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Discussion Starter #1 (Edited)
We have successfully swapped a 3rd generation Haldex controller into our V50 and completely transformed how it drives. Launching off the line is insane with power going to the rear wheels immediately and the car now behaves like a true AWD vehicle.

While it's still no Evo or STI, this makes the V50 feel very similar to the Focus RS and it is rather easy to kick out the back end and hold a 4 wheel drift.

There is most definitely an improved front/rear power split. You can actually feel the car pushing you like a RWD, rather than predominantly pulling you like a FWD.
Aside from how the car drives, does anyone know of a cheap or free way to determine the new power split? I'm not looking to spend the money to put this car on a dyno.





The stock gen2 Haldex on our cars is a reactive system with a 70/30 power split.
The gen3 Haldex on the V8 XC90 (aka "Instant Traction") is a proactive system with a 60/40 power split, so the rear wheels are ready to go almost immediately like a real AWD vehicle.

All first generation V8 XC90s and some 3.2L XC90s use the gen3 Haldex controller.
Confirmed Haldex part numbers are: 5Wp33504-01, 5Wp22228-02, 5Wp33504-03, or 5Wp22228-04
Volvo part number is: 36001160

You will need to swap the DEM (differential electronic module), solenoid, and pressure sensor. It takes about 5 minutes and only 2 screws. It's a plug and play upgrade with no software required.





Important Notes:

Just because the back end can kick out so effortlessly does not make this a drift mode like the new RS. Considering the 3 piece drive shaft and tiny rear axles, I would highly discourage attempting to build a drift mode for this car with stock parts.

While this swap is successfully working, with no warning lights or errors, on a 2009 with DSTC and on my 2006 with no traction control. We cannot yet confirm this will flawlessly work on all P1 Volvos.

The real testing begins now, as we determine how this effects the fuel economy and how the rear differential holds up with the added power.

As a full disclaimer, the handling characteristics of the car will be transformed from an easy driving AWD Volvo to a rather insane AWD system. While the car is a lot more fun to drive and actually feels like a sports car, you will have to completely relearn how to drive the car. Throttle control is key, as simply mashing the gas pedal can easily make the back wheels spin.

@MooseTech gets full credit for finding this discovery in the process of successfully building the worlds first AWD C30. More details about that here: https://forums.swedespeed.com/showt...legal-and-consumer-owned-C30-AWD-in-the-world

Update: I think we have ultimately concluded that three results can come from this mod.

1. It works for instant power to be delivered to the rear wheels, making these cars behave more like an all-time AWD when you're in the twisties. My V50 is still showing the improvement after 1 year and 25k miles.
2. It works for a few drive cycles and then the car disables awd until the original module is replaced.
3. It doesn't work at all.

There does not appear to be any indication on why it will or will not work depending on model, year, options, etc. The only way to find out if it works for you is to test it yourself.
 

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wow sounds great

This is the most interesting post I have seen in a long time. Definitely interested in this and looking forward to what you learn as you continue to explore this new upgrade. Thanks for sharing. I am tempted to buy this part now.
 

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This is the most interesting post I have seen in a long time. Definitely interested in this and looking forward to what you learn as you continue to explore this new upgrade. Thanks for sharing. I am tempted to buy this part now.
Junkyard and 20 minutes total of your time. Probably $20 if you play your cards right

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Insane! Totally different car for $20 bucks! I am getting giddy.
 

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Seems like I could use this same plan to upgrade my 2004 V70R to the next Gen Haldex, eh?
 

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So just one part or am I going to have to look for a bunch of pieces and sensors?
 

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Looking at wikipedia. The first gen xc90 is from 2002-2014. Although it says the engine was first offered in 2005. Quite the range of years to look for. Not sure how common the v8 is in the xc90.

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GREAT find. The next question is what's the difference to stock unit. If there's little (or no?) difference in solenoid and pressure sensor, it might be possible to clone the software from an XC90 instant traction unit. Reflashing possibility would be a massive bang-for-the-buck game changer.

Food for thought. I already started to browse through some wreckers' inventories to find a 36001160. They seem to be a couple of grand brand new.
 

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Ok the answer all of the above...

Watch the video Michael posted to show exactly how to do this. So simple...just watch the video.

