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M56 Swap: The Ultimate Parts List

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

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M56 Swap: The Ultimate Parts List

Post by bmdubya1198 » Sat Jan 04, 2020 2:02 pm

Now that I've completed two manual swaps on P80s, I think it's time to make an up-to-date list of parts that you will need to do this swap. Keep in mind, this isn't a writeup on the swap itself... there are a few already that do a great job of showing the process (polskamafia mjl on here, for one!), so I don't feel like I need to make another one. I just wanted to have a single thread with current information that is easy to find for someone like myself who wants to shift their own gears in their P80!

Used Parts
-Transmission… M56H or M56L. You can do your own research on the gear ratio/final drive differences, but most prefer the H. This is what I used.
The transmission should include the bracket for the shifter cables. Clips may not be included, though.
These are the part numbers for clips that you may need:
-3502507 “clip”. 4 required, these are used at both the shifter assembly and at the transmission.
-989037 “lock brace” 2 red’d, these are the clips that hold the shifter cables where they attach to the shifter mechanisms on the transmission.
-986417 “washer” 2 req’d, these are used with the above clips.

-Flywheel… you can buy this new if you wanted to (I’m pretty sure it’s still available), but you’re better off just getting a used one resurfaced. This applies to the single mass, the dual mass is not typically resurfaced.
Dual mass and single mass flywheels are 100% compatible, so it’s literally as simple as swapping from one to the other (this statement assuming your car is already manual, therefore with a manual swap you can use whichever you have/can find). Both work with either the internal or external slave cylinder configuration. SMFs are known to chatter, so keep this in mind if that may bother you. There is some info floating around on this topic already, so I won’t get into that. However, the SMF is better for power, being much lighter. I used a SMF on both swaps that I’ve done.
-Pedals... two options here. If you have an 850, you need 850 pedals. If you have an S/V/C70, you need S/V/C70 pedals. The brackets are totally different. Now, you CAN in fact remove the brake and clutch pedals from the 850 bracket to use on the X70 bracket, but you lose the ability to have a return spring. The return spring design is totally different between the 850 and X70.
On X70 cars, the automatic and manual pedal brackets are exactly the same, so all you realistically need for these cars are the clutch pedal and the manual brake pedal. I cannot confirm this for the 850, so it’s safe to just get the whole assembly.
Additional part you may need:
-983479 “lock brace” clip that holds the master cylinder ram rod to the clutch pedal. Same as the clip on the brake master cylinder rod to the brake pedal.
-Shifter assembly... again, different between the 850 and X70. They are 100% compatible except for the shift knob, but that depends how picky you are. ‘98 and older cars use a different style, which is a royal pain to remove. ‘99+ shifters are slightly different, so the new style knob attaches. The boot is also different, but I’ll get to that!
-Shifter cables… nothing specific you need to know about these, at least I haven’t come into any issues with them yet!
-Reverse light switch… should be attached to the transmission
-Shift knob and boot… this is up to you, but if you want the correct knob for your car, you have a couple options.
The following are compatible with the 1993-1998 shifter assemblies:
-850 shift knob, black rubber/vinyl, 1993-1997. PN 6814305.
-1998 X70 shift knob, gray hard rubber. PN 9176166.
Then, the 1999 and 2000 shift knobs are different. They mount slightly differently, and are not compatible with the shifter rod on the -1998 style shifter.
-1999 X70 shift knob, gray plastic/hard rubber, PN 9445851.
The boots are different as well. For 850s, you may want to get a manual center console. The area around the shifter is slightly different, and there is no cutout for the automatic transmission mode selector button. 850 shifter boots are all the same.
1998 X70 boots have a plastic collar like the 850 boots, but are made for the X70 center console and are gray in color to match. There is no need to replace the automatic center console for the manual swap in these cars, as they are exactly the same. The boot clips right into place.
1999+ boots are the same on the bottom, but have a different neck to attach with a twisting action onto the newer style knob. These do not have the plastic collar like 850 and 1998 X70 boots.
There are some other shift knob options from Volvo out there, but I that topic deserves its own thread!

