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Old 05-04-2021, 07:19 PM   #26
Alex Mcknz
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The progress looks nice, I am excited to see how it will turn out.
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Old 05-05-2021, 11:47 AM   #27
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Recently got a big score for the car. An M410 with the rare B20 bell housing. I'll have to put some work in adapting it for a hydraulic clutch. My hope is that I can figure something out that doesn't involve cutting or drilling the bell housing. Maybe forced induction is a possibility in the future.

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Old 05-07-2021, 05:58 PM   #28
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Waiting on some parts. So I decided to give the gearbox a new coat of paint with some of the red I had left over from the engine. I found bits of the original dull red and some black paint on it. After some thinking this gearbox is probably overkill for what I will actually end up doing with the car (as opposed to wishful thinking). I'll use it for the time being while keeping an eye out for an M41. Most of what I need to do carries over to the M41 anyway




I've got to clean up one or two spots of over-spray. Doesn't look too bad for a paint job done during a lunch break.
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Old 05-07-2021, 06:05 PM   #29
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You were not kidding about the crate...
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Old 05-07-2021, 06:08 PM   #30
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You were not kidding about the crate...
I inadvertently got a good amount of scrap wood. I am pretty sure there is 40-ish lbs of wood and deck screws in that crate. Given what lumber is now going for the previous owner probably could have packaged it in gold. They even bolted the gearbox down inside in three spots.

I just have to swap the OD flange and top cover. Then it can go in the car. If I recall correctly I can test the four speed part of it without wiring up the OD solenoid. So I'll likely do that to do my own test for noisy bearings and synchro function before making a new harness for it.
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Old 05-07-2021, 07:45 PM   #31
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I have the long handle shifter in the 142 (it's a '71) and while it's murky and slow it's got a great old school vibe. It's shifting like you mean it!
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Old 05-08-2021, 06:56 PM   #32
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I have the long handle shifter in the 142 (it's a '71) and while it's murky and slow it's got a great old school vibe. It's shifting like you mean it!
I definitely want the long shifter but apparently there are some incompatibilities between the two setups. I am not sure if I will be able to make it work.
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Old 05-08-2021, 07:13 PM   #33
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Also I am not sure how much play the input bearing on an M40 is supposed to have. I pulled mine today to grab the top cover and investigate a leak. Either way it may need some work.

https://i.imgur.com/8xcWcD8.mp4
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Old 05-08-2021, 10:18 PM   #34
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I just gave the spare M41 in the garage a jiggle and I can't say it's much different. The rando off craigslist I bought it from assured me it was mint.
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Old 05-08-2021, 11:50 PM   #35
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I just gave the spare M41 in the garage a jiggle and I can't say it's much different. The rando off craigslist I bought it from assured me it was mint.
I'll probably rebuild the M40 as a spare at a later date. Seems like a relatively easy gearbox to learn how to do it with.

The only reason I bought that M410 from craigslist is because paypal protections and the rather rare bell housing for a low price.
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Old 05-09-2021, 11:53 AM   #36
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Update, drained the oil in the M40. It is glittery. That combined with a messed up input shaft bearing means it gets to come apart.

I started the disassembly process and all the gaskets were slathered in badly applied RTV. This bodes well.
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Old 05-09-2021, 01:46 PM   #37
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Tore down the M40 for fun to see what the cause of the glittery oil was. I thought it would be harder, only took about 45 minutes to do. Turns out I have one bad synchro (teeth sheared off), chunks out of the reverse idler gear, a bad lay shaft, pitted bearing surfaces in the lay shaft gear cluster, and both input and output main bearings could use replacement. Oh boy.




Last edited by spock345; 05-09-2021 at 04:00 PM..
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Old 05-13-2021, 09:31 PM   #38
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Default Gearbox fully torn down

Had some difficulty getting the rather badly chipped reverse idler gear out. Also got the main shaft apart to replace the bad synchro. Painted the case because there wasn't much paint left under the grime.

