I've had a couple of requests for pictures of the M47 swap. Today I can finally say the project is completely finished. I won't bore you with all the details. Total cost was about $400. This included lots of parts from the JY like 2 M47s (the first one I bought was broken) an a 3.31 axle (covered the cost by reselling the 3.73 that came out) and a bunch of brand new parts like throwout bearing, clutch, trans oil, trans mount etc etc etc. The idea first popped into my head because the AW70 was making a horrible rattling noise. As it turns out the AW70 was perfectly healthy. The flex plate on the other hand had failed, allowing the big stater ring gear to rattle around. In the end the whole project took 1 month of working evenings through several set backs. This is not a step by step how to. Just an overview. The car in question is an 89 240GL with LH 2.4

Start by buying lots of used parts at the JY such as a broken M47 (little did I know), X member, flywheel, pressure plate, clutch cable, pedals etc. 50% off sale is a good thing.


Bought new wear items like the clutch from FCP.


Part one is chaging out the pedals. You can drive an automatic car with an extra clutch pedal but not the other way around. Pedals must come first.


Side by side.


Some of the mounting bolts can only be reached with lots of extensions and wiggle joints.


Half way there, or so I thought.


After the pedals were done, I started on the trans itself. Thats when I discovered the source of the horrible rattle. The ring gear studs were rattling in the flex plate. Here you can see how the hole has become elongated. The rattle became so bad that It would trigger the knock sensor and cause the engine to stall. I would love to meet the volvo mechanic that can diagnose this problem correctly.


Found a $12 impact wrench clearance item at sears with 1 year warranty. This thing made the job so much easier.


AW70 was out in all its greasy glory. My rear cam seal is leaking.


While I was at it I revamped the whole intake and ignition system with fresh gaskets, injector seals, cleaned out the intake and EGR (California car) etc...


Flywheel, clutch and pressure plate in place.


Fast forward a couple of weeks. I discovered the M47 I bought had all the teeth on the input shaft sheered off. It functioned when turned by hand but as soon as you applied any meaningful torque to it the gears would just click past each other. The only way to be sure if ur getting a good M47 is to pull the top cover and look inside. Don't be scared, you can't hurt it. Just be careful not to drop the shifter spring inside. So on to M47 number 2 out of an 89 240 DL. By the way did they produce an 89 240 GL 5 speed? I don't think so. Somebody correct me if I'm wrong. You can save yourself a lot of trouble by filling the M47 with MTL while on its side in your trunk. I put in 2.5 quarts.


Finally had the car on the road with the M47. What a great day that was. I quickly realized that running around with M47 and 3.73 gears would was annoying. I thought I would be able to live with it, but I can't. 3000rpm at 72mph is just too much. First gear is useless and fourth is too close to 5th. I went back to the junk yard for a 3.31 axle out of a manual trans car.


Finally tonight the car was completely back together. All the little things like connecting the reverse lights, neutral starter lock out and hand brake cables were done. What a relief. Took the car for a spirited 75 mile drive through the hills as well as a Seafoam session (this stuff works) and wow what a difference a 5 speed makes.


So knowing what I know now, would I do it again? Absolutely! It would probably take half the time and effort from start to finish. Would I recommend a project like this to somebody else? NO! There are so many more details besides the transmission itself that will eat up more time than you can possibly imagine. Reinstalling the e brake shoes, taking off and reinstalling the whole exhaust, bolting up the pedals, splicing together lots of wires, bleed the brakes, etc. Whatever amount of time you think this project will take, multiply it by 3.

Justin