New Parts
-850R clutch… clutch is your choice (although we have relatively limited options), but I always use the 850R clutch, part number 272218. Still available from Volvo. I am not 100% certain that this is compatible with the DMF, as it is designed for use with the SMF.
-Rear crankshaft seal/rear main seal… trust me, JUST CHANGE THIS while you’re in there. The flywheel has to come off anyway, so it would be stupid to leave it alone. Just because it isn’t leaking now doesn’t mean it will stay that way! Part number 9458178.
-Axle seals… you need two, PN 6843481.
-Clutch master cylinder... take my advice, USE A NEW ONE! I have been alright with a used one for now, but I am going to replace it soon so I can use a clutch pedal position sensor (old 850 master doesn’t have provisions for the clutch sensor). I’ll get into this later on in this post. PN 9163880. Absolute bear to install, but it’s a straightforward process. Just no space to work.
-Flywheel bolts… you need to replace these, as they are different between the auto flex plate and manual flywheel. PN 9454743, 10 required. Not a bad idea to order a couple extra just in case you lose one!
-Pressure plate bolts… PN 959219, 6 required, just like the flywheel bolts, extra isn’t a bad thing!
-Clutch master cylinder fluid feed hose… PN 9157190. Just a simple rubber hose connecting the brake master cylinder reservoir to the clutch master cylinder. You don’t necessarily need to use the genuine Volvo part here.
-Transmission input shaft seal… there are two different diameter input shaft seals offered for the M56 transmission. Your best bet will be to measure the one you have before ordering. The part numbers are as follows;
-1381798 41mm OD
-8675580 44mm OD
-Transmission fluid… you can either use Volvo 1161645 or a generic gear oil if you’re in a pinch. Otherwise, you can use your choice of a better quality transmission fluid like Redline MTL. I used Mobil 1 75w90 and I have no complaints. Best to get 3 quarts, the capacity is 2.2 qt., IIRC.

Now here’s where we get into more specific info dependant on your car… continuing on with the “new parts” section…

Cars with external slave cylinder
-Clutch release bearing… 9181780. Sachs will work just fine
-Clutch release fork… 9181780… you could use a used one as well, that’s what I did.
-Clutch fork dust boot… 6843840. This part is no longer available, but this is the part number.
-Clutch slave cylinder… 9181017
-Clutch hydraulic hose... 9181437. You could realistically use a used one, but as always, new is better in the case of a hose like this.

Cars with internal slave cylinder
-Clutch slave cylinder... 31259445. FTE is fine (OEM) but the genuine Volvo part comes with the dust boot, which at the time of typing this is on backorder from Volvo.
-Clutch hydraulic hose… 9181324 YES, this one is different from the hose for external slave cars.
-Clutch release bearing dust boot… 9181326, only required if you don’t use the genuine Volvo slave cylinder that includes this part.

Now, please keep in mind this is mainly for cars that use the ABS module for the speedometer. I do not know the specifics on transmission mounted speed sensors, which I believe were used on 1993-1994 cars. Possibly even 1995. But, this is mainly meant as a parts list. I do not know what other parts may be required, but I would assume that you would need to use a transmission with provisions for a vehicle speed sensor. I’m sure there is info on Volvospeed on this topic. I will update this thread if I feel it’s needed. In the two cars I’ve swapped (1999 and 2000) I have not needed to worry about this.

All of these basic parts that have been listed are for M4.3 and M4.4 cars. Now we’ll get into the special parts for ME7! Well, the special part at least...

-Clutch pedal position sensor w/ connector… 9472979. This part is exclusive to ME7 P80s (1999+) and is used for both the cruise control and to assist in taking off from a stop. It helps open the throttle to make it a smoother launch. If you don’t have this, a code will appear on VIDA, but it will not affect anything else aside from the fact that it will be slightly harder to take off if you’re not used to the ETM. You will need to add a pin to the ECU connector, but I won’t get into detail on that in this post. There is some information on that in this great thread over on Volvospeed, though: http://volvospeed.com/vs_forum/topic/15 ... nt-2382487
You will need this sensor in order for you cruise control to work. I actually just got the correct master cylinder today with the mounting “nubs” to install this, so I will update this thread if this works. I don’t use cruise control anyway, so it doesn’t really bother me.
Fortunately, the current version of the master cylinder is compatible with all P80 models and has provisions for the clutch sensor. The sensor mounts to little nubs, one on the flange where it goes against the firewall and one on the ram rod that connects to the pedal. The original 850 master cylinder did not have these mounting provisions, but you should be using a new master cylinder anyway.

