Volvo Under Drive

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.


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 )

Next thing was making of sub frame. It was wery important to get axles alignet well to avoid vibrations and get all running accurately.

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



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.


And here is whole "thing" from side perspective


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: