ago I convinced my brother to buy a 98' S70T5SE, and I just fell in love with the whiteblock. For a long time I would lurk on threads with RWD swaps. I followed closely threads like Narancs, and yellow t5R, thefullbanana, Canuck, and Lloyddobler in their respective builds..
As well as finding myself reading ever more swedish content through google translate...

I started getting serious about it last winter, and I picked up what I thought was a low mile 2006 B5254T from a crashed XC70. The oil change sticker read about 140xxxkm, but I realized after pulling it and looking back that the car had been imported from the usa. So not the low mileage I was going for, but probably fine for me to get started. The motor sat for the better part of year while I got distracted by other things.

Starting a few months ago I got more serious about collecting parts.
Rather than shorten a pan (which Canuck very graciously offered to help me shorten) I ended up buying Lloyddobler's second one. Lucky for me he had welded up 2 of them! So the original sits on bottom, with the welded one on top for comparison.
Got the engine on a stand.
Flipped it, pulled the pan, and test fitted the oil pickup and engine mounts. At this point it had been nearly a year since a 960 had showed up at the yard, and 2manyturbos came through and hooked me up with some mounts so I could get to fitting.
(My grandpa's antique tool collection the he gifted me in the background)
Pickup too long!
Used metal plated to allow for all 4 bolts to fit
Mildly clogged pcv
Cleaning pan of metal shavings from when it was resurfaced. Doesn't seem to leak!
Not all holes were present on this block. I was missing one for bolting in the middle of the pan, and one that holds a support for the oil pickup tube. Had to drill them, and then tap to M7x1 (apparently a very hard tap size to find indeed!) Had to get it off ebay.
Also had to track down a few oil pan bolts that the 960 pan used, which were not present on the s60 pan which I had bolts from. There is a single bolt that is M7 by I think it was 80mm, where the 4 at the back are 100mm and just won't quite work.
Keeping shaving out of the engine
Ready to be tapped
Tack welded oil pickup
Nearly there
And soldering some resistors per Aaron's helpful instructions from vast

poulrais 04-13-2018 08:42 PM

Whiteblock swaps is the flavor of the year I think! :-P

Are you planning on keeping this engine pretty much stock?

Have fun!

940 16 valve 04-13-2018 09:25 PM

Definitely! I've been watching your and Roger's threads regarding the CD009 transmission adapter, very tempting!
The plan is start out stock and work the bugs out, who knows from there, it's an addiction right?

Pete.M 04-14-2018 02:59 AM

Yes! I've had the itch for over 5 years.
Are you going to wire in the stock ecu and engine loom?

DET17 04-14-2018 07:47 AM

I'll also be watching this with interest.... got a B5244T5 on the engine dolly waiting for my 242.

What gearbox behind yours? Staying auto for now?

poulrais 04-14-2018 08:26 AM


Originally Posted by DET17 (Post 5782133)
I'll also be watching this with interest.... got a B5244T5 on the engine dolly waiting for my 242.

What gearbox behind yours? Staying auto for now?

The only auto tranny he could "easily" use is the AW30. I don't know why would anyone use that piece of crap on a swap.

Broke4speed 04-14-2018 09:47 AM


Originally Posted by poulrais (Post 5782135)
The only auto tranny he could "easily" use is the AW30. I don't know why would anyone use that piece of crap on a swap.

Ow...that hurts, lol :P.

poulrais 04-15-2018 08:19 AM


Originally Posted by Broke4speed (Post 5782150)
Ow...that hurts, lol :P.

Oh! Sorry about that! :oops:

We'll see how long it'll last! :-P

Hank Scorpio 04-15-2018 10:52 AM

I'm very curious to watch this. I keep having a real debate about running modded m4.4 or going standalone. The 4.4 is so appealing in regards that so much of the tuning has been paid for by Volvo and not me. I can just focus on tweaking vs starting from the ground up.

The flip side ofcourse being you don't have as much extra potential but for what I want, I'm not sure that's really needed.

