All you need to know about the M90

[wooble]

Whoo, finally got round to installing the M90 in my 245 this weekend. It's only been sitting in the shed for 2 years. The box itself fits fine in the tunnel, no hammering required. I used the standard dog-dish flywheel and diesel clutch setup. LuK 623224000 has all the parts in one box, and they're actually Sachs branded parts in an LuK box.

The clutch pivot was spaced out 4mm with washers. The clutch bite is about 30% of the pedal's travel off the floor, which is just where I like it. It's a very light and smooth action, definitely an improvement over the M47, but that could just be due to everything being taken apart, cleaned and greased for the first time in 20 years and 150k miles. I'm using the standard 240 clutch hydraulics, all the way from the pedal to the slave cylinder. The 240 slave works perfectly with the M90.

The shift linkage and the arm that holds the shifter were shortened 100mm and welded, and a short shift kit from Craving Boost was installed. The top arm that holds the shifter also had to have the rear locating pin cut down to fit in the tunnel, and the bracket it locates in was cut down and re-drilled to be bolted to the existing captive nuts in the 240 tunnel. Shift feel is good, but there's a bit more side-to-side slop in the shifter than I'd like, it's actually got the same amount of slop as the 150k M47 I pulled out. I'm not sure what I can do about that as it appears to be in the actual box rather than the linkage, but we'll see.

The rear mount was custom-made for me by Peter of www.retroturbo.com (goes by 'silveruser' on here) in the same style as the Captain Bondo rear mount seen previously in this thread, it uses a standard M47 rubber mount and crossmember. He also made me a custom driveshaft spacer which lets the M47 driveshaft bolt up to the M90, and modified the M90 shifter to accept a standard M10 threaded gearknob as I didn't like the M90 knob.

The only other modification required was the bracket for the front exhaust hanger which is held on by the bellhousing bolts. It doesn't fit the M90 as is, 10 minutes love with hacksaw and file had it fitting fine.

Now I am going to crack a beer and wonder when I am going to stop hurting from wrestling the damn box up into the car while laying flat on my back on a brick driveway.

[Captain Bondo]

Originally Posted by luyopadre

thx, could you give me any more details, how to weld it, and if possible pictures, I'm not so familiar with swedish .

Have a look at the picture that says "svetsanvisning" under it. You tack weld the ring to the top of each gear tooth, exactly at the point the white pen is pointing at in that picture. That's all there is to it.

[Ben960]

Hi, I am currently trying to save my 960 as the dual mass flywheel has failed & Volvo are not making replacements anymore. I have been trying to find detailed instructions for fitting an 850 T5 flywheel & clutch to my 1996 960 with a whiteblock 6 cylinder engine & found this forum thread, has anyone here done this conversion?
Will I need to put washers behind the pivot ball & extend clutch slave rod?
Do I need to use the release bearing from the 850 T5 clutch or the one from the 960?
Is there anything else I should know before I give it a try?

Any help on this will be most appreciated.

[Captain Bondo]

Originally Posted by Ben960

Hi, I am currently trying to save my 960 as the dual mass flywheel has failed & Volvo are not making replacements anymore. I have been trying to find detailed instructions for fitting an 850 T5 flywheel & clutch to my 1996 960 with a whiteblock 6 cylinder engine & found this forum thread, has anyone here done this conversion?
Will I need to put washers behind the pivot ball & extend clutch slave rod?
Do I need to use the release bearing from the 850 T5 clutch or the one from the 960?
Is there anything else I should know before I give it a try?

Any help on this will be most appreciated.

Use the 850 release bearing. You may need to rig up a spacer for the slave pushrod/fork but that's a minor detail overall.

Other than that it'll work fine. The only other thing to confirm is that the single mass flywheel does note require shorter bolts than the dual mass (for attachment to the crankshaft).

Also you may need to swap the wires on the crank sensor if you get a flywheel with "dimples" instead of "teeth".

[Ben960]

Originally Posted by Captain Bondo

Use the 850 release bearing. You may need to rig up a spacer for the slave pushrod/fork but that's a minor detail overall.

Other than that it'll work fine. The only other thing to confirm is that the single mass flywheel does note require shorter bolts than the dual mass (for attachment to the crankshaft).

Also you may need to swap the wires on the crank sensor if you get a flywheel with "dimples" instead of "teeth".

Thanks for the advice, I have a flywheel already I may have imagined it but I think it has two rows of teeth around the outside, would the inner row be the trigger for the crankshaft if not where exactly should I look?

[RoadZombie]

Hello from germany
can anyone say me wich type of m90 i have when 10236508 is stamped on it?
I have found that it will be a m90h, is that correct?

And who can say me which clutch setup i can choose for 350-400hp?

Thanks alot!!

[MCRAZER]

Hello,

I got a whiteblock b6304fs (from a 960 '94 with auto tranny) that I want to put in my 244. Now I want to use the M90 on the block but it uses the motronic 1.8. So I'm not sure of the 850/S70/V70 flat flywheel will work. Any solutions on that plz.

Grtz Mathew

[RoadZombie]

No one has an idea which clutch setup?
Things has changend i need a clutch setup for 500hp now(16VT build soon).

Greetings

[Captain Bondo]

I used a sachs 707 and a southbend heavy duty organic disc. It held 540whp and 470wtq. It had a progressive engagement which was quite good but it did chatter.

I would buy and 850r clutch kit just for the disc and install it in a 707 pressure plate. I think for 500hp and 450ftlb it'd do the job and drive almost like stock.

Not sure how many responses you'll get, I'm not aware of any other folks who post here with any regularity other than myself who have done 500+hp m90 setups.

