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I have a 92 volvo 240 with an aw-71 trans and it is dead
I am going to do a m46 conversion.
Could someone look over my list of parts and tell me if anything is missing or if I dont need it..
M46 trans
m46 bellhousing
new clutch pack
clutch pack bolts
m46 flywheel
flywheel bolts
new pilot bearing
new throw out bearing
Cluthc lever.
clutch cable.
manual pedal box(Is sheet the metal pedal box welded in or is it bolted in??)
manual car brake and clutch pedal
ecu?? ( Is there such a thing as a manual or auto ECU ???)
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2. What do I need to change in the driveshaft area ??
3. Which cross member do I use and are the trans mounts compatible??
4. how do I adapt the auto trans reverse back up light switch to the manual ?
5. Will I run into any problems with rear end ratio? ( I have 3.75 rear gears)
6. Since this is a 92 I have the electric mag speedo pickup, what do I use to plug up the speedo gear port on the new m46 trans..
thanks alot for answering my quesitons..
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I've added my comments below. I have done the reverse of this job, so be aware it is a major undertaking.
M46 trans: Consider an M47, that way you won't have to worry about the OD (true 5 speed)
m46 bellhousing: Comes with the transmission.
new clutch pack: Yes
clutch pack bolts: Yes
m46 flywheel: Yes, and spacer plate
flywheel bolts: Yes
new pilot bearing: Actually, a pilot bushing
new throw out bearing: Yes
Cluthc lever.: Even if the trans you get has one, consider a new one as they have been known to crack/fail.
clutch cable: Yes, factory only for reliability.
manual pedal box(Is sheet the metal pedal box welded in or is it bolted in??)
manual car brake and clutch pedal: Replace the entire pedal assembly. Also consider replacing the firewall plate as well, that way all the holes will be there.
ecu?? ( Is there such a thing as a manual or auto ECU ???): No, your LH2.4 ECU will work fine.
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2. What do I need to change in the driveshaft area ??: The driveshaft.
3. Which cross member do I use and are the trans mounts compatible??: The cross member is compatible, it just uses a different set of bolt holes in the floor.
4. how do I adapt the auto trans reverse back up light switch to the manual ?: You may find the wires are already there, you also need to take care of the neutral switch.
5. Will I run into any problems with rear end ratio? ( I have 3.75 rear gears):Unless you want to run some high RPMS.
6. Since this is a 92 I have the electric mag speedo pickup, what do I use to plug up the speedo gear port on the new m46 trans..: Get a rear axle from a 91, 92, or 93 manual car with ABS, that will take care of your sensor. Use an M47 instead of an M46 and there is no speedo hole issue.
Looks like you are in VA, I'm in Western NC. As I mentioned, I converted our M47 92 to an AW70, except for one part and that is the rear end. In short, I'm running with low torque and low RPMs as a result. If you are interested in swapping rear axles let me know, I think I still have an M47 driveshaft as well.
Let me know and I'll do an "inventory on my "leftovers" from the conversion.
jorrell
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92 245 245K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!
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I've done this job, on an 88 745. I went with an M46, because I was able to get the whole car it was in for cheap. Had to buy a second parts car to get a 3.31 rear, which is an important part of the package. The result is 2500 RPM at 70, and around 31-32 MPG on the highway. You need a 3.31 rear from an 86 or later if you want to have a speedometer. If there are a different number of teeth on the tone ring, the speedo will read incorrectly. You may be able to solve this by swapping the instrument cluster. (but maybe not) Using an axle from a 91, 2 or 3 should avoid speedo issues. Jorrell's idea for a swap sounds like a good one, if you don't live too far apart.
Make sure to get a flywheel with the correct number and spacing of holes for the crank position sensor. There are two different configurations (Bosch and Rex/Regina?) that are not interchangeable.
M46s do exist with the late configuration with crank sensor. Mine came from a 90 744 GLE 16V. These late gearboxes, have a P-type overdrive, considered to be even better than the plenty sturdy J-type.
While the M46 is stronger than the M47, the M47 should do just fine if you drive sanely and make sure to keep plenty of oil in it.