240wagonguy 04-15-2018 11:19 AM

Nice another one. I'll be watching. :oogle: I got a I6 that'll be going into my 740 soon.

Broke4speed 04-15-2018 08:36 PM


Originally Posted by poulrais (Post 5782468)
Oh! Sorry about that! :oops:

We'll see how long it'll last! :-P

My goals are far lower than yours, so hopefully it lasts a long time :).

940 16 valve 04-21-2018 11:52 PM

Went to the junkyard last weekend and this weekend to get some parts that were needed to progress this any further. First 960 I've seen in about a year, and thankfully only had 80,000 miles.

I had the same debate between 4.4 and standalone Doug... I decided this seems like the way to go, at the very least to get started, but really people are putting down some impressive numbers with the motronic.

4.4 harness, in process of cutting out un-needed wiring.

I convinced myself that grabbing a few extra pieces off the low mileage car while in there made sense.

as well as a few things I actually needed, like starter/alternator/power steering. I toyed with the idea of using the updated accessories, but seeing these are lower mileage, and it was half off day, I went for it. Also grabbed a bellhousing in case I decide to do the CD009 swap that roger is working on.

Also got this off ebay, since the newer style keys seem to be a problem.

Also got the tabs at the top of this image, which hold the engine mounts in.

And then with those in got the engine prepped for install. Last look at the mounts with plates to adapt them.

4.4 cam sensor in

aaaand, engine going in

poulrais 04-22-2018 08:31 AM

This is coming along fine! What are you doing with the twin VVT?

940 16 valve 04-29-2018 02:33 PM

Not sure about the twin VVT at this point, thinking I'll chat with Vast tuning about it when I get there. Probably just leave it alone to start.

got the accessories installed

And now just toiling over the transmission options... Cd009, or a GS6-37 shipped from sweden, and welded to the volvo bellhousing. Similar gear ratios, advantage that the gs6 can use a volvo driveshaft. Seems like the Cd009 is quite a refinied tranny in it's final version with triple synchros on the first 3 gears...

One of the next things is decoding the wiring. Anyone have suggestions as to where I can find wiring diagrams for a s70turbo with motronic 4.4, as well as for the 760 with prv engine. My least favourite part....the wiring...

DET17 05-04-2018 06:40 AM

Looks like good progress being made. Just remember the absolute rule of HotRodding, as explained by Freiburger:

"It will cost twice as much, take three times as long as you expect".

Considered the DeeWorks T5 adapter? I think you can buy a brand new T5 with Z spec gearing (2.95 first close ratio) for $1200 USD.

240wagonguy 05-04-2018 09:27 AM

T5z is at 1995 now. Almost not worth it with the TKO being $2600ish. I myself am hunting down a good used 96-04 V6 T5 from a Mustang. Supposed to have all the factory upgrades in it already.

940 16 valve 12-27-2018 12:03 PM

I hate it when I follow a thread with interest, and then no update for month and months.
Where does the time go...? Seem to have less car time since my daughter was born.
But some progress
Exhaust side coming along, welded up the piping to the water pump
Welded the oil feed to fit with the turbo flipped for RWD
Not a ton of room for the exhaust with the 5 cyl manifold...
Most of the wiring is in place for motronic 4.4, just need to figure out the power to the 760 fuel pump relay, and run wiring for the COP. Any suggestions on those folks? Ok to ground them to the head?
relocated the battery to the drivers side, and ran wires for alternator/starter
And found some Ferrari Compomotives that I've been looking for for years. They were advertised as 16", but are definitely 15" unfortunately. They just fit.
I like the look in profile
Testing ride height
Clearance to bump stop
Nasty suspension angles. Have to find the compromise between form and function.
And finally, decided that a CD009 isn't in the budget right now, especially since I already have a driveshaft and shifter setup for a T5 transmission in the 940, which will likely get retired once this runs. This is a spare V6 T5 that I plan to use for mockup. I'm considering if a dual mass flywheel will quiet it down, and I think with my power goals I don't need anything more. The T5 is pretty civilized in the 940 now that I have my driveline angles sorted, but at high revs on decel it still rattles. I hate to go to all the trouble of getting the beautiful sound of a 5 cylinder, and then drown it out with the rattle of a T5 transmission.

