Volvo C30 AWD Conversion

Discussion in 'NFC Forum' started by lookforjoe, Dec 30, 2018.

  1. lookforjoe

    lookforjoe True Classic

    Installed new rear hubs today.

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    Took screenshots from VIDA, since one cannot screenshot or export as PDF from VIDA, at least on mine install.

    Haldex overview & CAN signal I/O description

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    Not sure there is any point cutting a hole for the PS (main) sender, as that cannot be removed unless you also lift the DS sender to release the cross tube and level sender wiring. Looking at the floor, the PS unit would have to be cut right where the seat belt mount is located. It's also not a flat area. I dunno. Not sure I want to mess with this now.

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    Tavalin likes this.
  2. lookforjoe

    lookforjoe True Classic

    Last edited: Mar 10, 2019
  3. lookforjoe

    lookforjoe True Classic

    Working on the fuel sender tool. I found a couple listed as applicable, but they didn't fit. Not spending another $60-80 looking for others, so I started making my own.

    Took a bunch of measurements, as part of determining whether a Mercedes tool would work.

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    Cut up some aluminum square tube, and a section of 6" tubing.

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    Tack welded the tabs. Have to add two more. It's around 25º in the garage, so a PITA to weld aluminum.

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  4. fastx19

    fastx19 Administrator Moderator

    Location:
    Santa Clara, CA
    You are a brave man. Every time I get close to anything with Fuel, such as the tank, it makes me pucker. Yeah, I know it is drained of gas, etc. but still... Looking good.
     
  5. lookforjoe

    lookforjoe True Classic

    Found out today that the two tank senders are different sizes. The main sender is a little over 6.5" OD, the secondary sender is approx 6.3". Fortunately, I ( purely by accident) used a box section to make the tabs that is deep enough to fit both sender caps.

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    Last edited: Mar 10, 2019
    kmead likes this.
  6. lookforjoe

    lookforjoe True Classic

    Finished the tool for now

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  7. kmead

    kmead Old enough to know better

    Location:
    Michigan
    Looks like an innocent T Square gave it’s life to the cause
     
  8. lookforjoe

    lookforjoe True Classic

    I have 5 or 6 old Aluminum T squares I got from our tech department - the kids bend the crap out of the ruler, rendering them useless as measurign tools.
     
    kmead likes this.
  9. lookforjoe

    lookforjoe True Classic

    Had a few hours this afternoon to work on the AWD subframe & Haldex.

    Removed pinion flange

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    Removed Haldex pump and filter. Has 95k, so I'm replacing the pump.

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    dismantle pump housing

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    new pump going in, new orings & shaft seal

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    housing cap & rotor/vane

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    cap with new orings on the screws

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    filter screen back on, new outer orings

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    New Filter & cap

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    Torque flange to 80ft/lb, bitch to counterhold

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    Replaced the three diff bushings, donor was auto trans, which uses different composition bushings

    Torque bush - absolute PITA to extract

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    pressing in the two rear bushings (plastic cage) - using an old Volvo 240 tool - for the large trailing arm bushings, didn't think I'd ever use this again

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    dllubin likes this.
  10. lookforjoe

    lookforjoe True Classic

    Drained the Haldex & rear diff yesterday, neither holds much over .75L, but take forever to get it out, they only provide fill plugs.

    Added the connectors for the new Haldex pump

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    ready to accept the DEM

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    kmead likes this.

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