[RoadZombie]

That helps alot! Thank's alot!

Is there any machine work to do on the flywheel to fit the 850R+707 clutch combo?

Greetings from germany

[DennisvdB]

I have a TTV lightened flywheel specially made for use of a 850R clutch.

http://www.ttvracing.com/Volvoflywheel.html
Partnumber 1090

[RoadZombie]

okay good infos! Thanks!

can anyone show me which modifications i can do on the 3rd gear?
i have read that some people weld it on the shaft for more strength or anything like that.

Has anyone pictures of that?

Greetings

[mark244turbo]

Take a look at this: http://www.pukema.com/bilsport/container13-3.html

And this: http://forums.turbobricks.com/showpost.php?p=1048135



And this: http://forums.turbobricks.com/showpo...3&postcount=10

[RoadZombie]

My clutch blowed up yesterday:(
My M90 will go in my 740 in a few weeks and i only must know if the 707 pressure plate bolts right up on my flywheel.

@Captain Bondo
can you say me if that pressure plate is plug and play?
What i have read is that it is from an audi so it is not p&p?
What must i modify?

Thanks and Greetings!

[enrgy]

I have a quick question that i can't find answer through search. I think I know the answer but just want to double check. Is M90 diesel gearbox interchangeable with older diesel gearboxes? The main thing I want to know if diesel bell housing to engine bolt pattern is the same in 240/740/940/960 regardless of the gearbox?
Thanks.

[Fivehundred]

Originally Posted by enrgy

I have a quick question that i can't find answer through search. I think I know the answer but just want to double check. Is M90 diesel gearbox interchangeable with older diesel gearboxes? The main thing I want to know if diesel bell housing to engine bolt pattern is the same in 240/740/940/960 regardless of the gearbox?
Thanks.

There are 3 versions of the M90, diesel, whiteblock and redblock. A Diesel M90 will bolt onto a D24 that previously had an older gearbox.

[enrgy]

Should I stay away from M90 if car will be mostly used for drifting, meaning it would get much more abuse than usual? Planned power is about 300-350hp(not whp). I'm from Europe so finding M90 is possible, but I am not sure if it will hold up the abuse.

[DANLOLASDAD]

Hello im a Noob. Does the M90H bolt straight to the Audi 5cylinder 2.2 20v Turbo engine? i found this thread

http://www.racingforum.pl/index.php?...04&hl=bm%20vag

but the google translation from polish to english is horrendous on page 4 of the thread

http://www.racingforum.pl/index.php?...bm%20vag&st=60

there is this picture which i believe is a Volvo M90H Maybe someone polish can confirm from the thread or another knowledgeable member on volvo/audi comparisons and compatability.

http://www.fotosik.pl/pokaz_obrazek/...1a71d80e5.html

Thanks in advance for any help that may be frovided Im planning an Audi 3B into a BMW E36 and wondering if this Volvo M90H is the perfect RWD gearbox to use

[Gatling]

DANLOLASDAD, unless You found out it allready by Yourself - You need the Diesel M90 for VAG 5-cyl fitment.

D24 bolt pattern bellhousing and so on.

[DANLOLASDAD]

Originally Posted by Gatling

DANLOLASDAD, unless You found out it allready by Yourself - You need the Diesel M90 for VAG 5-cyl fitment.

D24 bolt pattern bellhousing and so on.

Thanks ive gathered that since i last posted here thanks for the reply Im hopefully going to see a full 940 D24T at the weekend €500 ovno I can weigh in what i dont use ha

[Gatling]

Slight OT:
If You don't allready have the 3B You might allso consider AAN or ABY transplant to get rid of the dizzy.

5 cyl. sound out of e36 will defo make them Bimmer guys scratch their heads

[DANLOLASDAD]

Already have the engine and ill be able to run COP setup with standalone ecu I waited for ages for an engine to become available in ireland so i snapped it up when it did. Yes i think an Audi 5 cylinder will confuse a few people haha id like to do a T5 conversion too at some stage

[Gatling]

It's allso noteworthy that a m46 bellhousing for a D24 could work as starting point and allow freedom to use commercial adaptor plates for a BW T5 / equivalent Tremec / some other transmissions with similiar bolt pattern.
Part supply would be remarkably better to say the least - allso plenty of dog ring kits available.
Or make an adapter of Your own for a, say ZF of Your choice.

M90 is a good box, especially with the welded 3.ring - up to a point.
If frequent 1/4 mile visits with lot of power and traction are on the program something more racey could be a better call.

[DET17]

Well I've taken the M90 plunge....found a reportedly low mile M90L2, purchased from a UK fellow complete with front half of the prop shaft, shifter, and hydraulic clutch bits. This came from a 97 9 series, so it will drop right into my 92. Not thrilled about the 3.91:1 first "hill" gear, but it is what it is, and I do live on a hill

The main piece missing which I will need to source is the clutch. From gleaning this thread, reportedly the LUK 3 pc. clutch kit from the 940 TDI, part # 623224000, is actually composed of the SACHs kit 4000 874 001.

I found this one for sale on the UK eBay:

http://www.ebay.com/itm/390449097931...84.m1438.l2649

When I contacted the seller and asked them to confirm it was SACHs, they could not and rather stated that all components are LUK brand.

Can any of you fine UK folks confirm if the contents of this clutch by previous experience?

Web searches have found none of these referenced clutch bits in the States.

Thanks (in advance) for your help!

[DET17]

Well then, as no one from the UK / Europa has replied, I'll shoot a PM directly to some of those listed in this thread. Findings will be updated here for M90 posterity.....