940 16 valve 06-09-2019 01:09 AM

Any motronic 4.4 gurus out there? Was working on wiring the fuel pump relay today and am confused about the purpose of wires B19 and B27.

Sounds to me like B27 should trigger the relay, but then what is B19's purpose. The stock 4.4 fuel pump relay is just a simple 4 prong relay.

oldschoolvolvo 06-10-2019 04:07 PM

Nice work!

DET17 06-11-2019 07:12 AM

Check with Lankuu in Finland..... he has apparently mastered these whiteblocks & engine management of same.

940 16 valve 06-17-2019 12:22 AM

Some more discussion on it here. http://forums.turbobricks.com/showthread.php?t=349620
My brother gave me some help today and we got the .bin from Vast tuning loaded, turned it over and the coils are giving me spark! Just need to wire the fuel pump and it may be time to try starting it!

940 16 valve 09-09-2019 08:28 PM

So it roared to life for the first time (very briefly) a little over a month ago. Now it's time to sort out the clutch. Those single mass flywheels are hard to find! Anybody have one they want to donate to the cause?

LloydDobler 09-12-2019 12:12 AM

You can still buy it new if you want to spend 4x TB price. https://www.tascaparts.com/oem-parts...ItM2wtbDUtZ2Fz

Can verify this is a good working part number, it's the one I bought for my C70 manual swap. Technically the 850R flywheel.

240wagonguy 09-12-2019 02:56 PM

Try local indy volvo shops. On a whim I walked into a local shop in town and as luck would have it, the guy just parted a manual 850 and gave me the flywheel for $25!

940 16 valve 09-17-2019 12:13 AM

I'm surprised it's not NLA! If I go new, I've been eyeing the steel TTV flywheels. With the British pound down it's cheaper that the new one one.

Thanks for the suggestion. I did try the local Volvo shop to no avail. I guess I'll watch the junkyard for a bit and then make a decision.

940 16 valve 02-25-2020 08:11 PM

Overdue for an update. been plugging away. Also started a business so that's kept me busy.
Registration on the 940 ends in June, so the goal is to have it running sometime this summer.

Progress so far.
Got a 240mm clutch from southbend with T5 center
They were able to make the clutch the same thickness as stock, so no engagement height issues like I had with the 940.
My brother wants to swap his s70 from dual to single mass flywheel when do the clutch, so you can see the TTV flywheel under the clutch. Considering getting one for mine, but there is so much material taken off I wonder if it will make the already noisy T5 transmission unbearable. Still searching for a used single mass in the meantime.
Found some 5" outer diameter moog coils (Moog 8088) that were new in box for $10 locally. We'll run them and see. I think they're 260lb/in which should play well with the motion ratio or the rear arm which looks to be about .73. They're 15" long so will need cut though.
Wife's S40 had shifting issues so I got sidetracked replacing some linear solenoids.
Played with ride height and some 18's I have while I had the springs out. I think around here would be nice.
Plumbed the Idler motor and got the intake installed.
Pretty adapter plate
Picked up an ebay intercooler. had to do some trimming where the elbows are, and welded in some angle iron beside it to not lose structural integrity.

At this point I just need to get a flywheel and then I'm on the home stretch.
I found a input retainer from a s197 mustang with the 4.0 V6 and T5 transmission. Allows you to run a hydraulic slave, so I'm going to see if I can adapt that. They offer a short version of the slave (SB60317) which I will likely use.

Then it's just taking the 940 off the road to swap the driveline, and then a million little things. Progress though!

James M 02-25-2020 08:30 PM

Progress indeed!

Do you by chance have a part number on the southbend disc, or know the compressed thickness to aim for off hand?

