Mercedes OM647 & 722.6 Swap into 1983 Volvo 760 GLE

[Bluevanacd2005]

Hello all! I just wanted to take a second to share my recent project of converting my 1983 Volvo 760 GLE to a more modern powertrain:

I purchased the car in 2015. It came from the factory with the D24T 2.4L VW inline 6 turbo diesel – basically a six-cylinder version of the Rabbit engine. It also had a 4-speed automatic ZF 4HP22 transmission. Not long after I got the car, I rebuilt the engine with head studs, a bigger turbo, a bigger rotor in the injection pump, added an intercooler, and converted it to a manual transmission using a T5 from Anders. I had a lot of fun driving it like that for about 8 years.

In the Fall of 2024, I began a conversion using a 2004 Sprinter van powertrain. This conversion utilized the OM647 Mercedes 5-cylinder common rail turbo diesel and 722.6, 5-speed automatic transmission. I used a Baldur DID1 ECU and PCS TCM2800 for controls. I decided to paint the engine Detroit Diesel Green.

I attached some pictures. I first rebuilt the engine and transmission. Next, I test fit the engine to the car and made modifications like: converting it to rear sump, cut out the trans tunnel and front crossmember for more space, and made a custom intake manifold. Other mods include: custom trans cooler/power steering/AC lines, aftermarket DO88 intercooler, added an electric fuel pump and regulator (stock was all mechanical), added a 2nd small fuse box for the additional equipment. I also converted the HVAC controls system to a manual type, rather than the automatic type because it never worked. I interfaced to the existing Volvo instrument cluster and added boost and EGT gauges. I have two maps in the ECU & TCU and can change them at the flip of a switch (efficiency or power). I did all the work myself with the exception of the driveshaft (Fleetpride), the powder coating of the intake (Jeff's Powder Coating, Monroe MI), and some assistance from Baldur setting up the CAN Bus between the controllers.

It runs quite well and has a good amount of power. It can squawk the tires when it shifts into 2nd and 3rd. With that being said it does need a locker, and higher gearing in the rear end (does anyone have 3.31 gears for a 1031 axle???). I've been daily driving it and tweaking the programming as I find quirks. We just took it to Carlise for the show in May- the first long trip of about 7 hours, and happy to report there were no issues - and the AC works better than I thought it would!

Future upgrades I am looking forward to include: limited slip/locking differential and higher gearing (from 3.91 to 3.54 or 3.31), getting the sunroof working and converting it to glass instead of metal, getting the exterior repainted, and upgrade the radiator to aluminum.

It also had an appearance on Dan's channel:

Thanks for looking!

Spenser

[volvolugnut]

What a massive project. You had to overcome many problems including structural and controls. You combined my two favorite brands. Thanks for sharing.
volvolugnut

[Fishman009]

I've got a Did1 with TCM 2800 too. Did you get the tcm to communicate with the Did1 for torque limit during shifting?