240 "81 4+OD => 240/740 5 speed w/o OD

Discussion in 'Volvo 740' started by Martijn, Jul 13, 2004.

  1. Martijn

    Martijn Guest

    I have a 1981 240 with 4 speed maual gearbox +OD. Can I fit for example a
    late 240/740 5 speed gearbox?
    The OD isn't working proper. The car ran 210.000Km's and I allready changed
    the OD relais with no result. I also checked the gearbox' oil and cleaned
    the filter. The sollenoid is clearly making a "click" noise when I engage
    the switch on the gearstick (the relais also clicks).

    It seems as if the OD had a bad humour or so. When I engage it works at
    random (yes or not). If I wait a while, lets say 2 minutes, it does work. Or
    sometimes it works fine the first time. (enigine is on operating temperature
    and the soldering in the relais is fine).

    So, I can solve the problem by fitting a normal 5 speed, but will I need an
    other drive shaft (length)? Or how much would an OD overhaul cost, can this
    be done by myself?

    Thanks for your kind advise any hits would be appreciated.

    Cheers,

    Martijn
    The Netherlands
     
    Martijn, Jul 13, 2004
    #1
  2. Martijn

    Ken Phillips Guest

    Martijn,

    The later 5 speed gearbox will bolt straight onto your engine with no
    modification, you will however, need a longer (I think) front section for
    your drive shaft because the five speed box is shorter, the front section
    slots onto the rear section via splines, you also get a 'new to you'
    replacement support bearing with the shaft, unless it's been removed; check
    that the bearing runs absolutely smoothly without any sloppiness, otherwise
    you'll get a hell of a lot of drivetrain noise, check the U-joint on the
    replacement shaft is in good order, also make sure that the gearbox has got
    it's rear support brace, and that the engine mount that should also be on it
    is ok, this item is different from the one on the 4+OD box.
    While the 5spd is still off the car check the front and rear seals for
    leakage, the front seal can only be changed by removing the bellhousing, the
    rear seal is easy to change, less than 30 mins of a job, even if the box is
    installed.
    The hardest bits of the job are the mating of the new box to the engine, and
    the loosening/tightening of the propshaft bolts, and starter motor bolts
    (lots of swear words!!).
    When I did this job on my old '84 240, it was so radically different
    afterwards that it was hard to believe it was the same car, a much nicer
    drive, better acceleration and engine braking., and seemingly endless power.
    I kept the 4 speed stick (just to confuse the passengers), and cunningly
    used the overdrive button to make the central locking lock the doors for
    when I was driving in dodgy areas.

    Best wishes
    Ken
     
    Ken Phillips, Jul 13, 2004
    #2
  3. Martijn

    James Sweet Guest

    I put an M47 (5 speed) transmission in an '86 240 converting over from an
    automatic and it was straightforward, you simply need the transmission and
    the front half of the driveshaft from the donor car.

    I thought the M47 would be cool since they're quite uncommon, but if I were
    to do it again I'd use an M46 (4 spd+OD) instead. The 5 speed shift pattern
    feels awkward to me and the syncros are a little weak, a common problem so I
    hear. A good M46 just feels nicer and more solid.
     
    James Sweet, Jul 13, 2004
    #3
  4. Martijn

    Duane Hoberg Guest

    Before you change the transmission, what happens to the dash light when the
    OD does not work?

    If the light goes out, or does not come on, the 4th gear switch on the
    trans may be bad.

    If the light stays on, the yellow wire to the solenoid or the ground wire
    for the solenoid may be dirty or loose or the wires inside the insulation
    may be broken.

    Volvo also had trouble with the wires inside the shift lever breaking.

    Duane
     
    Duane Hoberg, Jul 13, 2004
    #4
  5. Martijn

    Martijn Guest

    Dear all,

    Thanks for your exellent findings. I've done some additional desk researsch
    and it seems thet the 4+OD has a livespan off over 500.000Kms whereas the
    5sp gearbox ~ 300K km's. I've decided to keep the 4+OD.
    Today I've replaced the middle rubber bearing off the prop shaft. What a
    change!!!! No more rumbling and shaking!! It really pays off.
    I've removed the bolts with an angle grinder, they where to tight to be
    remove. BTW it's US measure not metric or English, but size 14 metric is
    just perfect.

    The next thing is that I will have all seals replaced from the motor
    (crankshaft) and 4+OD. If the leakage is gone perhaps the gearbox can build
    a better preasure ans shift normally. 200K km's is not much for an OD I was
    told. What are your experiences on the OD's millage? It will take the Volvo
    garage about 3 to 4 hours to have them all replaced, peghaps the clutch will
    be replaced at that time also. I'm a handy guy but chanching all the
    sealings is a bit too much for me I think.

    The light on the dash works just like it's suposed to be. I've check the
    wireing in the gearstick, they're fine.

    Thanks in advance.

    Martijn
     
    Martijn, Jul 13, 2004
    #5
  6. Martijn

    don hodgdon Guest

    Before you go ripping your tranny out, check the 4th gear switch. Sometimes
    it only needs a slight adjustment to make the OD work correctly.

    Good Luck,
     
    don hodgdon, Jul 13, 2004
    #6
  7. Martijn

    AJAY Guest

    I can appreciate the O/D sometimes working, sometimes not - mine has the
    habit of not working if the fuel tank is less than a quarter full. Don't
    ask me why, but that's the way it is !!!!

    Andy R
     
    AJAY, Jul 14, 2004
    #7
  8. Martijn

    Martijn Guest

    Andy,

    I will try to notice if there is any patern related to the fuel tank ;-)

    Cheers,

    Martijn
     
    Martijn, Jul 15, 2004
    #8
  9. Martijn

    apereyra Guest

    I put a 740 gearbox in my 242 1984 4 speed + OD my question is What happend
    with the spedometer? because 740 is electronic and my car is mecanic
    sorry my english I`m from chile
    My e-mail i
    Please HELPME
     
    apereyra, Sep 1, 2004
    #9
  10. Martijn

    apereyra Guest

    I put a 740 gearbox in my 242 1984 4 speed + OD my question is What happend
    with the spedometer? because 740 is electronic and my car is mecanic
    sorry my english I`m from chile
    My e-mail i
    Please HELPME
     
    apereyra, Sep 1, 2004
    #10
  11. Martijn

    James Sweet Guest

    You'll need to install a rear axel from an '86 or newer 240, as well as the
    wire and the speedometer.
     
    James Sweet, Sep 1, 2004
    #11
  12. Martijn

    apereyra Guest

    I have another question if can I install only the interior of the rear axle
    from a 740 with the wire an a electronic gauge of a 240
    sorry my english
     
    apereyra, Sep 1, 2004
    #12
  13. The impulse for the speedo on a 740 comes from a unit in the rear
    differentail gear.



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    Ken Hutchison, Sep 2, 2004
    #13
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