940 16 valve 02-25-2020 10:50 PM

No part number, I just chatted with Ryan at Southbend and gave him the specs. He said he could make it 7.5mm thick (uncompressed), and that seems to match up with the stock 850r disc.

940 16 valve 03-10-2020 10:52 PM

Anybody got an 850 flywheel they would sell to help this project along?!

James M 03-10-2020 11:17 PM


Originally Posted by 940 16 valve (Post 6055094)
Anybody got an 850 flywheel they would sell to help this project along?!

I'm looking as much for you as I am for myself at this point, please help this man.
Someone as sweedespeed is selling a FW,PP, and clutch kit for 400 but then you gotta get rid of the PP and another disc

DET17 03-15-2020 09:02 AM


Originally Posted by 940 16 valve (Post 6055094)
Anybody got an 850 flywheel they would sell to help this project along?!

I might have a spare.... been hoarding for so long, I'm not sure! What's your budget?

940 16 valve 03-15-2020 11:09 PM


940 16 valve 04-09-2020 05:08 PM

Progress! Being forced to stop work has some silver linings... junkyards are still open
Went to the yard looking for a flywheel and came across a medium case BMW diff with LSD.
3.91 ratio which I think should work. Out of a 89' 735IL. Looks to have the flanges that will work with the volvo IRS halfshafts. My next question is to see if the 960 driveshaft with the CV joint at the end is compatible with the flange at the front of the diff.
In the meantime a local volvo guy Matt (Uglyduck) was kind enough to turn town my pilot bushing on his lathe, so now it will fit the RN crank bore (at about 0.825" OD)
Then one of these showed up at a local yard
And clutch is installed. Got a mounting face to pressure plate fingers depth of 3.3" (83mm) so I'm considering this slave cylinder solution

James M 04-09-2020 10:15 PM

Congrats on the flywheel, it's quite a hunt.
I forgot what it's like to work on cars in the snow, probably makes pulling parts much more fun.

I got away with a V6 TOB with some fork modification but it's not ideal, hydroponic TOB is probably a much better choice

940 16 valve 04-30-2020 10:12 AM

Seem to be finding more time to tinker lately... I think I may actually get this thing done soon!

Got distracted first doing the clutch on my brother's S70. I feel like whiteblock clutches is all I do lately!
I decided to go with my own solution to the slave cylinder.
I noticed that the S197 mustang input bearing retainer (with provision for internal slave) has a smaller internal diameter than all the other mustang retainers; so the outside diameter won't center in the adapter plate. Here you can see the slight difference in diameter between the two input retainers (stacked).
But it just so happens that it's bore on the back is the same diameter as the shoulder on this 94 input retainer. A few cuts, and you can mount the S197 retainer on the SN95 mustang retainer quite nicely. (and you have to move one bolt hole)

Just a note for any looking to do this in future:
I have a 2005 Mustang 4.0 V6 (S197) Slave, per my measurements it would almost work if you found a way to mount the S197 Input retainer directly on the transmission. (but then you have to find a way to make it center in the bore of the adapter plate)
My solution was to go with the shorter ~2010 Supercharged mustang 5.4 V8 slave which is much shorter. With that setup you have enough clearance to stack the 2 input retainers and end up with a bit to spare to allow for clutch wear (about 3mm). I think you could probably get a fem more mm if you skim the front of the input retainer.

It pains me, but initial steps toward decommissioning the turbo 16 valve 940. T5 transmission out.
Input retainers swapped, and the input shaft shimmed for 0.003" clearance per factory spec. Per my measurements the input shaft was 0.20" too long, so I took 0.25 off the front of it.
Transmission is now installed in the 760! As it sits now I have just over 3mm of extra depth that the slave can compress to allow for clutch wear. Does that sound reasonable to any who have experience with setting up a slave?

