Volvo Transmission Swap - Your Thoughts, Opponauts?

"liquid_popcorn" (liquid-popcorn)
09/20/2013 at 15:11 • Filed to: 240 project

I've decided that at some point I need to do a 5-speed swap on my '83 240. It has a four speed auto; I want a 5-speed manual to prepare for an eventual motor swap to something quicker.

How brutal is the changeover, and where's a good place to start for research and stuff?

Thanks. E28 interior for your troubles.

DISCUSSION (22)

MonkeePuzzle > liquid_popcorn
09/20/2013 at 15:14

the picture had me thrown, no matter how long I'm on oppo the "picture unrelated" thing still confuses me sometimes :P

do eet, depending on difficulty, swapping to a 5 speed will make even a boring engine more enjoyable

*in most cases

** picture is unrelated

Kinja'd!!!

Casper > liquid_popcorn
09/20/2013 at 15:15

A) Are you sure the transmission you would be moving to would be compatible with the engine swap you have planned? It would be pointless to swap in a transmission only to remove it with the engine during the swap.

B) Does the automatic and manual transmission options of the era directly interchange in the car in question?

Swapping from automatic to manual isn't all that hard if you can get the required parts from a junk yard (transmission, clutch, flywheel, clutch pedal assembly, clutch lines, etc) and it's usually not extremely scientific doing the change, but there will be A LOT of hidden costs you won't even know until you are started. For instance what bolt differences you will need, weird mounts, extra tools, etc.

505Turbeaux > liquid_popcorn
09/20/2013 at 15:17

Easy as pie, although how did your 83 come with a 4sp auto? I thought they were all 3 till 84 when they went to the AW70. going for an M47?

Here is a good writeup for you http://www.brickboard.com/RWD/index.htm?…

Just Do It ™

liquid_popcorn > 505Turbeaux
09/20/2013 at 15:20

Mine has an AW70...I haven't done any research on when they switched. Maybe it was a late '83?

Also, probably M47; I'm not certain yet. I haven't really started looking yet, I've just been cataloguing upgrades to make over the past few days and trying to figure out in what order the work needs to be done.

Thanks for the link!

liquid_popcorn > MonkeePuzzle
09/20/2013 at 15:20

Hah, thanks. Also, yeah, I was on Stanceworks earlier and couldn't not share that.

MonkeePuzzle > liquid_popcorn
09/20/2013 at 15:22

had me wondering if you jsut didn't know what you posted, or if you were going to do a volvo trans in a bmw. But then reading

liquid_popcorn > Casper
09/20/2013 at 15:23

A) No idea yet; I haven't settled on an engine. All I know is I'd like it to be roughly 200-250hp minimum, revvy, and not tremendously heavy. I also haven't decided on N/A vs forced induction. I have no idea what I'm doing here, so I have a lot of research to do.

B) There is a manual for this car that should slide in relatively well, if I go with it. It mostly depends on what I find for an engine option.

I figured that; I read a build thread for a TDI out of a Beetle going into a Ford Ranger...that was ridiculous.

505Turbeaux > liquid_popcorn
09/20/2013 at 15:24

It was a totally random thing for the 84's, ah well who knows. The AW70 from the 3 sp swap is common too. My 2.1 242 with the 3 speed used to run 3500rpm at 65 on the highway, just geared so badly. Drove it back from Chicago to Maine after purchase, no radio and my ex-wife for company. Notice EX in that, it sucked. The whine of her and the engine...

Anyhow, I assume you are going to go with a 16V or a red block turbo in the future, out of a 740/940T? All those work fine

liquid_popcorn > 505Turbeaux
09/20/2013 at 15:31

Probably the redblock turbo, based on the very cursory research I've done so far. Plus it's common enough that I can get help with it. I need to make up my mind on how far I want to go with this...it only has ~110,000 miles, and I have more ambition than talent.

Also, that sounds horrible; geez.

505Turbeaux > liquid_popcorn
09/20/2013 at 15:38

first off, join this forum http://www.turbobricks.org/

second research the B230FT and the B204GT red blocks. 204 had a porsche designed 16V head and intercooler, but the 230 is the old faithful 8V redblock with some heavier duty bits in there. Either will work with the M47.

liquid_popcorn > 505Turbeaux
09/20/2013 at 15:46

Awesome, thanks!

