SwedeSpeed - Volvo Performance Forum banner
321 - 340 of 1289 Posts

·
Registered
Joined
·
1,897 Posts
Hello, me again. Sorry for hogging your thread, just have a few more questions.

Are the calipers the only thing you need to accomodate the bigger discs, or do you need the brackets as well? Do you know which years or models got the bigger brakes, and did the get bigger front and back at the same time? Over here, most XC90s have them, but they are expensive compared to say Sweden, so I probably won't get to see the part in anything else than a grainy pic.
 

·
Registered
Joined
·
5,527 Posts
Discussion Starter · #325 ·
Hello, me again. Sorry for hogging your thread, just have a few more questions.

Are the calipers the only thing you need to accomodate the bigger discs, or do you need the brackets as well? Do you know which years or models got the bigger brakes, and did the get bigger front and back at the same time? Over here, most XC90s have them, but they are expensive compared to say Sweden, so I probably won't get to see the part in anything else than a grainy pic.
I'll share what I know.

There are 3 different sized brakes, 316mm, 328mm, and 336mm. I'm unsure which models came with 328mm, but from my understanding XC90 2.5T came with 316mm as they'll fit under 16s, and XC90 T6 and V8 came with 336mm, rear brakes are the same size for all models. All calipers require the correct carrier. Most likely which ever caliper you purchase will come with the correct carrier.

The 336mm calipers are larger than the 316mm and also require a different sized carrier. Here's a side by side of a 316mm caliper and a 336mm caliper.




Numbers are:
316mm Calipers: 30639520 and 30636355, or casting number 969 and 970

336mm Calipers: 30657307 and 30657303, or casting number 960 and 959

Sent from my Nexus 5 using Tapatalk
 

·
Registered
Joined
·
1,897 Posts
You, sir, are a hero. The part numbers will make it tons easier.

I was used to the P80 brake upgrade from 280mm to 302mm, where you keep the caliper and carrier, and swap out a bracket holding the carrier to the hub assembly. That's the bracket I was talking about, there is no bracket in between here, then? Caliper and carrier assembly bolts directly to the hub assembly?


The 316s are pretty common here on XC90s, thet were standard on the diesel cars, and the 336s probably were delivered on the T6 and V8s here as well, I've been led to believe. The part numbers are a step up in searching, though. Thanks for that.

I fiddled around with this last summer, but let the plans go since I really didn't think the OEMs were bad brakes - but seeing how nice your discs fill out the wheels I'm gonna have to pick this back up.
 

·
Registered
Joined
·
5,527 Posts
Discussion Starter · #327 · (Edited)
That's all...

"Hub" - Spindle enlarged to 14mm


Carrier and Rotor mounted

(No steering limiter, you'll need a limiter enlarged to 14mm for non-XC models along with longer M14 bolts)

Caliper mounted to carrier via guide pins (7mm hex)


Bleed the beetch


and...




Just make sure you bleed them well. I had 2L of Pentosin LV DOT4 and my pressure bleeder. Bled the rear right (furthest from master cylinder) first then worked up to the front left (closest to master cylinder), pumped the brakes to engage the pistons to the rotors then bled again to get any remaining air out. A pressure bleeder is HIGHLY RECOMMENDED!

Sent from my Nexus 5 using Tapatalk
 

·
Registered
Joined
·
1,453 Posts
Looks fantastic! I've been wanting to do this so badly. If I can find the right XC90 locally to pull em...I totally will. Getting to rebuild and paint calipers without any down time with the car is massively appealing. Thanks for all the helpful info here!


Sent from my iPhone using Tapatalk
 

·
Registered
Joined
·
5,527 Posts
Discussion Starter · #330 · (Edited)
Welp....

Got the XC into the garage and I was just going to change the oil. While underneath the XC I noticed that there was soot collecting around #1 and #5 exhaust ports... bah. A little more than a year ago I replaced the exhaust manifold gasket with the Snabb one piece copper gasket, it seemed to have fit fine and I had zero issues with install. It was later suggested to me that I should use the OE gasket from a S40 T5 by Dougy, I had purchased one to have on hand in case I needed it. Well I guess I needed it.




Lining up the S40 gasket. PN: 8699467


...but there's something else. Upon reinstall I took a look in the turbo exhaust housing, what I noticed isn't so pretty.




