Volvo RWD 200 Forum

Hi everyone. I'm a little confused about the transmission input shaft size on the M45/M46 transmissions. I thought they were either the coarse spline (10 teeth) or the fine spline (22 teeth), and all the same diameter. But, when looking at a clutch web site, there was some indication that the later 22-teeth spline clutches had either 15/16-inch diameter or 1-inch diameter, depending on year and model. The trans I have appears to be 15/16-inch diameter 22-teeth spline on the input shaft.

Also, does anyone know if any of the Volvo transmissions have a matching 22-teeth 15/16-inch OUTPUT shaft for the driveshaft flange on the back? I looked at the output shaft on my M45 and it looks to be larger in diameter than the input shaft.

I'm asking these crazy questions because I'm trying to come up with the best way to couple my electric motor to my M45 input shaft without having a machine shop involved. Yes, I'm converting a Volvo to an EV (more info here: http://evalbum.com/2356 if you want to have a look!)

Regards,

Greg Sievert
Melbourne, Australia

Howdy Greg,

I think the 1 inch input shaft was used on the M90 transmission. The M45/46 should be 15/16.

I was reading the information available on the WarP9 motor and I saw this:

This motor has a 1.370" diameter hardened drive shaft with a 32-tooth, splined shaft that matches a Turbo 400 transmission. It can also be ordered with the optional Turbo 400 "shorty" tail shaft housing, and matching 1350 style slip-yoke. The 1350 slip-yoke can be easily adapted to any manufacturers drive shaft.

Hi Shannon - thanks for the reply. For some reason the system won't let me update my email address, so I had to log on to see the messages.

I have a Warp9 with a 1.25-inch keyed shaft, not the TransWarp9. I'm going clutchless, so just need to couple the 1.25-inch keyed shaft to the trans input shaft. The Warp9 has a recess for a pilot bushing, so the pilot shaft of the trans will fit in there and be supported, and the motor housing and bellhousing will be firmly connected with 1/2-inch aluminium spacer disks. If worse comes to worse, I'll modify a clutch disk to enable mounting it to a machined motor shaft coupling...I was just hoping to find some other splined object that was more robust than a clutch disk...although many people use a modified clutch disk.

Using an auto trans is not feasible due to the need for hydraulic pressure - needs an electric pump which wastes battery power. With around-town driving, a manual trans with no clutch works great because you can pretty much stay in 2nd or 3rd gear, depending on the speed zone. Shifting isn't too difficult, even without the clutch, if done slowly.

I'll try the library link - thanks!

Greg