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Well I heard from a couple of sources, and it clarified things some more so here's the latest revision:
Best I can tell here's the scoop:
1) Seems that 200 series turbo's, diesels, V-6's and some wagons likely came with the 1031 rear end. Everything else should have the 1030 which is the Dana30. Looks like 700 series cars came with both the 1031 and 1030 depending on how they were optioned. More than likely, turbos have the 1031. The bottom line is that it's difficult to say with complete certainty that any particular option or gear ratio definitely had one rear or the other, so physically checking is the best way to be sure. Read on for some of the checks that will distinguish between the two. 2) Any diff that will fit the 1030 will also fit the 1031. If you're just swapping diffs without replacing bearings, etc., you just need an assorment of Dana30 shims to do the job with either rear end. If you're rebuilding everything, then you need a Dana30 master rebuild kit for the 1030. The inner and outer pinion bearings and races in the kit however, will not work with the 1031 pinion; different one's are required. So, if you're rebuilding the 1031 you'll need the master rebuild kit for the Dana 30, plus the following parts. The inner bearing is part no. 89449 and the race is 89410. The outer bearing is no. 86647 and the race is 86610. All these parts are Timken, however the numbers are from Randy's Ring & Pinio catalog in Seattle. For what it's worth I found them to be much more knowledgeable and helpful than any other supplier.
3) Ways to tell the 1030 from the 1031. Some said they are tagged externally with info that distinguishes. Many of the paper tags on the driver's side axle tube have gone missing over the years. Mine was there, but the part numbers require deciphering - that is, it doesn't actually say 1030 or 1031 anywhere on my unit. However, in talking to folks the following differences seem to be consistent:
a) If the distance from the mounting surface of the back diff cover to the leading edge of the housing casting (pinion side) is 10.125" it's a 1030. If that distance is 10.625" it's a 1031.
b) on either side of the center section there are strengthening ribs or gussets. If the unit has one rib on each side it's a 1030. If it has 2 ribs on each side it's a 1031.
c) If the center housing casting or the ring gear has the word "Volvo" stamped or cast on it anywhere, then it's a 1031.
d) If it's got a 7.25" od ring gear - it's a 1030. If it's 7.75 od then it's a 1031.
Hope that helps - Michael
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