auto to manual conversion

volvee850glt · Post by **volvee850glt** » 18 Apr 2010, 21:47

I've been thinking about trying to find a manual trany to put in my 97 850 glt. I know the first problem and probably hardest is going to be finding a manual transmission for a 850 in the US. But after that will I need a different ecu? I found a post on volvoforums of someone walking through the process on a RHD model and it outlined a couple things like making it think its always in neutral or park so it will start and something about the reverse switch.(reverse lights maybe?) There was also some stuff about cruise control but mine doesn't work anyway so I'm not really concerned about that. It also said the TCU box was useless after the switch and just to take it out. Other than those few things would the ecu need to be changed or switched with a different one?

Post by **jblackburn** » 18 Apr 2010, 22:23

The ECU will work OK, but shifting will be a bit jerky. The manual ECU's hold on to the revs when you let go of the gas and push the clutch to make the shifting a little smoother. You would then remove the TCU computer entirely, it has no use anymore and won't have 2342424 codes to be mad about.

The reverse switch on a manual is on the transmission itself - I think the wires can just be re-routed from the PNP switch to it.

Poke around Volvospeed a little bit - many people over there have done this swap with their T5's. Or look up Japedo here, he just recently did a manual swap on his car and might be able to give you some pointers

https://www.matthewsvolvosite.com/forums ... 30#p128730

volvee850glt · Post by **volvee850glt** » 19 Apr 2010, 00:01

Ok cool thanks alot. Also do you know anything about the radiator since the auto has trans cooler would I need a manual radiator?

Post by **jblackburn** » 19 Apr 2010, 05:12

Nah. Just drain the cooler and plug off the ports.

Japedo · Post by **Japedo** » 19 Apr 2010, 05:34

- You need the pedal assembly with clutch pedal form a manual 850.

- You need a manual transmission M56 H or L "any 93 to 98 850 turbo or n/a"

- You also need the two control cables, and the shifter assembly that replaces your auto shifter.

- You need the master cylinder, slave cylinder, and pressure line.

- You do need to eithrer plug you pnp switch back in so it will allow the car to start. Or put a jumper wire in the connector.

- You also need to wire the manual tranny reverse switch to your harness so youhave reverse lights.

- Lastly you will need a clutch assembly, "cutch plate, pressure plate, throw out bearing,"

I got all this stuff for 500$ off a 94 850 n/a

The manual trsanny doesn't have an oil cooler, so you can just use the auto radiator with no problems. Just one less thing to put back together.

Good luck , and don' hesitate to ask more questions.

zhenya · Post by **zhenya** » 19 Apr 2010, 07:03

Japedo- once you have sourced all of the parts, how long would you expect this to take an average mechanic with average home tools, say with the help of a friend or two?

Japedo · Post by **Japedo** » 19 Apr 2010, 07:59

Well, that is a good question.

It depends what you have for tools "manual vs air" and also which method.

Here is a link for transmission removal/installation that is done while leaving the engine in the car, drop driver side of subframe etc. http://www.volvoclub.org.uk/tech/servic ... emoval.pdf

I decided to remove the entire drivtrain, swap the transmission and reinstall the engine/manual trannay as one piece. I don't have air tools but I did have a friend help me for atleast half of the job. I did it over a period of three days and probably a total of 12 hours. Interestingly enough I spent atleast 5 hours of that time installing the clutch pedal, master cylinder and bleeding the clutch.

I have at this point pulled 3 850 engines

"all due to transmission's" and two of these instances were in 2010! Hence I bite the bullet and got the manual gear, as I seem to be to attached to the car to let it go

But I am not a mechanic, just an average guy who tries to do his own stuff. "tries"

I understand that volvo charges 8 to 9 hours to change the clutch in a manual 850. But there is alot more to it when you have to change everything inside the car too. pedals, shifter,cables, etc......

I actually found it to be an easy swap, short of the clutch pedal assembly. Had to dissconect steering column for this and very awkward position to work in.

I did have one huge issue, car won't run

But it is a damaged crank sensor not allowing spark/fuel. This is most likely my fault, or coincidence that the sensor finally died at this time. I have read many swaps and the guys didn't have the no start issue, so don't let that scare you. I'm just special..

Japedo

whoa · Post by **whoa** » 19 Apr 2010, 11:50

Japedo, have you pulled transmissions both ways (with the engine out the top and by dropping the subframe)? If so, which would you recommend? (RMS replacement looming.)

Japedo · Post by **Japedo** » 19 Apr 2010, 13:04

whoa wrote:Japedo, have you pulled transmissions both ways (with the engine out the top and by dropping the subframe)? If so, which would you recommend? (RMS replacement looming.)

I have only pulled the engine/tranny out the top. So I am not sure which is easier. With a hoist and a transmission stand im sure it would go pretty smoothly from the bottom as well.

I just used chain falls in my garage to hoist the engine/tranny up, then push the car sideways on the rolling car jack so I can set the drivetrain down on the floor.

I haven't changed a RMS with the engine in the car but I know it is done that way all the time. Good Luck

Japedo

Japedo · Post by **Japedo** » 19 Apr 2010, 13:15

I forgot 2 things that are needed in doing the auto to manual swap.

- You need manual tranny pilot bushing " goes in outside of crank, tranny shaft fits into it"

- You need Clips that attach tranny control cables to their brackets. "a total of 4, u can use the one from your auto cable and source 3 more"

I read a swap somewhere and the fella didn't switch the pilot bushing, the automatic's pilot bushing is larger and the manual tranny shaft will fit inside of it's inner diameter. BUt It won't support the shaft when under torque.
The fella in this swap was aware of this but not concerned, I have no idea how it worked out for him but for the price of a manual pilot bushing i recommend installing one.

Japedo