My '91 744 B204GT project - Page 9

tomasss · 10-08-2020, 05:47 PM

M90 receiving some cleanup & OEM love...

Old seals out...

Cleaned, new o-ring and input shaft seal...

New output shaft seal

tomasss · 10-13-2020, 05:11 PM

M90 stop ring welded. There is by the way very good new instructional video on >>> youtube <<<

tomasss · 10-20-2020, 05:35 PM

Finishing the M90...the shifter rod seal has been replaced, final checks done and the transmission case is sealed again

ZVOLV · 10-20-2020, 07:09 PM

What fluid will you be using?

tomasss · 10-21-2020, 03:09 AM

Quote:

Originally Posted by ZVOLV

What fluid will you be using?

I have some Febi API GL-4 75W-80 laying around so I wanted to use that, but reading now the >M90< topic I'll check with Volvo dealership. The issue is that the recommended 1161745 (GL-4 75W-80) seems to be no longer available and it's official replacement 31259380 is different spec (GL-5 75W-90). Not sure what is the best way to go here...

EDIT: Dealership responded that the replacement is #31280771 (API GL-4, SAE 75W), it replaces Volvo Transmission Oil 1161645 (API GL-4, recommendation for M45, M46, M90). So that one is ordered and will go in.

tomasss · 10-22-2020, 05:38 PM

Transmission filled, sealed and ready for installation

I have also ordered stainless braided clutch hose as I have been reading bad experience using the oem hose with a performance pressure plates.

Sjeng · 10-23-2020, 02:48 AM

Quote:

Originally Posted by tomasss

I have some Febi API GL-4 75W-80 laying around so I wanted to use that

I used exactly this in my rattling M90. Shifts smooth.

MadDog_945 · 10-24-2020, 03:03 AM

Quote:

Originally Posted by tomasss

Transmission filled, sealed and ready for installation

I have also ordered stainless braided clutch hose as I have been reading bad experience using the oem hose with a performance pressure plates.

have you ordered the KL.Racing one or any other?

tomasss · 10-24-2020, 03:14 AM

Quote:

Originally Posted by Sjeng

I used exactly this in my rattling M90. Shifts smooth.

Ok...in case it rattles with the original oil, I know what oil to switch to

tomasss · 10-24-2020, 03:16 AM

Quote:

Originally Posted by MadDog_945

have you ordered the KL.Racing one or any other?

I have ordered it from saabits.com...this one:
https://www.saabits.com/all/volvo-74...lutch-hose-kit

MadDog_945 · 10-24-2020, 02:26 PM

nice, curios if it works better..

tomasss · 10-24-2020, 04:57 PM

Quote:

Originally Posted by MadDog_945

nice, curios if it works better..

Means the KL Racing one is not a good fit? Just to know...

MadDog_945 · 10-24-2020, 07:51 PM

no, but 5 times more money

tomasss · 10-26-2020, 06:44 AM

Oh, ok. From >this post< I understood that the HEL units are good, and the same manufacturer (HEL Performance) is in the description on the saabits web, so it should be the identical one.

tomasss · 10-26-2020, 05:23 PM

Productive evening today...stock valve springs replaced by the Ford 4.6l ones (Melling VS1268). So relaxing job when you have the right tools!

EDIT: Hmm...just noticed that the manual says to put closely wound coils at the bottom. So few of them to be flipped

ZVOLV · 10-27-2020, 12:33 AM

Looking good!

I don't wanna derail the thread. Would you please post up the part numbers for those seals in the M90 thread? http://www.forums.turbobricks.com/sh...=94325&page=23 I need the seals for my M90. (I have quad square US 740 headlights for trade.)

I am interested to see the powerband with this engine/gearbox combo. My setups were freeway screamers and not stump pullers. What tire size and rear gears?

tomasss · 10-27-2020, 04:10 AM

Quote:

Originally Posted by ZVOLV

Looking good!

I don't wanna derail the thread. Would you please post up the part numbers for those seals in the M90 thread? http://www.forums.turbobricks.com/sh...=94325&page=23 I need the seals for my M90. (I have quad square US 740 headlights for trade.)

I am interested to see the powerband with this engine/gearbox combo. My setups were freeway screamers and not stump pullers. What tire size and rear gears?

The seals that you can still get from the dealership are the input/output seals 9183891-1 and 6843480-1 and also the 978268-1 O-ring.
Other than that you also need the shift linkage seal (Corteco 01019151B, NLA from dealership).

I am using 205/55 R16 tires and 3.73 ratio. Of course also very curious about the way how it behaves on the road

tomasss · 11-11-2020, 03:05 PM

Based on the aristg/Gary's >idea< I've fabricated my stainless steel oring guard ring too

tomasss · 11-25-2020, 06:01 PM

New bigger pistons from Yoshifab finally arrived, so I've gapped the piston ring ends and installed the pistons in the cylinders...hooray!

tomasss · 11-28-2020, 07:46 AM

Maxpeeding conrods got new bearings & were connected to the crankshaft, oil splash guard & oil pump tube & oil pan installed too...it's slowly coming together!

tomasss · 11-28-2020, 08:41 AM

Also a short video once the conrod caps were tightened to the spec:

tomasss · 11-29-2020, 04:11 PM

Is this board still alive?

Anyway...more progress today. Headbolt threads re-tapped, head surface cleaned, headgasket sprayed both sides with Permatex Copper Spray-A-Gasket Hi-Temp Sealant, ARP studs from Yoshifab fitted and head installed!

What surprised me is that the headgasket is missing some coolant passages, is that normal? For example the left side of the first cylinder...

oldschoolvolvo · 11-29-2020, 05:39 PM

nice and clean

tomasss · 12-11-2020, 06:15 PM

Thanks!

If there is something you really don't want to happen...it is to find out after assembling the engine bottom end that your torque wrench is pretty much off the scale

so that's exactly what happened. Set to 80Nm and clicking on 50Nm. That basically meant all my main cap bolts / crank pulley central bolt / oil pump gear were tightened with wrong (too small) torque.

So new calibrated torque wrench, disassembly and re-torqueing all these bolts and re-assembly was a task of today. All is back together so more constructive progress to be done during the weekend.

Oh and also I couldn't resist to put this one from >Pete.M< on

Pete.M · 12-12-2020, 04:12 AM

Nice. I'm guessing you managed to get someone to convert the image to something usable.
How did you find out about the torque wrench? That's a lucky save.

10-20-2020, 07:09 PM	#204
ZVOLV <Master Tech> Join Date: Nov 2002 Location: California	What fluid will you be using? __________________ No Start Thread Last edited by ZVOLV; 10-20-2020 at 09:32 PM..

10-26-2020, 05:23 PM	#215
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Productive evening today...stock valve springs replaced by the Ford 4.6l ones (Melling VS1268). So relaxing job when you have the right tools! EDIT: Hmm...just noticed that the manual says to put closely wound coils at the bottom. So few of them to be flipped Last edited by tomasss; 10-26-2020 at 05:38 PM..

11-29-2020, 05:39 PM	#223
oldschoolvolvo Board Member Join Date: Mar 2004 Location: Lancaster, PA	nice and clean __________________ -Mike ~~1998 V70 T5~~ 1979 242 DL 16v \|Feedback\|

12-11-2020, 06:15 PM	#224
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Thanks! If there is something you really don't want to happen...it is to find out after assembling the engine bottom end that your torque wrench is pretty much off the scale so that's exactly what happened. Set to 80Nm and clicking on 50Nm. That basically meant all my main cap bolts / crank pulley central bolt / oil pump gear were tightened with wrong (too small) torque. So new calibrated torque wrench, disassembly and re-torqueing all these bolts and re-assembly was a task of today. All is back together so more constructive progress to be done during the weekend. Oh and also I couldn't resist to put this one from >Pete.M< on Last edited by tomasss; 12-12-2020 at 04:37 AM..

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10-13-2020, 05:11 PM	#202
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	M90 stop ring welded. There is by the way very good new instructional video on >>> youtube <<<

10-20-2020, 05:35 PM	#203
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Finishing the M90...the shifter rod seal has been replaced, final checks done and the transmission case is sealed again

10-22-2020, 05:38 PM	#206
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Transmission filled, sealed and ready for installation I have also ordered stainless braided clutch hose as I have been reading bad experience using the oem hose with a performance pressure plates.

10-24-2020, 02:26 PM	#211
MadDog_945 Våga Vägra 8V Join Date: Apr 2006 Location: Lower Saxony	nice, curios if it works better..

10-24-2020, 07:51 PM	#213
MadDog_945 Våga Vägra 8V Join Date: Apr 2006 Location: Lower Saxony	no, but 5 times more money

10-26-2020, 06:44 AM	#214
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Oh, ok. From >this post< I understood that the HEL units are good, and the same manufacturer (HEL Performance) is in the description on the saabits web, so it should be the identical one.

10-27-2020, 12:33 AM	#216
ZVOLV <Master Tech> Join Date: Nov 2002 Location: California	Looking good! I don't wanna derail the thread. Would you please post up the part numbers for those seals in the M90 thread? http://www.forums.turbobricks.com/sh...=94325&page=23 I need the seals for my M90. (I have quad square US 740 headlights for trade.) I am interested to see the powerband with this engine/gearbox combo. My setups were freeway screamers and not stump pullers. What tire size and rear gears?

11-11-2020, 03:05 PM	#218
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Based on the aristg/Gary's >idea< I've fabricated my stainless steel oring guard ring too

11-25-2020, 06:01 PM	#219
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	New bigger pistons from Yoshifab finally arrived, so I've gapped the piston ring ends and installed the pistons in the cylinders...hooray!

11-28-2020, 07:46 AM	#220
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Maxpeeding conrods got new bearings & were connected to the crankshaft, oil splash guard & oil pump tube & oil pan installed too...it's slowly coming together!

11-28-2020, 08:41 AM	#221
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Also a short video once the conrod caps were tightened to the spec:

11-29-2020, 04:11 PM	#222
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Is this board still alive? Anyway...more progress today. Headbolt threads re-tapped, head surface cleaned, headgasket sprayed both sides with Permatex Copper Spray-A-Gasket Hi-Temp Sealant, ARP studs from Yoshifab fitted and head installed! What surprised me is that the headgasket is missing some coolant passages, is that normal? For example the left side of the first cylinder...

12-12-2020, 04:12 AM	#225
Pete.M Slow Member Join Date: Nov 2012 Location: UK	Nice. I'm guessing you managed to get someone to convert the image to something usable. How did you find out about the torque wrench? That's a lucky save.