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 Post subject: T5 into a 940 - Progress!
PostPosted: Wed Jul 30, 2014 10:44 am 
Vmax 200mph w00t!
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Joined: Mon Apr 19, 2010 4:21 pm
Posts: 265
Location: Saskatoon, Sk
Hey all, i have some progress to report!

Cutting the bellhousing for the LH2.4 crank sensor (snapchat special)
Image

Hanging waiting for a new starter and a couple odds n ends.
Image

Torquing the bolts to exact manufacturer's standards using best practices in safety and reliability:
Image

Engine in! had to do a little bit of fandangling this time around with so many variables changed. Especially since i ditched the pilow motor mounts in favor of something more solid.
Image

Eyeballing the shifter in the tunnel. Not too bad? I'll cut an inch or two off the tunnel and space back a bit and it should be fine. I have a dog-leg shifter as well.
Image

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94' 944t "The Good One"
87' 780 5.0L V8


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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Wed Jul 30, 2014 7:23 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Location: Lethbridge, AB
Looking good...I'm going to be doing a how-to as we're doing this exact install this weekend in my 242. How's it been so far?

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Wed Jul 30, 2014 9:45 pm 
Vmax 200mph w00t!
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Joined: Mon Apr 19, 2010 4:21 pm
Posts: 265
Location: Saskatoon, Sk
I still havent verified that the transmission is engaging etc...i'm still a little leary that everything is going to work as advertised.
Still need a transmission crossmember. that's this weekend's goal.

I was more worried about the timing and flywheel trigger with the new parts/underdrive i put in....

[youtube]https://www.youtube.com/watch?v=4EyYPwImeYU[/youtube]

...well it started, which means they're probably set properly =D> :lol: :roll:

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94' 944t "The Good One"
87' 780 5.0L V8


Last edited by solyeahman on Fri Jan 09, 2015 1:04 pm, edited 1 time in total.

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Thu Jul 31, 2014 6:35 am 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Dec 21, 2005 8:40 pm
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Location: Calgary, Ab
Love the photos, Sol. Glad the car's running!


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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Thu Jul 31, 2014 8:58 am 
Vmax 200mph w00t!
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Joined: Mon Apr 19, 2010 4:21 pm
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Location: Saskatoon, Sk
Thanks Matt!

Hey guys i have a question...I think the mounts i put in the car are putting a slight angle on the way the engine sits. How can i verify/correct this?

you cant really see it in this pic, but once the transmission is jacked up to full height it is no longer centered through the shifter hole

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87' 780 5.0L V8


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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Thu Jul 31, 2014 9:00 am 
First volvo in outer space
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Ugly Duck wrote:
Love the photos, Sol. Glad the car's running!


Same. The first pic made me think of Gene Wilder in Frankenstein. :lol:

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66 122S (Garage Queen)
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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Thu Jul 31, 2014 9:42 am 
Vmax 200mph w00t!
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Location: Saskatoon, Sk
woodenshoes wrote:
Ugly Duck wrote:
Love the photos, Sol. Glad the car's running!


Same. The first pic made me think of Gene Wilder in Frankenstein. :lol:


hahaha, did you watch the youtube video? i felt like Gene Wilder :lol:
#whathaveidone #ivecreatedamonster

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94' 944t "The Good One"
87' 780 5.0L V8


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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Thu Jul 31, 2014 2:32 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Dec 21, 2005 8:40 pm
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Location: Calgary, Ab
Unless it's WAY out I'm not sure I'd worry about it, Sol. The T5 shifter housing sits at a slight angle compared with the transmission mount pad, and it might not be centered in the hole even if you get the centerline axis perfectly centered in the car. There's slop in every bolt hole too, so if you think about the minor misalignment possibilities in the connections between the mount bracket and block, between the mount bracket and the mount, and between the mount and the crossmember, you can easily end up with 1/2" or more of misalignment by the time you get all the way back to the tailshaft.


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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Tue Aug 12, 2014 10:18 am 
Vmax 200mph w00t!
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Joined: Mon Apr 19, 2010 4:21 pm
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Location: Saskatoon, Sk
Well i did some more stuff...

