Ok fellows, Now I'm back from our clubs Russian Safari and I have time for short explanation about my home made Volvo under drive :)

First of all I got idea for it when I saw that system on summer-98. It was made by one Suzuki enthusiast and it's description is at http://www.suzuki-samurai.nl/volvo/volvo-eng.html
That system was made by using Suzuki carry's shorter tranny tail and by welding the yoke to Volvo trannys input axle.

Tranny is model M40 and it was ud´sed at 100-series in 70's and amazones at 60's. Also some early 240's has that box.

Next winter I took body from frame and started to measure how it should be done. I decited to connect suzuki tranny's output axle and volvo trannys input axle with yoke from original mid drive shaft (In pic yoke is over volvo trannys input axle and "ears" of u-joint are removed at lathe)
I also decited to use original tail to get better connection for subframe and move engine forward about 7cm.
http://photo.jippii.fi/fi/image//data/photo/jippii.fi/t/e/tessal/1021302938732.jpeg

Same spindles were cutted to Volvo input axle as suzuki output axle has. That was made by one metal guru who had spindle cutter at his garage. same guru also carbon hardened axle so that surface is hard but inside is viscid (spelling:confused: )

Next thing was making of sub frame. It was wery important to get axles alignet well to avoid vibrations and get all running accurately. http://photo.jippii.fi/fi/image//data/photo/jippii.fi/t/e/tessal/1021302936619.jpeg

It took time but result was better than I was expected.

http://photo.jippii.fi/fi/image//data/photo/jippii.fi/t/e/tessal/1021302931087.jpeg

Connection between volvo tranny and t-case is made with Mercedes rubber joint. Flanges for it are home made. I lathed and connected by welding MB's 3-arm part to volvo output and t-case input flange cores. http://photo.jippii.fi/fi/image//data/photo/jippii.fi/t/e/tessal/1021302932881.jpeg
http://photo.jippii.fi/fi/image//data/photo/jippii.fi/t/e/tessal/1021302927707.jpeg

And here is whole "thing" from side perspective
http://photo.jippii.fi/fi/image//data/photo/jippii.fi/t/e/tessal/1021302942026.jpeg

After all this was done I made test assembly and noticed that everything fits fine. I made special support under Volvo tranny so that in the big jumps engine mounts and t-case mouts are not so stressed.

Whole transmission tunnel was forced to redesign. and make one more hole for volvo shifter. it's bossible to shift both trannys separately.

Most important thing is keep everything as well as possible alighned. I have used this system as daily driver few years and there is small vibrations but generally I heve been very happy with it.

I have broken that connection yoke between SJ410 tranny and volvo tranny 2 times but now after right heat treatment it's been running about 3 years.
Only problem is oil which is running from suzuki tranny through splines. Next time I take it down I need to make some kind of seal for it.

Here is my "babe" after American Car Show 2002 where it was exhibited on off-road stand :smokin:
http://pic5.picturetrail.com:80/VOL83/530357/759623/9196068.jpg

That's sweet! I've seen that page too and some other funky one's in Sweedish. How does it handle the torque. Ya think the M40 wouldn't be able to handle a 100:1 gear ratio.

What im getting at is.......How does it wheel!

Originally posted by Stu
How does it handle the torque. Ya think the M40 wouldn't be able to handle a 100:1 gear ratio.

What im getting at is.......How does it wheel!

It wheels great :D :D :D It's nice to have 32 different gear ratios. Generally I wheel suzuki tranny on 1st and volvo tranny on 2nd. That seems to be good "all-terrain" gearing for slow trail riding. In though places as rock crawling I use both trannys on 1st.

Some Volvo gurus said that M40 is capable to handle 200hp.
Also volvo tranny is not so heavily stressed because most of the gearing is after it.....and I have Original SJ410 motor w/ 45 wild horses :mad: :mad:

On a hiway Its easy to find right gear ratio. I use volvo tranny on 3rd most of time. In volvo tranny gears are: 1st=3.41:1 2nd=1.99:1 3rd=1.36 4th=1:1 rev=3.25:1

At the begining there was broblems whit SJ410 axles, I broke many birfields and rear diffs. Now with Daihatsu Rocky axles there hasn't been any failures....yet:rolleyes:

I saw what appeared to be an updated Sammi coming down the road a cople days ago. When it got closer, I noticed "Daihatsu" written on it. I guess it was one of these. It looked pretty cool.

I don't know about you guys but this is starting to sound like something OTT would be pretty interested in. Not to start rumors but maybe the kicker 3?

:confused: :D

Back to lurking and finding an M40.

Dave

Very cool idea!!!!

How long is this? Looks long as a house;)

Originally posted by SeaBass44
How long is this? Looks long as a house;)

House is politically incorrect it could be as long as a mobilehome:smokin:

A newbie finally posts something cool and then runs off.......

hey ive seen this guy on offroad.com before. its a cool setup, but hes using a tranny tailhousing that i think is of a suzuki carryall? i dont think it was ever available in the US. it can be had in south america and europe. the volvo tranny can be found in canada from what i understand, but are tough to find here in the USA:usa: from what ive seen hes put lots of work and effort in this. and 30+gears, holy:bender: batman! thats the:nuke:

Originally posted by RudeZuk
A newbie finally posts something cool and then runs off.......

Sorry my english is not so good to know what that mean:rolleyes: :rolleyes: :laughing:

Originally posted by beefpuppet
its a cool setup, but hes using a tranny tailhousing that i think is of a suzuki carryall?

Nope, I have used original tailhousing from SJ410 because that way i got better connection for sub frame from bolts which are holding tail housing.

House is politically incorrect it could be as long as a mobilehome

Yes it's little long BUT t-case is in original position and motor is moved forward about 7cm =2 3/4 inch.

I know that easiest way to get similar gearing is swap t-case and R&P gears but main aspiration is keep it cheap and build my self as much as possible. We live here next to nothing (and I'm not meaning russia with that:) ) and it's very expensive to order parts here.

hey tessal,
Do you know anyone who is running a volvo b21 and m47 in thier samurai or sj410? It was a swap that i was contemplating but couldn't much info for, thanks.

:beer:

Originally posted by Stu
hey tessal,
Do you know anyone who is running a volvo b21 and m47 in thier samurai or sj410? It was a swap that i was contemplating but couldn't much info for, thanks.

Yes i know that there is that kind of combinations in Sweden but I haven't seen any in live. it sounds like nice and stout swap.

By the way I have under developing B23E, Volvo Valp "Laplander" tranny/t-case + Valp axle swap.
B23E is from ´83 240 and it should have 136hp and axles and gear boxes are from Swedish army vehicle which had only 38000km at the gauge.

Here is some pics of those parts...:D
http://photo.jippii.fi/fi/image//data/photo/jippii.fi/t/e/tessal/1005288119995.jpeg

http://photo.jippii.fi/fi/image//data/photo/jippii.fi/t/e/tessal/1005288114541.jpeg

http://photo.jippii.fi/fi/image//data/photo/jippii.fi/t/e/tessal/1005288112707.jpeg

TessaL - Keep up the work. I like what you have done. Please keep us posted on the new project. Those new axles you mention, are those the portal design (the hubs hang down)?

Any pictures of your vehicle on the trail?

Thanks,

-Wayne

Those Volvo Valp axles are NOT portal style:( they are made by Salisbury company at England and they are "almost direct" copy of dana44. Rear has LSD and front has birfilds (Toyota size)
Portal axles are from Volvo C303 "Laplander" and Valp is C303's little brother

I will post some trail pics l8r