IDROVEAPICKUPTRUCK > liquid_popcorn
09/20/2013 at 15:54

Here ya go
http://yoshifab.com/store/index.ph…

liquid_popcorn > IDROVEAPICKUPTRUCK
09/20/2013 at 15:56

You are an excellent person.

Have you used this part, by chance? I'd love firsthand feedback on parts if possible, which is why I ask stuff on here and turbobricks (and occasionally bimmerforums...I still need a 635csi someday...)

IDROVEAPICKUPTRUCK > liquid_popcorn
09/20/2013 at 15:58

Or if you want to change to a Getrag 242/245 you can get this:
http://yhst-26451710505916.stores.yahoo.net/ge26tradkitt.h…

IDROVEAPICKUPTRUCK > liquid_popcorn
09/20/2013 at 16:11

I have not, my 242 still has a M46 since It's still N/A.

I know Cameron from ipd using the getrag conversion in his turbo wagon:
http://turbobricks.com/feature.php?co…

ZeroOrDie - Powered By MZR > liquid_popcorn
09/20/2013 at 16:13

Getrag 5 speed. Volvo inline 6. B3064e or something. The 2.9/3.0 N/A. Do it.

liquid_popcorn > IDROVEAPICKUPTRUCK
09/20/2013 at 16:19

Awesome, thanks!

liquid_popcorn > ZeroOrDie - Powered By MZR
09/20/2013 at 16:23

Haha, I'll look into it! The engine swap/transmission swap will probably come late next year - there are a number of other things I need to do first, such as finish my degree, unfortunately. I won't have money or time until next fall, which gives me plenty of time to research.

ZeroOrDie - Powered By MZR > liquid_popcorn
09/20/2013 at 16:40

Came in RWD format in the 960/S90 Just needed a proper manual behind it. Its a really pretty engine too.

BiTurbo228 - Dr Frankenstein of Spitfires > liquid_popcorn
09/20/2013 at 16:43

I'm doing a manual swap on my Jag at the moment. It's taking a while, but it'd have been finished yonks ago if I didn't have 4 or 5 projects running simultaniously.

The job itself isn't terribly challenging. A fair amount of lugging heavy things around, and depending on the access you have down the transmission tunnel it can be tricky to get all the bolts off the bellhousing, but nothing that actually requires any more expertise than your average parking lot mechanic.

A couple of things I've learnt though:
-Check to see if there are any bellhousing bolts that stick out into the air. If any do, they will most likely be rusted and will need freeing off before you try and get them out. The topmost bolt on mine stripped because I didn't realise it stuck out of the other end of the bellhousing. Caused me a hell of a lot of grief.

-Make sure you've jacked the car up high enough to get the gearbox out from underneathe the car. Seems obvious, but I completely blanked on it and had to faff about with jacking it up again.

-Make sure you have all the parts you need, or at least access to them. It's trickier for me as there weren't many manual Jags produced in the first place, and most of them have met the scrappers, so parts are hard to find. The only thing I'm left waiting for is some non-standard sized hydraulic unions so I can make up a hydraulic pipe between the clutch master and slave cylinder.

A list of parts you'll probably need:
-gearbox (duh)
-clutch
-maybe a bellhousing adaptor plate (I think that might just be specific to the Jag)
-pedal box
-clutch master and slave cylinders if it's a hydraulic clutch
-a pipe between the master and slave if it's hydraulic, a clutch cable if it's not
-flywheel for a manual car
-gearstick
-interior trim to fit the stick
-ECU if the auto box is tied into the engine management (unlikely for the Volvo, I think the Jags in '88 was an early adopter)

You might also need to weld on a bracket to attach the solid clutch line to (again, only if hydraulic).

liquid_popcorn > BiTurbo228 - Dr Frankenstein of Spitfires
09/24/2013 at 08:41

Awesome, thanks a lot!

Also, you should post up pics of the Jag sometime.

BiTurbo228 - Dr Frankenstein of Spitfires > liquid_popcorn
09/24/2013 at 12:19

I've got a couple of it before it was holed up, but none of it during the swap yet.

I'll get something sorted once it's back on the road. Get a nice little background for it.

Kinja'd!!!