Made a transmission xmember entirely out of spare metal pieces i had. not horrible, but no idea how long it'll last. "eyeballed" the driveline angle with a laser level.
Image

This shifter thing is just, bad. I cut more out of the tunnel than i would've liked. and i wont be able to use my coin tray with this.
Image

I did order this thing off of ebay:
http://i.ebayimg.com/00/s/MTIwMFgxNjAw/ ... k/$_57.JPG
Maybe it'll help a bit? who knows.
Maybe in the future i'll get a camaro tailshaft or do something else with it. I just want to get it in and driving.

Transmission stuff to finish:
-Plug off the speedo hole
-wire the reverse lights
-connect slave cyl and verify that the clutch disengages properly
-driveshaft

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94' 944t "The Good One"
87' 780 5.0L V8


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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Tue Aug 12, 2014 9:46 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Jun 14, 2006 4:19 pm
Posts: 3126
Location: Lethbridge, AB
Is that transmission mount solid? Why?

I used the standard urethane mount...I'll report back when the car rolls.

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Wed Aug 13, 2014 8:42 am 
Vmax 200mph w00t!
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Joined: Mon Apr 19, 2010 4:21 pm
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No other reason than simplicity. I've seen others make a solid mount so I thought i'd give it a try. I considered using the urethane mount from the m46 but decided against it

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94' 944t "The Good One"
87' 780 5.0L V8


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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Wed Aug 13, 2014 5:47 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Dec 21, 2005 8:40 pm
Posts: 3482
Location: Calgary, Ab
But a solid transmission mount with soft motor mounts? Something's gotta give.


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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Thu Aug 14, 2014 10:13 am 
Vmax 200mph w00t!
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i swapped out the bags with urethane motor mounts.

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87' 780 5.0L V8


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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Tue Sep 16, 2014 11:49 am 
Vmax 200mph w00t!
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Joined: Mon Apr 19, 2010 4:21 pm
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Location: Saskatoon, Sk
Hey guys,

Not much progress lately, i'm having some problems with the swap.
The more i read the more i see that it's a prevalent problem.

My setup is:
-flat flywheel, resurfaced and cut for LH2.4
-Clutchnet hybrid organic/CF clutch (looks like this on one side, organic on the other: http://m4.i.pbase.com/o3/22/59322/1/107 ... tchnet.jpg)
-Clutchnet pressure plate
-hydraulic 740 master/slave
-Unknown throwout bearing. if memory serves it's physically larger than the OEM throwout bearing.

The car is still up on stands so here are my observations thus far:

- I can shift the trans into any gear with the engine off.
- the driveshaft spins when the engine is running. regardless if the clutch is in or not.
- I can start the engine, pull the ebrake, and shift it into 1st with the clutch pedal depressed. (it crunches a bit, but goes).
- I cannot shift into any other gear easily with the engine running.

I've added a shim where the slave cylinder rod meets the clutch fork. (ie. a bolt with a recessed head)

According to my reading it could possibly be:
-Pilot bearing issue. (i packed it and made sure it slipped in properly with the input shaft, so i'm thinking that's not it)
-TO bearing doesn't push the Pressure plate enough.(The TO does not appear to be bottoming out on Pressure plate yet)
-The clutch disk is too thick...Pressure plate should be shimmed away from the disk
-Clutch disk is oriented incorrectly....?
-Just get in and start driving and the clutch will burn a layer off and sort itself out after a few days

I'm not sure how to diagnose or test this properly. Can anyone impart some wisdom?

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94' 944t "The Good One"
87' 780 5.0L V8


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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Tue Sep 16, 2014 4:16 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Dec 21, 2005 8:40 pm
Posts: 3482
Location: Calgary, Ab
The hydraulic throwout linkage and the flat flywheel/clutch/TOB don't play nicely together. It takes a certain amount of bodging to get the rod long enough to disengage the clutch. For my car I added a few washers between the pivot and the bellhousing, for Dale's car we lengthened the throwout rod (and have been meaning to make something a little more permanent, now that I think about it).

Don't "just leave it". If you're not careful, you'll pop the slave cylinder trying to push the clutch too far.


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