James M 04-30-2020 10:04 PM

Looks much nicer then my solution, no assbackwards bracket required
No idea about the internal slave depth, but the disc I got (copy of yours) seems like after 3mm of wear it will probably be to the rivets

Always sad to tear apart one project to build another, but some sacrifices must be made

Leon_pp 04-30-2020 11:08 PM

Beware, Ferrari wheels could be in milimeters for Michelin TRX tires (not XXX/XXR15 style tires)

240wagonguy 05-02-2020 10:18 AM

interesting. But how do you bleed the slave?

I'm curious about the shifter setup you have there too.

940 16 valve 05-02-2020 01:11 PM

Agreed, the new project rises from the ashes of the old. I guess I'm just sentimental though.
I was thinking with where the fulcrum of the pressure plate diaphragm is, 1 mm of of disc wear would probably move the fingers contacting the slave 2-3mm. Oh well, figure that out down the road.

Thanks for the heads up on the metric wheels, I guess they ditched that right before these wheels were made, but I did come across that in my research. Didnt know there was such a thing before that.

To bleed the slave I've got a stock union from the mustang (almost identical to what an S70 with internal slave uses) which has a bleed nipple. The shifter setup is one BNE was selling about 10 years ago. It needed some modification to work, but does the job now.

DET17 05-03-2020 05:26 PM


Originally Posted by 940 16 valve (Post 6075323)
The shifter setup is one BNE was selling about 10 years ago. It needed some modification to work, but does the job now.

IIRC, Ben just copied what Nathan built for his 940. When the T5's were in vogue, that would have been a valuable part to "clone". However it seems that the T5's are now passe, with folks looking to more modern 5 speeds to transplant into our old RWD Volvos.

Nice work on your slave work for the 5 cylinder..... I'll keep an eye on your progress. I've got my own 5 cylinder sitting a dollies in my shop.... and an M90.... and a T5! I'll go one way or the other, yet TBD. You planning to use factory engine management, or roll your own?

redblockpowered 05-03-2020 06:20 PM


Originally Posted by 940 16 valve (Post 6049482)
Found some 5" outer diameter moog coils (Moog 8088) that were new in box for $10 locally. We'll run them and see. I think they're 260lb/in which should play well with the motion ratio or the rear arm which looks to be about .73. They're 15" long so will need cut though.

Sneaky hiding of some information I've been looking for for a while!

940 16 valve 05-04-2020 12:08 AM

Ah the old 5 cylinder sitting around waiting to be but to use scenario, been there! The plan is to use motronic 4.4 and see what Aaron at Vast can do tuning-wise.
Glad to hear some of the info from the thread is getting put to use!

Interesting fact from today, the 960 engine mounts/5cyl ends up about 0.6" (my rough measurement with calipers) forward of where my B234 sat. Had to modify my trans mount that I had made for the old 940/T5 setup so it would bolt up.
It's feeling very close to ready to start. Need to finish plumbing the intercooler, a couple of turbo cooling hoses, and finish welding the downpipe, and then I think I can start it!

240wagonguy 05-04-2020 08:37 AM

I noticed that the whiteblock sits slightly further forward in the chassis compared to the redblock when I was building my T5 shifter. I had initially bought a blown up Camaro T5 to use the tailhousing, but the shifter would have ended up under the floor anyways. So I built a custom remote shifter and measured off the motor mounts back to get it right in the hole where the M46 shifter popped up.

940 16 valve 05-23-2020 01:25 PM


So I built a custom remote shifter and measured off the motor mounts back to get it right in the hole where the M46 shifter popped up.
I'd be interested to see pictures of what you came up with if you have any.
My shifter now comes up at the front of the shifter hole, just usable. It'll work for now.

A little update, I got the hydraulic clutch in. I Used a 4an line with a M12x1 to 4an banjo adapter at the master, and a adapter for the push in fitting that a lot of modern clutches use at the slave end. Disengages well after a few bleeds, in psyched that my setup seems like a go!
Waiting on some intercooler hoses, weld the exhaust today, and then I think we can give it a test run.

Anybody have a eggcrate grill for the foglught front they want to sell me?

