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95 850 M56 manual transmission Swap Write Up

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

polskamafia mjl
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Year and Model: 1995 Volvo 854 T-5R
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polskamafia mjl

Re: 95 850 M56 Swap Write Up

Post by polskamafia mjl » Sun Sep 20, 2015 7:24 pm

I found this lovely Photobucket album that has some great shots of the modified wiring harness after swapping in a M56. I wish I had found this much sooner!

http://s42.photobucket.com/user/ludeles ... t=3&page=1
'All my money is gone and I have an old Volvo.' - Bamse's Turbo Underpants

Current: 1995 Volvo 850 T-5R Manual - Bringing it back from the brink of death
Previous: 1996 Volvo 850 GLT - Totaled

polskamafia mjl
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Year and Model: 1995 Volvo 854 T-5R
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polskamafia mjl

Re: 95 850 M56 Swap Write Up

Post by polskamafia mjl » Mon Oct 05, 2015 8:35 pm

I've had the T-5R off the road for about a week and a half while I've been adjusting a few things. I also took this opportunity to correct some of the things from when I did the swap. The reason my cooling fan was staying on continuously was because the ECT sensor connector was broken. I repaired the connector and I'm hoping that will fix both the cooling fan issue as well as the rough idle issue.

I also installed wiring for the reverse lights. The M56 I bought came with a VSS plug. That plug fits perfectly on the reverse light switch so I used that and lengthened the wiring enough to reach the transmission plug at the front of the car. I had an old PNP switch laying around so I stole two pins off of that and spliced them onto the end of the wiring so they can just be plugged right into the transmission plug.

I replaced my basic jumper wire (for pins 6 & 7) with a thicker wire that I also stole off of the old PNP switch. I crimped another pin onto the end of that wire and now the starter bypass wire can also plug right into the transmission plug. With some simple modifications I managed to use the old PNP plastic connector to keep my new wiring in place and make everything look fairly neat.
Jumper Wire Final.jpg
Jumper Wire between Pins 6 & 7
Jumper Wire Final.jpg (111.03 KiB) Viewed 1157 times
Jumper & Reverse Light Wiring Final.jpg
Jumper & Reverse Light Wiring Plugged Into Transmission Plug
Jumper & Reverse Light Wiring Final.jpg (168.61 KiB) Viewed 1157 times
I'm installing an IPD HD TCV tomorrow and possibly adjusting the wastegate as well. Once that's done I can put everything back together and test out the new modifications. Hopefully it all works! :D


Edit: New wiring works perfectly!
'All my money is gone and I have an old Volvo.' - Bamse's Turbo Underpants

Current: 1995 Volvo 850 T-5R Manual - Bringing it back from the brink of death
Previous: 1996 Volvo 850 GLT - Totaled

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abscate
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abscate

Re: 95 850 M56 manual transmission Swap Write Up

Post by abscate » Wed Mar 25, 2020 4:50 am

Bumped for link to Alex’s thread and VRD note too

ECM flashing service

viewtopic.php?f=6&t=91782

Polska, this is an excellent write up and we thank you again
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Re: 95 850 M56 manual transmission Swap Write Up

Post by Eddystone » Wed Mar 25, 2020 11:48 am

I found this very enjoyable and easy to read. Having done so, I will be taking the liberty of removing this task from my bucket list. ;-)

Converted an different vehicle from auto to manual many years ago. Fun and satisfying, but I have learned to love my automatic.

This is a very nice write up and an excellent resource. Thank you for making the effort to document this process. I'll bet there are some readers here who don't know what it was like to do these things without the internet as a resource. Sometimes we had factory service manuals, but usually it was like inventing the wheel over and over.
1998 V70 Non-Turbo/Auto
1993 945 Turbo/Auto
1999 S70 T5 Turbo/Auto
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;-)

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