Pilot bushing is for auto trans. That's what's in the end of your crankshaft now. You need to change it to a bearing for either an M46 or 47.
If you use an earlier transmission, you don't need to do anything to plug the speedo drive hole. The speedo output will spin freely in open air. If it leaks, replace the seals.
Careful study of the wiring diagram should show how to get the Reverse lights, overdrive circuit, and even the light on the dash (a green "5") hooked up correctly. You will need to swap the OD relay and a small section of wiring harness (kind of like a jumper---it just plugs in, no cutting or soldering required) and move one wire on the back of the instrument cluster. Sorry, don't remember any more details of this part.
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Your car is equipped with a crank position sensor that uses the flywheel as the device to feed the sensor on the top of the bellhousing.
I am not familiar with the manual transmission setups but I don't believe what you have planned will be possible.
You probably need to be thinking of swapping in an M47 5 speed manual setup from the era that used the crank position sensors; 1989 and newer.
Randy
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Personally, I'd go with the M47 (follow the threads therein, too):
http://www.brickboard.com/RWD/index.htm?id=1169761
What you need is a manual transmission flywheel for an '89-up B230. This'll have the crankshaft position sensor reference holes in it. Plus the M47 bell housing will have the notch in it for the crank sensor. Granted, you could grind a notch in the M46 housing.
You'll need the front driveshaft for the manual transmission you go with. You can use the same ECU, it'll work fine. Your '92 should have LH2.4, and my '90 has LH2.4 with the stock manual tranny.
You might as well do the rear main seal and front transmission seal while you're at it. The manual tranny will have a reverse light switch in it. You'll also want to splice the start inhibitor switch.
-Ryan
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Athens, Ohio
1990 245 DL 133k M47, Cibié E-codes, Now with working wipers!
1991 745 GL 290k (Girlfriend-mobile)
Buckeye Volvo Club
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thanks for the response..
I just read that post.. it was really good, I learned alot..
I am now going ahead for sure.
I will use the m47 for sake of ease, but arent you concerned about the
m47 weak link.. I think in the OD gears.?
now I just need to find the parts..
thanks
Geoff
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Blackbear:
The M47 does not have an overdrive, it is a true 5 speed. The reason a lot of people prefer the M46 over the M47 is because the M47 was not designed to handle a turbo motor.
The M47 is "weaker" but the one I pulled out of our 92 at 236K+ miles on it shifted fine and was bought by another person in VA... haven't heard any complaints!
jorrell
--
92 245 245K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!
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I have had an m47 go bad on me, so I would go with an m46. Also the m46 final ratio in overdrive is lower than the m47 in 5th so this will compensate for the 3.73 rear end. My car runs about 2900 rpm and 70 mph with a 3.73 rear end. If you do a lot of driving above 70mph you should look for a 3.31 rear end.
I did this swap on my 93 last year. Most M46 geaboxes have a knockout for the crank position sensor. You just bang it out with a hammer. I have actually not seen an m46 without a knockout. You need a dished flywheel with the holes drilled for the crank postion sensor. You can find this on 89 and later 240s and 740s. The M46 gearbox works with this flywheel. This flywheel was used on intercooled 240 turbos with M46 gearboxes, but the turbo flywheels are not drilled for a crank sensor so you can't use them on your car.
If you are getting a new clutch you can use the m47 clutch ( very expensive) or the 240 turbo clutch. I used the heavier turbo clutch because its cheaper for some reason.
Each tranny has a specific crossmember/mount, but I am currently using my Aw70 mount and crossmember on my m46 because it was so nice and rust free compared to any m46 crossmember I could get around here. It was a little tight but I have had no problems so far.
The only big problem is that your firewall probably does not have the hole for the clutch cable. I my case a mechanic welded the corner of a standard firewall plate over my automatic plate to create the hole for the cable. Its not pretty but it works. Pedals are bolt on.
You also need the shifter, wiring harness and relay for the M46. Getting the OD light to work is a bit tricky. Most of the lights are negative signal including the auto OD light, but the M46 od light is a positive signal. I had to modify the instrument panel board to make the auto OD light work for the M46 light.
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