DET17 05-23-2020 05:50 PM


Originally Posted by 940 16 valve (Post 6081511)
Anybody have a eggcrate grill for the foglight front they want to sell me?

I sure do! Check my FS thread, front and center. If that NOS grille is too rich, I also have a used one that will work as well.

940 16 valve 09-10-2020 09:23 AM

How far we've come!

It's so close. Since May:
- Got the eggcrate grille from DET17, thanks!
- Took the coolant pipe off to re-weld it after finding 2 pinhole leaks - damn!
- Hooked up the exhaust -2.5" downpipe and stock rear... for now
- Plumbed in the intercooler
- Hooked up intake side of things/PCV/etc
- Swapped the Koni's over from the old 940 - adapted the rear ones to fit IRS
- new hood and trunk shocks so it stops trying to decapitate me!
- Got some goodies from Kaplhenke (Thanks Ben!) 11x275lb springs for the rear (should be around 200lb with the motion ratio of the rear arm.
- Rebuilt the driveshaft - center support and front U joint were notchy
Found a NOS trans mount for the T5 to replace the knackered old one

I just need to bolt in the drivers seat, find a spot to mount the ECU (I pulled the wiring harness through the firewall to put it in the drivers footwell). and wire the headlights, and then it's testdrive time!

I've run it already with the VAST tuning euro map and coil on plug and all seems well. Here's hoping it's driveable to start without the VVT plugged in!

740atl 09-10-2020 06:20 PM


Originally Posted by 940 16 valve (Post 6074622)

Wow, this has piqued my interest in a big way. I have a T5 that I kludged an external slave cylinder to work with the clutch fork but I'd love to go with a hydraulic throwout bearing like you've got going here.

I'm confused, why the need to stack the bearing retainers? You're saying the 2010 slave cylinder will bolt (with modifications) to the T5 input bearing retainer?

Can you clarify this for my age addled brain?


940 16 valve 09-11-2020 12:32 AM


Originally Posted by 740atl (Post 6112296)
Can you clarify this for my age addled brain?

Lol, happily Mike. I always hope posting all this stuff up will be of some help to others.

So with the s197 input retainer that has the provision for mounting the hydraulic slave cylinder, it can bolt to the front of the T5 transmission. (Well 3 out of 4 bolts) Awesome right!? Got me excited...
Then I realized it's diameter is about 1/4" less than that of the normal fox body/sn95 bearing retainer. So basically you lose the ability of the input retainer to center then transmission in the bellhousing, or adapter plate in our case.
I was just playing around with the parts I had on hand and noticed one of the SN95 retainers had the same outside diameter lip on it as a recess on the back of the S197 mustang retainer. So basically the sn95 retainer centers the tranny to the adapter plate, and the S197 retainer sits on it and centers on another smaller groove, and then the slave can bolt to that and is nicely centered.

Anyways, saved me getting machine work done to accomplish what I wanted. If I did it again (and I may) I would bug Roger at Deeworks to see if he would make a thicker adapter plate so I could use the longer input shaft from a SN95, have the shifter slightly further back, and use the stock S197 slave instead of the shorter version from the supercharged model. But hey, it works!
Hope that helps

740atl 09-11-2020 01:01 PM

Hey man, thanks very much.

It just dawned on me why you were able to stack to two bearing retainers because of the adapter plate.

I was was looking for a cheaper hydraulic t/o for a t5 with the stock ford bellhousing and I see that this probably wouldn't work... not that I've made any measurements.

Thanks again and awesome project!

940 16 valve 09-12-2020 12:41 AM

Well let me know if you get some measurements. I have notes on the length of the 2 slave cylinder types somewhere...

And it runs! Well... I knew it ran, but it was always just for a few seconds before as a test. Tonight I ran it and let it idle up to temp. Seemed smooth!

How do you all post videos? Imgur who I use for photos doesn't seem to play the video when I upload it.

Hopefully a test drive tomorrow!

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