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Old 04-05-2021, 03:17 PM   #76
940 16 valve
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I wouldn't say the T5 is cheaping out, I really do love the feel of how they shift. I had convinced myself I would be happy with the T5 behind the T5,and In almost every way I was. In really of 2 minds cause with the MGW shifter, the shift feel was so crisp and, and I thought the gear ratios were quite good.
But at the end of the day it's a bit of a noisy trans, and my perfectionism set in. And how is a 6 speed not more fun?

I considered the CD009 for quite a while too, but ironically it seemed like it would inevitably be more than the GS6 by the time you get a custom driveshaft and shifter figured out. And then I came across a 740 with a M47 to donate the front driveshaft which is drop in with this trans...

I had contacted bakaxel, but they wouldn't ship overseas, so I ended up going with MKM motorsports. I got the trans in 3 days which was impressive!

Hoping to get the trans in next weekend!
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Old 04-09-2021, 11:38 AM   #77
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Gotta love that Volvo made a recess in the flywheel that takes the same pilot bearing that BMW used in a lot of models.

Decided to reinforce the clutch fork where I had to take out some material for clearance. Probably overkill
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Old 04-18-2021, 12:43 AM   #78
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Progress!

Figured out a mounting solution for the shifter. I was initially thinking I would have to find the mount from a M90 to hold the back of it, but it turns out BMW part #25-11-7-539-193 fits nicely, and after drilling 2 holes I was able to just rivet it in. Shifter assembly from an e90 was almost dead on for length.



Finished installing the short struts, and moved the mounting bolt over to improve my -0.3 degree camber per last alignment.

Fancy mounting plate from MKM to give leeway for mounting.

All installed with new flex disc (the thicker one that M cars use)

Found a stock BMW slave cylinder line that uses a universal push fit fitting - same as the newer ford slave cylinder had with my previous setup - so I just reused the -4AN line and universal push fitting from before.


Ran out of time, so tomorrow I'll do a final once over, and get it back on the ground for a test drive!
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Old 11-05-2021, 11:16 AM   #79
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Has it really been over 6 months!?

Been having lots of fun with the car, approaching 10k kms on the 5 cylinder and it has performed nearly flawlessly. Only had one issue where the fuel pump relay went (I always have a spare in the glovebox, but I finally bought a new OEM one). Otherwise I haven't done anything major. I got the Motronic ecu tucked properly away above the clutch pedal. But now I am gearing up for the next project on it: the BMW LSD to help with traction.

I found this housing on Ebay - from california. Seemed like a lot less effort than getting the rusty one sandblasted, so that'll be my starting point. The plan is to rebuild it with new clutch packs, bearings and seals. I entertained the idea of putting a truetrac in the volvo housing and save the custom work, but a lot of the parts to rebuild them are NLA. Oh well, the 2.93 BMW rear end will play better with the transmission gear ratios.

I also flipped the ackermann inserts to get the steering to a point where it feels like the car tracks normally on turns (not feeling like it's dragging a tire)

And most recently, got rid of the old square panel lights for the more modern style. Now on the hunt for proper 760 lights.

And now that this project is in a good place, I've been getting distracted with my BMW E21 build. A friend called in the spring with an E36 M3 that he was parting out, so now I'm working on dropping in an S52. I guess this makes my car collection redundant, 2 5 cylinder cars, and 2 S52 powered cars!
The thread if anyone is interested:
https://www.bimmerforums.com/forum/s...entual-rebuild
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Old 11-07-2021, 10:22 PM   #80
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I missed this somehow. Think you could throw together a quick parts list for the trans swap? MKM's prices are pretty good.
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Old 11-08-2021, 02:18 AM   #81
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Quote:
Originally Posted by 940 16 valve View Post
Bla bla, I've been getting distracted with my BMW E21 build. A friend called in the spring with an E36 M3 that he was parting out, so now I'm working on dropping in an S52. I guess this makes my car collection redundant, 2 5 cylinder cars, and 2 S52 powered cars!
The thread if anyone is interested:
https://www.bimmerforums.com/forum/s...entual-rebuild
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Old 11-11-2021, 03:27 PM   #82
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this thread is plenty full of inspiration, keep the good work goin´

Is the 960 turbo 16v irs a direct swap to a 940?
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Old 11-12-2021, 12:45 PM   #83
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Quote:
Originally Posted by 240wagonguy View Post
I missed this somehow. Think you could throw together a quick parts list for the trans swap? MKM's prices are pretty good.
For sure, probably good I do it now while I remember. I agree, once you factor everything in, the prices are decent when compared with the other options out there.

