Soooo, I've been searching and I'm still searching and while I do so I have some questions. I'm purchasing my 5th Volvo, this time a '92 240 sedan non turbo with an AW70 auto trans. I'm an EV guy (electric vehicle) so I plan to convert this one to electric. I plan to switch out the auto trans to a manual for the conversion.

There will be no engine any longer of course so that should help with the trans switch out. Also I won't be needing the clutch pedal or slave cylinder for it. I would be installing the clutch, throwout and flywheel because like many other ev conversions they are needed for proper connection to the ev motor, alignment and balance. In an EV, the clutch function isn't needed since an ev motor doesn't spin when stopped. You simply put the car into gear and press the accel pedal, no clutch needed. When you shift you simply put it into the next gear. It usually takes a second or two but drops right in.

Is there a manual trans that is a direct bolt in that will replace the AW70? Believe it or not, I haven't found this info yet mostly because I never had the need to find out until now. Is there any trans that is better to get? Likewise is there one to avoid?

 

normally, EV's don't use a transmission at all, as an electric motor has full torque at 0 rpm, and they can spin up to crazy high RPM while maintaining flat HP.

the manual transmissions used with volvo 240/740/940 are the M46 and M47.. the m46 is a 4-speed with separate overdrive, while the m47 is a conventional 5-speed. about the only place you'd find these would be on manual volvo 240/740/940. like most RWD front engine cars, the transmission mount supports the back of the transmission, and the engine supports the front.

 

I think he states in his post that the clutch won't be needed. The trans is just needed to couple the motor to the driveshaft. I assume he'll just use one gear.

As far as I know, all manual transmissions had a different driveshaft than the automatics. So when you get your transmission, make sure you get the driveshaft as well.

 

Correct act1292, the clutch and related are just for motor to trans joining purposes. One of my ev's has a 4 speed trans, clutch etc. I usually start out in 2nd and shift up and down as needed. It's pretty much the same as an ICE car except I never touch the clutch pedal.

 

yeah, that about the driveshaft! and note that the front shaft and rear shaft are phased and balanced as a unit, so when you remove it, put tape or chalk or something on the spline so you can reassemble it the exact same way it came out.

the manual drive shafts have a 'flex disc' (aka guibo) at the output of the transmission, while the automatics have a U joint in front. All of them have a center and rear U joint. And, the m46 and m47 transmissions are different lengths, so have different drive shafts, too. there's also an older M45 transmission used on early 240s (76-80?) that was a straight 4-speed without the overdrive. if you get one from a 740/940, you'll likely have to modify the drive shaft length and rebalance it (any drive shaft specialty house should be able to do this...). Supposedly the 5-speed M47 is not as sturdy as the 4 speed M45/46, and the M47 was never used with a turbo.

These transmissions are all Volvo specific, they were designed by Koping, and built by Volvo AB.

Gear ratios for the M46 and M47 are (1) 4.03:1 (2) 2.16:1 (3) 1.37:1 (4) 1.00:1 .... the M46 OD 5th is 0.79:1, while the M47 5th is 0.82:1 or 0.80:1 (sources differ).