I do believe this is an option on the 04 R but that hasnt been tested. Go for it.

As for the differences and reprogramming to have the XC90 instatrac...guys, lets not overthink the **** out of this. The DEM takes its own software and is a plug and play module. Meaning you can swap it into another like vehicle and itll work. The later cars have an 80 psi sensor and software instead of a 40 psi. This is where we are seeing a benefit.

The xc90 was from 03-14 in the states but the only modules that work are the v8 xc90 and 3.2l 08-14

Lets also not destroy the market on these. Go find a truck and take the module off. These junkyards dont know wtf that thing is so you can get them cheaper. If you search for the part number or buy online, surely your cost will be much greater.

Have fun ladies and gents.




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Discussion Starter #12
Probably $20 if you play your cards right
I paid $180 for my unit. I only see one available on ebay for a little over $200.
Specialty Volvo yards know what this part is... I found a few online selling for $400-$500.
New is about $2500, so definitely go the junk yard route!

So just one part or am I going to have to look for a bunch of pieces and sensors?
The three main parts are shown in the video: the differential electronic module, the solenoid, and the sensor. Most modules being sold used are listed with everything you would need.

Looking at wikipedia. The first gen xc90 is from 2002-2014. Although it says the engine was first offered in 2005. Quite the range of years to look for. Not sure how common the v8 is in the xc90.
I spent a full day trying to figure this out and cross referencing part numbers between all AWD Volvos from the last decade. I counted 10 different Haldex modules used between the S40/V50, S60, XC70, and XC90.

36001160 is the DEM for 2007-2010 3.2L XC90s and 2005-2010 4.4L (V8) XC90s. <-This is known to work.
36001159 is the DEM for 2011-2014 3.2L XC90s and 2011 4.4L XC90s. <-This should also work.

Of course, the unit itself does not have the Volvo part number on it. The Haldex part number 5Wp33504-01 is what you're looking for on the side of the module and also generates more results on an internet search.

I found a 2008 3.2L XC90 for my donor.

GREAT find. The next question is what's the difference to stock unit. If there's little (or no?) difference in solenoid and pressure sensor, it might be possible to clone the software from an XC90 instant traction unit. Reflashing possibility would be a massive bang-for-the-buck game changer.
I'm not sure what the differences are, but there are differences. The Gen3 solenoid and sensor had different markings and numbers on them and the connector was also black on my Gen2 but white on the Gen3.
Honestly, with as messy as tuning can get with these cars, I wouldn't attempt at replicating this with software. Especially when there's a proven plug and play hardware solution.
 

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Discussion Starter #13
These junkyards dont know wtf that thing is so you can get them cheaper. If you search for the part number or buy online, surely your cost will be much greater.
:thumbup:
If you tell the junk yard check out it's an oil level sensor, they might even let you have it for less!
The yard I went to obviously knew they had something, but I figured $180 was cheap enough for testing this out.
 

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If you tell the junk yard check out it's an oil level sensor, they might even let you have it for less!
The yard I went to obviously knew they had something, but I figured $180 was cheap enough for testing this out.
Or a headlight module. Get two and say its both sides. Lol. They will have no clue.



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Discussion Starter #16
Does it have to be from the xc90 because I’m seeing the xc70s also used the same unit
I think so... Referencing 4 major parts websites, 36001160 and 36001159 are only listed as compatible with the 3.2L and 4.4L XC90.
 

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&quot;Real&quot; AWD Upgrade - Improved Power Split - Gen 3 Haldex

Ok, and we’re you re-using the s40 solenoid and pressure sensor or you need all 3 from the xc90?


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Ok, and we’re you re-using the s40 solenoid and pressure sensor or you need all 3 from the xc90?
You need all three from the XC90.
 

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Gen 3 haldex came on all P2 volvos starting in 2006, and P3s in 07, I’m not sure about P1s.

Did you put a stock gen 3 system in your car, or a modified one?

The stock gen 3 haldex is not 60/40 split from a stop. It can also only send 50% max power to the rear wheels. It is pre charged though, and pressure builds with throttle input and steering angle. In slippery conditions it will allow 1/17th of a wheel spin before it engages the clutch as well.

As far as just cruising down the road, it is mainly a FWD system.
 
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