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Old 03-20-2019, 06:35 PM   #1
tomasss
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Default m46 to m90 swap list

As my target horsepower is around 300hp, I am considering a preventive swap of my m46 to m90. I went through >this< topic, but as I found a guy selling the m90 today, I just want to double check what do I need to take from the donor car.

My car: '91 740 sedan b204gt with m46 (lh2.4)
Donor car: '97 940 wagoon b230fk with m90

So as far as I know:
I want to keep the single mass flywheel, so that one will be reused from m46.
Clutch and pressure plate cant be reused, I need to get it separately new.

And therefore I need:
- transmission
- shifter linkage
- gear shifter itself
- crossmember


How about the driveshaft, do I need to take it from the donor? Will wagoon driveshaft fit the sedan?
Anything else to take out?
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Last edited by tomasss; 03-20-2019 at 06:42 PM..
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Old 03-20-2019, 07:10 PM   #2
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And therefore I need:
- transmission
- gear linkage
- gear lever itself
- gear lever support and gaiter
- crossmember
- propshaft
- keep the bolts etc

Clutch, do you know what power level you are at?
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Old 03-21-2019, 04:12 AM   #3
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Quote:
Originally Posted by classicswede View Post
And therefore I need:
- transmission
- gear linkage
- gear lever itself
- gear lever support and gaiter
- crossmember
- propshaft
- keep the bolts etc

Clutch, do you know what power level you are at?
Ok. For the propshaft, do I need the whole one or just the first half?
Stock power level is 200 engine horsepower, my target is somewhere around 300 wheel horsepower. No racing though, more likely an occasional pulls...
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Old 03-21-2019, 04:50 AM   #4
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Quote:
Originally Posted by tomasss View Post
Ok. For the propshaft, do I need the whole one or just the first half?
You need the whole one because they are balanced as a unit. Also Mark the orientation they were in before separating.
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Old 03-21-2019, 06:36 AM   #5
classicswede
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Best to use the full propshaft as mentioned they are a balanced unit.

Clutch if you want to keep the 228mm flywheel you are really looking at a paddle clutch or use a sachs 763 cover with a sinter plate
The other option is to upgrade to a 240mm flat flywheel and use a 850R clutch or a sachs 707 cover.
Makes sense to get the right clutch while it is all apart
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Old 03-21-2019, 02:16 PM   #6
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Yeah each half is balanced separately from the other. Then they slide together. I've put different halves of different driveshaft together over the last 30 years any way I wanted and never ever had a problem. Who worked at the volvo factory and balanced both half's of a slipped together yoked driveshaft at the same time slipped together? Buehler???

Show me the machina that does that???


More BS...
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Old 03-21-2019, 09:45 PM   #7
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Quote:
Originally Posted by classicswede View Post
Best to use the full propshaft as mentioned they are a balanced unit.
Never had driveline issues when swapping an m90 in. You only need the front half of the shaft from the m90 car. Never been an issue for me up to north of 120.

I recommend the ttv flywheel as thatís what Iíve been running for 3 years and swear by it. I recommend a better clutch than the stock 850r one.
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Old 03-22-2019, 04:25 AM   #8
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90 odd % of the time you are fine with just the front half. The 2 halves are balanced in phase and on odd occasions you can get vibration issues. If both halves are there for the taking then it makes sense to take it as a complete unit.

I have TTV flywheels drilled ready to accept the Sachs 707 cover as a popular choice for an upgrade
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Old 03-25-2019, 05:14 PM   #9
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The Sachs 763 pressure plate with an 850 glt fiber disk has been holding my 16v turbo @15psi just great.

You'll like the m90, it's a fantastic upgrade!
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Old 03-26-2019, 09:31 AM   #10
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Thanks to everyone, last weekend I picked her up...directly went to the pressure washer to get rid of the dirt. Now I need to collect the rest (clutch, PP, release bearing etc...) to finally dive into the swap

https://forums.turbobricks.com/showp...1&postcount=20

Quote:
Originally Posted by JerryJS8 View Post
You'll like the m90, it's a fantastic upgrade!
Yeah...unfortunately I won't be able to appreciate the change as I have never driven the m46...this car we towed to my garage
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Old 03-27-2019, 06:26 AM   #11
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I will actually use this topic for another list - what parts should I get while going for the swap.

I will reuse the m46 flywheel combined with the 850GLT clutch and 763 pressure plate.

