Well, I finally got that grief with the block heater/frost plug situation on my '95 940T resolved (Lorne at Revolv store in Saskatoon found me a block heater that worked in my late style B230 block) so I was able to continue on with my AW71-M46 swap. After a few more minor complications and setbacks I finally rolled the car out of the garage yesterday for good. And it works great !! No problems whatsoever with the modified B21/23 flat flywheel with the LH2.4 holes drilled in the side. It just fired right up and ran perfectly from the get-go. No issues with the hydraulic clutch either thanks in part to Ian's bleeder gizmo which made bleeding the clutch system a breeze..

I haven't driven the car a whole lot yet but from what I can tell so far I like it way better with the M46 in it. I did get one chance to do a quick start from a standstill and blast it through gears 1-3 and man does that sucker ever go now ! What with the way lighter flywheel and the manual tranny it has waaaaay better acceleration. The revs come up so fast it seems as though there's almost no turbo lag. And that's just with the stock T-cam in it. I can't wait to see how it goes when I put the IPD Turbo cam back in. V-rooom !! (I probably won't swap cams until spring though.) I like the short-throw shifter I got from Matt & Dale too...

Just one funny note to add: I actually first took the car out of the garage on Friday night and road tested it. As you may recall it was friggin' cold that night. Anyways, I parked it for a few hours at this place we went to and when I went to drive it home I started it up and tried to put it in reverse and guess what happened ? Of all things that could happen the plastic link dealy that works the reverse inhibitor snapped and I couldn't put it into reverse !

I've been driving a car with an M46 since 1981 and have NEVER had that happen before. In fact, I've never even heard of that happening to anyone. Only fitting it would happen on the maiden voyage after just having all the grief I had with the tranny swap & block heater/frost plug debacle. Anyways there were a few other issues with the drivetrain to deal with so the car went back into the garage until I was able to get over to PnP to get the parts I needed, fix everything and put it back on the road which happened yesterday.

Yaaay !! Now it's time to celebrate !!!

P.S. Many thanks to Trevor and Chris for their help with the tranny swap !

Nice work Roj. Enjoy better fuel economy too!

Glad to hear eveything finally worked out


You can drop it off at my house at anytime, just call first to make sure I'm home.

I've now had a chance to do a bit of driving on the car and I have to say yah baby, yah ! I really like that car a whole lot more with the manual in it. Waaaay more fun and a lot peppier. I love driving it ! The 940Ts are real nice cars with manuals in them. It's a pity all we got were automatics in North America.

Call this one a success !

Rojer! So happy to hear it's finally going! Sorry I couldn't be more help with the swap with me having moved...
I'd love to compare our cars now and feel the difference between my stepped flywheel, and your flat one. Although I suppose 16 valve compared to 8 valve turbo is apples and oranges, but still. Also wanna see how that short throw compares!
On a side note, does your cruise control work after the swap? I'm trying to tackle that problem on mine right now (hasn't worked since we did the swap on mine), now that I got mine running properly!
Hope you're having fun with er'!
-Trev

pics? I've got a 940 that's getting +T'd this summer, and is cursed by a dying aw70L (me thinks.... it's a turd either way) and would like to do a manual swap. I see 740s with M46s all the time, and am just wondering about how to get LH2.4 to work short of finding a manual tranny LH2.4 car (240 perhaps?) Maybe a thread on TB I should be looking at?

You can either get aLH 2.4 manual (stepped) flywheel from a '90 740 Turbo or I can get a B21/23 (flat) flywheel modified to work with LH2.4 for you. This was a method I thought up and I'm the first one to do it as far as I know. It worked out great and I'm glad I went that way.

The advantage of the B21/23 flywheel is it's about 9 lbs lighter than the monstrous 29 lb stepped LH 2.4 flywheel so it's much easier to get your revs up in a hurry. You have to use an 8.5" clutch with the flat flywheel instead of the 9.0" clutch that works with the stepped flywheel. That shouldn't become an issue unless you're pushing a lot of horsepower. Even so there is a heavy duty 8.5" clutch from Centerforce that you can get which would mitigate that problem if it were an issue.

You will also have to modify the CPS bracket if you want to go with the B21/23 flywheel option. (It needs to be made about 0.110' thinner than stock to get the sensor lined up right over the center of the timing holes.) I'm looking into getting some of these brackets made so I can sell them with modified B21/23 flywheels but if you're a little bit careful you can modify your existing CPS bracket yourself with a set of digital calipers, a dremel and a file. It took me about 30 - 45 minutes to do mine.

If you want to go with the standard heavy LH 2.4 flywheel there are a couple places you might be able to get one from. Your best bet would be the ReVolv store in Saskatoon (www.usedvolvoparts.ca). Alberta Auto wreckers out near Medicine Hat may also have one. Schramm's in Surrey might also be able to sell you one.

I thought I had that system completely figured out and wired up properly when I put the car together. Even had the vacuum switch on the clutch pedal teed into the vacuum system so I was expecting the cruise to work perfectly right out of the box but I just tried it out the other day on the Deerfoot and it didn't work. I'm not sure why just yet but I'll have to look at it again to figure out why it's not working. It could be that I wired it wrong or perhaps one of the vacuum switches is not adjusted properly.

Well I've been trying to figure mine out the last few weeks....

I noticed on the bottom of my vacuum pump (lower drivers side shock tower) where the hose coming from the servo at the throttle body connects, there is a second nipple that doesn't have anything plugged into it. Also if I disconnect the vacuum hose from the servo and suck on it, I can't create a vacuum, but if I plug that spare nipple, it does hold vacuum. Maybe there was a connection there that went to the tranny that got pulled when we did the swap? wanna check yours and see if it's the same? Can anyone with functional cruise verify that that's normal/not?

Also I assume there's a connection from the old auto shifter that would tell the cruise that the car was in drive, is that the connection you're referring to? I don't think I ever figured that out when I did the swap so maybe that's the issue and yours is just hooked up wrong (and mine not at all)?

Well there is an on-board diagnostic for the cruise that they describe on brickboard that I should try out, I'll tell you how that goes!

Do the manly thing, rip your cruise control, A/C and other lame creature comforts out and go racing!

- R

I dunno about you raz, but I know cruise keeps me outta trouble when I know theres cops afoot....

learn to drive better? Throttle control is so easy

When you get old like me cruise is a nice thing to have. Nothing to do with "throttle control" I can easily keep my foot in one spot. But why would I when I can let something do it for me?

I use to be worried about weight and getting that 5lbs of cruise control out but it's just not worth it to me. The performance gain just isn't there. If it was a show car and I wanted a clean under-hood, well then I can understand it.

Maybe the cruise is more important to someone who lives in Saskatchewan, where you stay at the same speed for hours at a time .

But like anything, different strokes for different folks. I can't wait to drive the Lexus to the track with cruise and A/C and make a decent run and cruise back home in comfort.

Well I've got to say I miss the cruise control on my 2 hour drive home most weekends...Plus my foot seems to wander down on the accelerator without me noticing, and I can't afford any more speeding tickets!

cruise control accelerates up hills, its very annoying... you're supposed to accelerate lightly before the hill and keep it in vacuum all the way up it ... Cruise control is terrible for mileage, I hate that shit.