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Swapping automatic to manual transmission, what do I need? 200

posted by  Epic2112 on  Sun Nov 27 11:16 CST 2011
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last visit: Mon Oct 20 12:15 CST 2014
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My current car is a 1991 245 (wagon) with an AW70. I have a parts car, a 1988 244 (sedan) with an M47. All the transmission parts are on the parts car, what pieces do I need to remove? Also, what will I need to purchase that I don't already have?

So far, my list of parts to pull is:
* Transmission
* Transmission crossmember
* Shifter assembly
* Pedals
* Clutch cable
* Clutch/Pressure Plate/Flywheel/Bellhousing

My list of parts I'll need to buy is:
* Pilot bearing
* Throwout bearing
* Transmission Mount
* Clutch disc (maybe)

What am I forgetting? Is the rear end on the auto wagon geared the same as the one on the manual sedan? Are the driveshafts the same length, or do I need to use the one from the manual car? Any other tips of suggestions? Is there a writeup anywhere?

Thanks!








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    Swapping automatic to manual transmission, what do I need? 200

    posted by  jon_h on  Mon Nov 28 00:21 CST 2011
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    last visit: Fri Oct 24 11:57 CST 2014
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    1. rear ends are different ratios AT vs stick

    2. Most US 1988s don't have a CPS

    3. Driveshafts are different AT vs stick

    4. New clutch & pilot bearing would be a given for me; throwout st inspection
    --
    240s: 2 drivers and some parts cars








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    Maybe the bell housing & flywheel (viz., CPS) .... 200

    posted by  Ken C on  Sun Nov 27 14:10 CST 2011
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    last visit: Fri Oct 24 11:39 CST 2014
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    I'm not sure when the crankshaft position sensor, on your '91, was incorporated into the cars (in place of the distributor counterpart in earlier cars), so I'm thinking about the bell housing and flywheel.

    If your '88 donor car already has the CPS on top of the bell housing, then all is good.

    If your '88 is still relying on the distributor, then you'll have to find a bell housing (to mount a CPS) and a manual transmission's flywheel that can generate proper signals to the CPS.







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    Swapping automatic to manual transmission, what do I need? 200

    posted by  montysano on  Sun Nov 27 12:54 CST 2011
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    last visit: Thu May 29 16:46 CST 2014
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    You'll also need the correct flywheel. There's a FAQ writeup here:

    http://www.brickboard.com/FAQ/700-900/VolvoAW70M46Conversion/AW71M46Conversion.htm

    I considered swapping auto to manual on my '90 240 wagon, but if I recall correctly the rear ends ARE NOT the same, which kind of stopped my in my tracks.

    Monty
    --
    Past: '79 245, '91 240, '88 245. Current: '90 245, '83 245, '95 940








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      Swapping automatic to manual transmission, what do I need? 200

      posted by  Epic2112 on  Mon Nov 28 10:40 CST 2011
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      last visit: Mon Oct 20 12:15 CST 2014
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      Thanks everyone. I'm adding to my list the rear end and the dirveshaft. It doesn't make a difference that they are coming off a sedan and being put on a wagon, correct?

      If I'm able to punch out the CPS opening in the bellhousing of the donor car, I just need the right flywheel, correct?








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        Swapping automatic to manual transmission, what do I need? 200

        posted by  famousdan on  Fri Dec 2 16:07 CST 2011
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        last visit: Fri Dec 2 16:32 CST 2011
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        No one has mentioned the most difficult part of the whole job. Fitting the clutch pedal assy. When my son asked me to convert his 84 wagon from auto to stick I said ok as long as he did the pedal assy. He is a good tech but it took him 2 full days. and he said he will never do it again. Neither will I. Good luck.







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