So far I have (front to rear):

Crankshaft oil seal
Clutch 850GLT (1862 314 032)
M90 Clutch release bearing
Clutch pressure plate (3082 999 763)
2l of transmission oil
M90 rubber mount
Rubber M90 flex plate (guibo)
Driveshaft center support + bearing

Thinking about the >pilot bearing< but found >different< opinions...

What about the clutch slave cylinder...should I replace it or just leave it as it was working fine without leaks?

Anything else to consider?

Last edited by tomasss; 03-27-2019 at 08:47 AM..
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Old 03-27-2019, 07:07 AM   #12
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As your clutch release slave is external, you can "run until failure" and not disassemble. I always like the comfort of NOS new parts.......
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Old 03-27-2019, 12:57 PM   #13
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Quote:
Originally Posted by DET17 View Post
As your clutch release slave is external, you can "run until failure" and not disassemble. I always like the comfort of NOS new parts.......
Yeah, I am also mostly inclined to that...
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Old 03-27-2019, 08:25 PM   #14
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Not to side track but would you sell the trans whenever you complete the swap?
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Old 03-27-2019, 10:43 PM   #15
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Quote:
Originally Posted by DET17 View Post
As your clutch release slave is external, you can "run until failure" and not disassemble. I always like the comfort of NOS new parts.......
Its real fun when the failure happens while in stop and go bumper to bumper traffic going uphill........
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Old 03-28-2019, 04:01 AM   #16
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Quote:
Originally Posted by Bproof View Post
Not to side track but would you sell the trans whenever you complete the swap?
Yeah, it will be for sale as a complete set. Clutch + pressure plate + transmission + driveshaft.
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Old 03-28-2019, 04:18 AM   #17
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..and back to the original topic...I bought some extra bushings...unfortunately it seems nothing is available in bronze so I just went with regular parts:
1232173 Ball Socket, Shift stick
1232165 Bushing, Shift selector block
9143298 Bushing, Gear lever
9163851 Ball Socket Clutch fork
1014858 Bushing, Gear lever Kit
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Old 05-14-2019, 06:46 PM   #18
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Update or pm when you have the package ready?
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Old 05-14-2019, 07:26 PM   #19
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Crank bushing Volvo PN1397077. Classic part but stock still available in NJ as of yesterday.
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Old 05-15-2019, 02:47 AM   #20
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Quote:
Originally Posted by shoestring View Post
Crank bushing Volvo PN1397077. Classic part but stock still available in NJ as of yesterday.
This bearing is not compatible with M90...either it will not give support to the transmission or it needs to be replaced with the M90 bearing type from retroturbo...

http://forums.turbobricks.com/showthread.php?t=324088
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Old 05-15-2019, 02:48 AM   #21
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Quote:
Originally Posted by Bproof View Post
Update or pm when you have the package ready?
Man, you should PM me earlier...I already made a deal with some other guy for the whole M46 setup...
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Old 05-15-2019, 08:52 AM   #22
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Quote:
Originally Posted by tomasss View Post
This bearing is not compatible with M90...either it will not give support to the transmission or it needs to be replaced with the M90 bearing type from retroturbo...
Unfortunately we HAVE the bearing from Retroturbo and IT isn't compatible with our M90. The bearing has too small an inside diameter and the bearing housing does not seat fully in the crank. We did not try to hammer it in for fear of not being able to remove it.

The 1397077 comes directly from the Volvo parts catalog.
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Old 05-15-2019, 10:15 AM   #23
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Quote:
Originally Posted by shoestring View Post
Unfortunately we HAVE the bearing from Retroturbo and IT isn't compatible with our M90. The bearing has too small an inside diameter and the bearing housing does not seat fully in the crank. We did not try to hammer it in for fear of not being able to remove it.

The 1397077 comes directly from the Volvo parts catalog.
The possibility of the first issue is known...

"NOTE: It turns out that some of the input shafts are about 0.035 mm greater in diameter than the others giving interference fit with our adapter. To avoid that, you have to sand the input shaft with sand paper until it fits with ease."

The second one I had no problem with...it went in the crank without any issue.
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Old 05-15-2019, 10:19 AM   #24
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Hmm. Bummer.

Edit to all my posts in this thread except reference to Volvo part number (which is application correct but does not address the issue raised):

I am dumb.

Last edited by shoestring; 05-16-2019 at 08:51 AM..
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