Hey, everyone. I'm really stuck on this one. I really don't know what to do. Here's the deal: My transmission is bad. Previous owner decided to pull the gasket off and seal it with silicone, basically there's sand in my tranny. I'm having minor issues with it now, I know it could be a week, a month or a year before it goes. Anyway--one mechanic told me he could rebuild it (for 1300 dollars!), that's not an option--not just the price, but it has SAND in it. Okay- I can find used tranmissions for 200-650 dollars. That's fine, but the question is this: I'd be putting another 15-16 year old tranmission (Reconditioned and everything) back into to the car. I'm contemplating maybe (if it's possible)to convert to a 5-speed. Having to replace a blow clutch vs. an entirely new tranny well, is almost easy. I would like a solid solution-I don't want to have to deal with this again, I'm just really lost.
As always, Thanks.

If I understand this right, sand creeped in from the silicone gasket?

I was faced with the same decision as you and opted to go with the M46 conversion and I'm happy with my decision. I was advised that it would cost about the same as you were quoted for a complete rebuild from a reputable shop and I was afraid to put in a used tranny that might have the same problem as mine! I spent about 2 1/2 days on mine, with the half day just double-checking things and re-wiring the OD circuitry.

Good luck,

Justin B.
83 Turbo

Just to make your decision harder, I should remind you that although manual transmissions are more efficient and much more fun to drive (RWD sticks are all that I will own) they are not without their own problems.

Volvo 5-speeds are generally harder to work on than American and Japanese RWD 5-speeds, and parts are prohibitively expensive. If it fails, (as mine did at 160k miles) you'll may well find it more cost-effective to get another whole box from the junk yard.

Actually, I should not say that that Volvo trannys are harder to work on, since I have never actually repaired one. I just read the manual and it looked like it was going to be ugly and require several special tools. When I saw the cost for a new main shaft, which I knew I needed, the decision was made.

I understand your pain. A manual trans 240 is much nicer to drive in my opinion. If you are comfortable with big car projects than this is a
bolt on changeover. Since you plan on removing the trans anyway you
will have started the project. You are going to need a comprehensive
parts list of all the parts the manual car has. From the pedal assembly
to the flywheel, pilot bearing and at least the front half of the drive
shaft you have a lot of parts to install. I think it's worth it to me.
I like the manual cars a lot better. An automatic car changed over to
manual will actually be quicker because most autos have 3.73 rear
and factory manual cars use mostly 3.31 and 3.54. Wish you well. Between
all the help here and a Haynes manual or Bentley you can do it.

In defense of the automatic trannys I must say that they are very long
lived when well taken care of. No auto is going to survive sand. It shouldn't be that big a deal to get a rebuilt or even a good used one. My mother's
90 wagon has 250k miles on the original auto and it's just fine.

Wish you well in your decision, it would be nice to have another manual car
on the road. Be aware that it is a labor intensive change and the more work
you can do the better.


Dave 82 242ti 280k mi

I switched mine to a manual a few months ago. It's not a tough job. It took one weekend. I bought a running car with a manusl trans for the conversion. It's much easier to do when all the parts are right on hand. Look in the archives for a list of parts required. I like the stick, the ol brick has a little more pep. Especially with thenew cam!

Good luck, Ed