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What is needed for a full manual swap in a 1990 Volvo 240?

howlett10

New member
Joined
Sep 22, 2020
Location
Edmonton, Alberta Canada
Hello, everyone. I have a 1990 Volvo 240 which is automatic and I?ve decided that I want to manual swap it this winter, I have the proper lh2.4 flywheel and today I picked up an M46 transmission, I?m a noob when it comes to this stuff and will be getting a shop to do the swap because I want it done properly and not half assed. Anyways, other than the pressure plate, clutch, clutch cable & pedal box, what else do I need? Could somebody maybe give me a list of the other things I need and a list of things that I can buy off rockauto for the swap? Thank you so much.
 
New driveshaft support bearing and carrier. It is annoying when that goes, the race bangs off of everything making a crazy noise.

Not necessary but would be sweet to have is the STS Machining bronze bushings to replace the old plastic stuff. It kinda sucks to do a swap like that and have the shifter feel like a soup sandwich.
https://www.stsmachininginc.com/products/m46-m47-bronze-shifter-bushings-240-740-volvo

Post in the wanted section for the M46 driveshaft. Probably a lot at a parts store. To maximize that investment, get new u joints, they are very inexpensive. Rockauto had them on sale for less than $5 each recently.
 
Not necessary but would be sweet to have is the STS Machining bronze bushings to replace the old plastic stuff. It kinda sucks to do a swap like that and have the shifter feel like a soup sandwich.
https://www.stsmachininginc.com/products/m46-m47-bronze-shifter-bushings-240-740-volvo

The bronze shifter bushings are worth it.

Get a new transmission mount. Volvo 164 engine mounts make a nice heavy duty upgrade for the M46/47. If you haven't encountered worn out engine/transmission mounts it will happen to you soon.

I agree with new u joints and the support bearing. You shouldn't be annoyed by new noises that way.

I would also replace the oil in the transmission while it is out of the car. A bit easier to do that way. Check all the gaskets and make sure you don't have catastrophic leaks. I think the M46 takes some standard of ATF (type F?).
 
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Other than the obvious move everything over from a parts car solution...

M46 specific shift knob and complete M46 OD wiring / & relay, pilot bearing & circlip, clutch fork, rubber bellows shifter boot, metal sheathed clutch cable, dog dish / 740 turbo clutch kit, and make sure the M46 short shaft is not the earlier smaller diameter one.

New driveshaft bolts or at least new nylock nuts as they tend to get rounded off with use, depends.

https://www.ipdusa.com/catalog.asp?CAT_ID=969&categorycrumbs=&searchwords=
 
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