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Old 10-08-2021, 09:31 PM   #39
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Really should give an update on how the car is going. The biggest thing was installing an M41 I got from a local guy. Need to reseal the OD. I really should have done that when the transmission was out but oh well.




Headrests installed. Also the neat seatbelt latch from a 140 on retractable belts. Plastidipped the little red handles as they had degraded badly.



Mud flaps and 15x5.5" wheels from VP autoparts. I got them locally and they were from that production run where the hub caps don't fit quite right. Some gentle work with a file fixed that. Tires were free from a neighbor who for some reason had one year old tires with 95% tread left.




Hella 500 driving lights and a new auxiliary switch panel. Ignore the dangling wires.



Finally got the dual circuit brake master installed.



Resurfaced the intake manifold and finally fixed my vacuum leak. Just taped some sand paper to a pane of glass and did it the cheap way.



Now with a functional backseat, 4x6" rear speakers to fill the holes cut by a previous owner, and seatbelts.

And the reason my progress has been slow lately (sadly not a Penta).

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Old 10-14-2021, 03:32 AM   #40
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Finally got the dual circuit brake master installed.
Manual brakes, always my favorite. Was this upgrade as simple as using a MC from a 1968-69, thus no need for mental gymnastics on bore calculations?

Looking good!
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Old 10-14-2021, 01:17 PM   #41
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Manual brakes, always my favorite. Was this upgrade as simple as using a MC from a 1968-69, thus no need for mental gymnastics on bore calculations?

Looking good!
Yep, the late 67-68 cylinder is the same bore as the single circuit one. Brakes feel the same as with the single. You just have to fabricate two short brake lines. Also my power bleeder fits the reservoir on this one. Before I was doing gravity bleeds that took forever.

I toyed with the idea of adapting a 140 style brake booster like they did with the '69 and '70 cars outside the US but this was just a simpler way to have some redundancy in the system. Still might do that someday, but I'll probably try EBC green stuff pads or something first if it becomes tiresome.
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Old 10-14-2021, 01:32 PM   #42
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Nice work! Like that aux switch panel
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Old 10-24-2021, 08:10 PM   #43
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Decided to design a few clusters for aftermarket gauges in an amazon. I am trying to somewhat emulate the 544 and 140 rally clusters. The idea is to have a drop in replacement without cutting into the sheet metal. Although it will mean modifications to the dash pad.






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Old 10-25-2021, 08:02 AM   #44
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I thought you could use a 140 rally clusters in these, is that not the case ?
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Old 10-25-2021, 10:00 AM   #45
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Have you seen what Andrew did for the gauge cluster in his car?

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Old 10-25-2021, 10:25 AM   #46
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I thought you could use a 140 rally clusters in these, is that not the case ?
No different shape.



The amazon and 544 clusters are a trapezoid. With the 544 all of it is exposed and has a nice "Volvo" lettering. The bottom bit is obscured on the Amazon one. Some people have fit the 544 rally cluster by cutting into the amazon dash but it never looks quite right to me.

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Old 10-25-2021, 10:28 AM   #47
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Have you seen what Andrew did for the gauge cluster in his car?

Yep, that is actually what sent me down this route. Although barring another dashboard kicking around I think I'll try to do it without cutting into the dash. I'll probably share the CAD files once I get a workable prototype.
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Old 10-29-2021, 10:15 PM   #48
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Recently when driving the car up to Sacramento I noticed a horrible whine from the blower motor. Luckily the aftermarket motor is ok but it seems my no name plastic blower fan has died. The fan was rubbing the motor housing. Need to find something with a set screw in the right size.

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Old 10-30-2021, 09:10 AM   #49
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There's an aftermarket blower motor available?
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Old 11-01-2021, 10:33 AM   #50
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There's an aftermarket blower motor available?
I found a Four Seasons 35593 just about fits if you widen the mounting holes with a needle file about half a millimeter.
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