Running to hot, bad Mexican ... The way that the metal is breaking apart in large crystals leads me to believe that the exhaust housing is of a poor casting, top grade Taiwanesium. I'm unsure who the manufacturer is, but the turbo as a whole was purchased through ARD in 2014, approx 40k mi on it to date and plenty of time on boost. The rest of the turbo is in top condition, zero shaft play and spins freely so that's a good sign. I've already placed an order for a new 7cm housing though Kinugawa, but delivery will take 1-2 weeks. Until then the XC will be out of commission, all alone, perched up on axle stands.

Meh, is what it is...
 

·
Registered
Joined
·
352 Posts
That's a bummer man. I was kind of under the impression that ARD used Kingawa for most of their stuff, wonder if it might be better to try and source a OEM? I've never seen anything like that before, even on some really high mileage turbos.
 

·
Registered
Joined
·
1,897 Posts
Looks so easy to pull the turbo and manifold. Did you drop the angle gear and go dowm, or up and above? Dreading the day I have to change mine, the VNT turbos are yuuuge (insert Trumpface).
 

·
Registered
Joined
·
5,527 Posts
Discussion Starter · #333 ·
That's a bummer man. I was kind of under the impression that ARD used Kingawa for most of their stuff, wonder if it might be better to try and source a OEM? I've never seen anything like that before, even on some really high mileage turbos.
I was under the same impression, and from my understanding Kinugawa is supposed to be a good brand.

I'm unsure where I could purchase a new OE hot side with out purchasing a whole turbo, and buying a used turbo just for the hot side seems wasteful.
Looks so easy to pull the turbo and manifold. Did you drop the angle gear and go dowm, or up and above? Dreading the day I have to change mine, the VNT turbos are yuuuge (insert Trumpface).
I'm unsure what would be different on a D5, but it's not that bad and can be done without removing the angle gear if you have a bit of an imagination and a sense of humor. If you check the first page on this thread there's a "How To" on turbo removal. This time I fished it up and removed it through the top.



 

·
Registered
Joined
·
1,897 Posts
There's a few differances, the cold side exit goes underneath the engine, so I have to go below no matter what. I've been led to believe going down is the easiesy option on a D5.
 

·
Registered
Joined
·
1,029 Posts
Wow sorry to see that. what tune and injectors are you running with that turbo?


MY02 V70XC, M66, 4T4, 650cc, 455 LPH fuel pump, TME DP+catback, MTE custom tuned
MY05 S60 T5, TME downpipe, Heico catback, MTE Stage 2 tuned
 

·
Registered
Joined
·
5,527 Posts
Discussion Starter · #336 · (Edited)
There's a few differances, the cold side exit goes underneath the engine, so I have to go below no matter what. I've been led to believe going down is the easiesy option on a D5.
Going down on the D5

Wow sorry to see that. what tune and injectors are you running with that turbo?

MY02 V70XC, M66, 4T4, 650cc, 455 LPH fuel pump, TME DP+catback, MTE custom tuned
MY05 S60 T5, TME downpipe, Heico catback, MTE Stage 2 tuned
Hilton Custom Tune
TD04HL-16T 11/11 blade turbine and compressor
Bosch Blue "T5" injectors 0280155830

AFRs are spot on for what it's tuned for and there is no damage to the turbine wheel from what I can see, haven't removed the housing yet because I had to leave it where it is. I have contacted Hilton for his thoughts.
 

·
Registered
Joined
·
5,527 Posts
Discussion Starter · #337 · (Edited)
Should also note that for approximately 20k mi it was operating with an ARD tune. Although I've had it apart before for the previous exhaust manifold job I did not inspect it. I truly believe that this failure is the result of a poor quality exhaust housing.

My new housing has shipped today and hopefully will arrive by the end of the week. It was shipped out by Kamak Dynamics USA.
 

·
Registered
Joined
·
5,527 Posts
Discussion Starter · #338 · (Edited)
Ready for some more ugliness...



There is no doubt in my mind that this is a poor casting. There's also flaking and chipping on the outside of the casting.

There's a bit scraping on the inside of the turbine housing that I could be blamed for. As I was removing the housing I had spun the wheel to make sure that it was coming out straight, which it wasn't. It was really rusted on there and took quite a bit of heat and hammering to get it off, but thankfully the turbine wheel looks good.


So yeah. The housing should arrive by week's end and I'll be glad to be back in boost. I'll be keeping a close eye on this new housing.

Hard on Things
 

·
Registered
Joined
·
2,075 Posts
I have a 16T in my basement that was intended for my 745 but needs a rebuild...I wish I would've known. I would've polished it and sent it your way for the parts and housings.
 
321 - 340 of 1289 Posts
Top