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95 to 94 960 engine/ trans swap 900 1994

posted by vineyarddrums on Thu Jun 3 22:54 CST 2010
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last visit: Sat Jun 26 00:41 CST 2010

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I have a high mileage 1994 960 with a great body from the south. I purchased a wrecked low mileage 95 960 with a good engine and trans. I intend to swap the engine and trans from the 95 to the 94. Anyone have any advice on differences or problems I might run into??? I noticed the 95 has an electric pump that appears to go into a port in the valve cover. My 94 does not have this. Is this an air pump blowing into the exhaust for emissions? Any suggestions??? I also noticed the 95 engine has oil leaking under the valve cover around each coil pack in the nooks and crannies of the valve caver casting.The engine had the top end redone due to a timing belt issue 10,000 miles ago. Any Ideas???
I intend to transfer whatever I can from my 94 to the 95 engine before I put it in.
Are the transmissions identical??? It appears that they may use different trans ecm's.
I have just started removal of the 95 engine. I notice that these cars are quite a bit different even though they are only two years apart. Am I opening a can of worms here attempting this swap???
This is my first attempt at any major work on a 960. I have been a mechanic for 30 years so I am not afraid to dive into this, but any help would be much appreciated. How reliable
are these 2.9l inlines???? This thing sure looks different than my 89 240 did.

Please help a newbie to the 960.
Thank you vineyarddrums

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95 to 94 960 engine/ trans swap 900 1994

posted by RWD forever! on Wed Jun 16 21:15 CST 2010
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last visit: Wed Oct 6 02:21 CST 2010

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I had a 92 with oil leaks that filled up the plug wells. Turned out the previous owner who was a mechanic didn't seem to understand how a torque wrench worked so every bolt on the cam cover was stripped. He repaired a few but when the gasket glue let go it weeped oil all the time. I removed the cover and drilled and tapped every hole one size bigger, reglued the cover and fixed the problem nicely. One thing to know with this engine is you need a tool to slowly release the cover from the head or damage will occur to the cams and/or bearings. I used two pieces of 1" flat bar with a hole in the center and then used threaded rod and two old spark plugs to make two hold downs. Before removing the cover bolts I inserted the plugs into 2 and 5 and snugged a couple of nuts down to hold the cover until I removed all the bolts. I then backed the nuts off just enough to tap the cover loose and then backed each one off alternately until the valve springs reach the limit of their travel. Reverse the procedure to pull the springs back down and you're in business. Hope this helps, I would suggest using the actual Volvo glue even though it is pricey as I have read about other after market stuff failing prematurely.

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95 to 94 960 engine/ trans swap 900 1994

posted by DanR on Thu Jun 17 04:21 CST 2010
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last visit: Thu Oct 23 15:25 CST 2014

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Great tip on the special tool, it sounds like the one shown in my volvo repair manual.

One question, why did you repair the bolt holes by going to a larger size?

Yes, those original fine thread bolts strip very easily, but I used helicoils to repair those, believe there near 50 of them. The aluminium is soft and can only really take a small number of tightening before failing, even with a torque wrench, after a few cycles, those threads start tearing out.

With the helicoils, you will never have to worry about them again.

DanR '94 964 352,000 miles (118,000 on the new engine)
--
DanR

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95 to 94 960 engine/ trans swap 900 1994

posted by bluedot on Fri Jun 4 11:05 CST 2010
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last visit: Mon Nov 15 07:05 CST 2010

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I have a 95 with a 94 motor.Use the wiring and injectors from the good body.

Plug the air pump hole in the top cover,the 94 won't need it.Re-seal the top cover while the motor is out,there is an o-ring around each spark plug hole.

Inspect the 2 bearings on the timing belt.If they don't look new,replace them.

Trans are the same,use the 94 ETM.

The biggest difference between 94 and 95 is the front sheet metal.

Reliable motor if well maintained,but it has twice as many cams and three times as many valves as a 240.

Bill

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95 to 94 960 engine/ trans swap 900 1994

posted by vineyarddrums on Sat Jun 5 02:42 CST 2010
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last visit: Sat Jun 26 00:41 CST 2010

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Thank you for the information.
I pulled the engine on the 95 yesterday. It came out pretty much without incident.
I notice quite a bit of oil in the intake of the "good" engine. I will seal up the bolt threads and replace the o rings as well. I will check the timing belt bushings, oil pump o rings, replace the cam seals, water pump and belt. Should I split the eng/trans and replace the rear main seal????
What are the differences between the injectors. I am going to spend a lot of time and money on this car so I want to save any spare parts I can from the donor car.
I hope to drive it for a lot of years. Do you think I need to use volvo antifreeze or will prestone and distilled water be ok? The engine ran great and comes from a wreck that had 112,000 miles on it. The head was redone 15,000 miles ago because a piece of the timing cover got between the belt and gear so it slipped a tooth and bent the valves. The oil in the intake does concern me , but the thing really sounded good before I removed it. Could it be a pcv problem???
I guess I should have don a compression test first.
Thanks again for sharing your expertise with me. It is cool that this site exists so we can help each other.
If yo need any 960 parts for a 95 let me know. (such as headlight assemblies etc)
If they won't fit my 94 and you need something let me know and I will send it to you.
John

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95 to 94 960 engine/ trans swap 900 1994

posted by ChrisS on Mon Jun 7 04:40 CST 2010
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last visit: Thu Oct 10 21:18 CST 2013

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I would *definitely* replace the RMS while you have this apart, it's a known issue, although I believe the 95-97 models were better than the previous years but I have no proof of that. I have both a 1993 and a `1997 and I'm letting go of the 94 and keeping the 97. Both cars are great, although the 92-94 were a bit torquey-er.

So....If you need any 94 parts I'm willing to trade you straight up for the 95 parts~! Many parts are interchangeable, so I will be keeping things like the power steering pump, but other stuff may be worth a trade.

are you on MV?
--
1991 745 & 1993 965 /// RIP: 86 764T; 79 262C

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95 to 94 960 engine/ trans swap 900 1994

posted by vineyarddrums on Mon Jun 7 14:04 CST 2010
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last visit: Sat Jun 26 00:41 CST 2010

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Sounds great.
I could use a good pair of 94 headlight assemblies. The pair in the 95 look new. Could you use them? I think the engine ecm and trans ecm are different from 94 to 95 If the 95 stuff fits your car and you want to trade that would be great as well.
I don't know what mv is. I live in Michigan. Shipping small stuff like these things would be no problem. I will be looking for an entire interior as well. I know shipping would prohibit a long distance purchase but if anyone has a good interior (cloth or leather) reasonably close to the Ann Arbor area, I would be willing to purchase it if reasonably priced and come and get it. My car is white so any color will do. Any other parts you could use from the 95?

John

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95 to 94 960 engine/ trans swap 900 1994

posted by ChrisS on Mon Jun 7 16:44 CST 2010
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last visit: Thu Oct 10 21:18 CST 2013

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very cool. I will only need a few things in the engine bay and some things in the interior. I'll trade the lights for sure, although mine exhibit that kind of yellowed haze on the fog lights, but all lenses are good. I can send you the front and rear lights if you like. I also have a black center console if you want. chris
--
1991 745 & 1993 965 /// RIP: 86 764T; 79 262C

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95 to 94 960 engine/ trans swap 900 1994

posted by vineyarddrums on Tue Jun 8 09:27 CST 2010
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last visit: Sat Jun 26 00:41 CST 2010

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Hi Chris,
A black center console would be great.
Please email me a list of parts you want from the 95 and an address. I will send them to you.
jnikolich1@yahoo.com

John

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