I -think- its a Dana 27, but my comfort level on that tidbit insn't terribly high.

However, I'd seriously think about replacing the rear axle with something a little sturdier if I were you. I've heard the PV axle isn't as sturdy as later model Volvo's had, and won't stand up to a lot of HP for very long. Perhaps a domestic pony car axle shortened appropriately?

How much HP are we talking about. And (more importantly really) how much torque?

I did the same thing when a B20 went into my 544. Firsst I changed out the whole rear axle to a newer 544 that meant from a 4.56 (1960) to a 4.10 (guess) from a 4 speed car. Then I still was revving too high for highway work so I placed a M41 with overdrive. A couple of years later, (winter driver) I chose to replace the whole floor/frame from the front seats back with one from a 1800ES. This included disc brakes and heavier springs and a flat floor inside. but I now had a 4.30 ratio. Since I really drive this car all winter long and to the tune of over 15,000 per year, I had a rear axle from an automatic with 3.91. I went with that and I beleive I have the lowest gearing possible....M41 with O/D and the rear axle from the automatic 1800.

http://www.georger.com/virgil.htm

Christopher

Geez... All this work with 122/1800 rear ends recently (see 122 forum), but I didn't get into the 544 at all.

My guess though... its a Dana/spicer 27 just like a 122 sedan. Take a look at the back of the differential cover. Then zoom in to about the 4 o'clock position, and look at the little flat part of casting immediately under the axle. After scraping and cleaning, you'll probably fine a "27" cast into that spot. Probably has 4.10 gears as stock...There should be a steel tag on one of the bottom cover bolts that will confirm this.

Which way do you want to go with the gears anyhow? I'm not sure what if anything is available in a lower set... but you could go with 4.56 gears from an automatic 122 sedan... '66 or earlier (B18 only). Actually, don't hold me to that automatic thing... I just found something that states they have the 4.10 gears too. Wagon gears won't work...they are different. As are all '67 or later Volvos.

But...a quick google search for something like "dana 27 gears" should turn some stuff up. They were common an many sorts of cars...including various Studebaker, Jeep, and others...

-Matt

Rear end is a Dana/Hardy-Spicer/Spicer Type 27.

You'd want a 3.31 (43/13)
or a
3.08 (40/13)

I'm running a 3.31 and 195/65/15 tires and a 2392cc Volvo 4 cyl and 3.13 1st gear.

Be aware no known limited slip for these axles in the lower than 3.73 ratio is known to exist new. Neither are the gears- look for Jeeps, Scouts and very early Broncos in New Old Stock.

With any decent torque- 180 lb-ft or better- the axle tips will break and the ring and pinion are marginal. The axle tips also break from cornering loads.

Consider a Ranger rear end swap, or a swap to a Dana 30 240-series Volvo rear.

I/We would love to hear more of your project.

Ian

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