GS6-37 (Suffix BZ if from a gas car, DZ if from a diesel car) swap parts list
This is the one I went with http://m.mkmotorsport.se/products/bm...sad-for-volvo/
-I also ordered the transmission crossmember from them for simplicity's sake

Driveshaft:
- Front half driveshaft from a M47 740 (hardest part to find)/ Front half of a M90 driveshaft if you want to go with the 5 speed
-Stock Volvo or BMW Guibo - save yourself some money and get an SGF one - as they're OEM. I used the E36 M3 version which is slightly thicker 26-11-2-226-527-M455

Flywheel/Clutch:
- Single mass flywheel/850R pressure plate with custom sprung hub clutch disc - I got mine from Southbend clutch and had no issues.
- As a second option you could use the volvo dual mass flywheel which would mate with the stock BMW unsprung 240mm clutch disc
- I used this throw out bearing 053151231032 - some have mentioned issues with the later throw outs BMW uses which are designed for the self adjusting clutches. I paired it with the clutch fork from a later self adjusting clutch (came with the transmission) which gives you about another 1/4-1/2" of clearance, but you'll still have to modify it like I showed earlier in the thread, and also cut down the plastic back of the throw out bearing a bit. This is all because the bmw 6 speeds use a pilot bearing mounted in the flywheel, so the input shaft is shorter - which is compensated for by having less bellhousing depth - and thus less room for the clutch and associated hardware.

Clutch slave/line:
- I used the stock one from the 6 speed trans - E36 BMW's also use the same diameter slave which matches perfectly with the volvo Master. I don't remember off the top of my head but I think they're 22mm diameter pistons.
- Clutch slave line from a newer BMW that uses the universal push fit fitting 546733049784
-Universal push fit fitting to AN4 adapter (like so
-AN4 line
- AN4 to M12x1 banjo bolt - attaches it to your stock volvo master cylinder https://www.ebay.ca/itm/112321763842

Shifter:
- BMW shifter carrier 7532492 puts the pivot point right in the middle of the hole in a 700/900 (assuming you go 6 speed - plenty of longer shifter options of you go 5 speed
- BMW Mount from back of shifter carrier to body 25-11-7-539-193 and bushing 25-11-1-222-015
- I welded the shifter arm to length, and used a short throw shifter from ebay (really short throw but with a full length upper section of the shifter). You need that combo so the throw is short enough that you aren't changing the track on the stereo when you shift forward, but that the shifter is high enough so it isn't awkward with the armrest height of a 7/900.

I had already made this compilation of gear ratios when trying to decide on transmission, so I'll share that too. Admittedly the diesel gear ratios (what MKM sells) aren't ideal - but if you're not building a race car, I'm not sure it matters. Probably need to change your rear end ratio with the 6 speed though. (why I'm rebuilding a 2.93 LSD from a BMW).

GS6-37bz (gas)
1 2 3 4 5 6
4.350 2.496 1.665 1.234 1.000 0.851
With 2.93 final drive
12.7 7.31 4.88 3.61 2.93 2.49

GS6-37dz (diesel)
1 2 3 4 5 6
5.14 2.83 1.79 1.26 1.00 0.83
2.93 final drive
15.06 8.29 5.25 3.69 2.93 2.43

T5
3.35:1 1.93:1 1.29:1 1.00:1 0.68:1
3.73
Final drive
12.5 7.2 4.8 3.73 2.54

Last edited by 940 16 valve; 11-12-2021 at 02:56 PM..
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Old 11-12-2021, 12:47 PM   #84
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Quote:
Originally Posted by GTFOUR View Post
this thread is plenty full of inspiration, keep the good work goin´

Is the 960 turbo 16v irs a direct swap to a 940?
Thanks! Feels good to be able to contribute some cool content after more than a decade of reading others project threads on this site.

IRS is swappable to a 7/900 with the live axle, but you have to swap gas tank/ and do some fiddling with the brake lines. This car is a 760 so I had IRS from the factory. Have a look at Sanders project thread for some good pictures on how to swap. I've borrowed on a lot of ideas from his thread.

Last edited by 940 16 valve; 11-12-2021 at 02:05 PM..
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Old 11-17-2021, 06:23 PM   #85
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Finally getting to work on the BMW LSD conversion. I figured if I'm swapping to 2.93 gears, then I'll rebuild everything while I'm in there. I was initially going to get a gearset online, but then I found out the LSD carriers are different sizes for the ratios numerically lower that 3.07 or something, so I ended up finding a good used E28 LSD and ordered some clutch packs, bearings, and seals. I ordered a racingdiffs Clutch set for the diff I'm rebuilding for the old BMW E21 (one of the places that makes aftermarket LSD clutches for these), and I'm not really convinced of the quality. The clutches are NLA through BMW, so I found a Porsche part # that is for the same LSD that Porsche made.

2.93 on the right for comparison.
Pressing on new bearings
I think this must be the factory marking for the pinion depth, got to figure that out next
The superimposed VSS trigger wheels. Apparently the earlier models use a larger diameter which won't fit in the later housings (I'm using an E36 housing). That led to a serious WTF moment last night where I was all excited to see it all bolted up and it just wouldn't go.

Now I have things assembled enough to start test fitting the diff in the IRS subframe, while I wait for the new clutch packs to come in. Hoping this might happen by spring
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