Info for AWD cars being swapped to FWD
Some crazy individuals (maybe me…) decide that it’s easier to just swap their AWD P80 to a FWD manual transmission, whether that’s due to their driving style (which may not be good for the relatively weak angle gear) or just due to cost or parts availability. Of course, ideally, you would use an M58 or M66 on an AWD car to retain the AWD, but in my case I got rid of it since the drive shaft and angle gear were already gone by the time I got the car. Plus I had a whole M56 swap available, so why not?

The parts you will need to swap from AWD to FWD are:

-FWD rack and pinion… the reason for this is that the AWD rack does not have a mount for the rear engine/trans mount. This is required for the M56. It’s a pain to replace, but it’s necessary. I HIGHLY urge against those remanufactured auto store racks… I got mine from O’Reilly and it’s already leaking after a year and maybe 5,000 miles. You’re honestly best off getting a good used one, unless you want to pay for a new one.
-FWD Passenger side axle, driver side as well if your car originally had the AW55 transmission… while automatic and manual axles are compatible with each other, the AWD passenger side/right axle should be replaced with a FWD axle. If your car originally had the AW55-50SN 5 speed automatic transmission (particularly 2000 V70R), you will also need the driver side/left axle since the splines that go into the transmission are different, and will not fit the M56. No need to worry about axles on AW50-42 FWD cars, they fit the M56 just fine.
-FWD rear engine/transmission mount w/ brackets… the whole thing. It consists of a black steel bracket, a plain steel bracket, and the hydraulic/rubber mount itself. I recommend getting this mount new, PN is below. The brackets can be sourced second hand, they are usually cheap.
Here is a picture of what I’m talking about.
Capture.PNG
Part numbers:
1- 1397889 “Engine mounting, rear”
2- 9141000 “protecting plate”
4- 9434435 “engine pad”

Hardware:
3- 982820 “flange screw”
5- 987891 “flange lock nut”
6- 982817 “flange screw”

Yes, it really is that simple!

Of course, you will also remove the angle gear and driveshaft. No need to remove the differential and viscous coupling, but I highly recommend doing so to cut some weight. I plan to do this in the near future, because my V70R currently weighs in at around 3,700 pounds… WAY too much!

That pretty much covers the parts required for a manual swap. Now, there are some other things you may want to change while you’re in there, but this covers the basic stuff. I wanted to compile a complete, up to date list, so here you go! Thanks to Abscate for giving me the idea!

Feel free to post any questions you have on the swap or any other input, I’ll answer them to the best of my ability! I tried to make this as complete as possible, but we're all human, it's easy to make an error and omit something. If I remember something else, I will update this thread.

Helpful manual swap resources:
viewtopic.php?f=1&t=70637
http://volvospeed.com/vs_forum/topic/15 ... /#comments
http://volvospeed.com/vs_forum/topic/65 ... rts-bible/
http://www.ardideas.com/Autotragic-to-M ... _b_20.html

And for parts, of course, my favorite… www.fcpeuro.com/! For the used parts (transmission) check out www.car-part.com/ or www.lkqonline.com/.
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850 LPTmatthew1abscate
2000 V70R Venetian Red/Charcoal M56 Swapped 195k
2000 S70 GLT Mystic Silver/Taupe 253k
2003 S60 2.4T Silver/Black 109k
2007 XC90 V8 AWD Sport Titanium Grey/Black 165k
1993 944 Base Beige/Beige 221k
1991 944 Turbo Dark Green/Beige 172k
1992 245 Base White/Beige 249k
Sold-
1998 V70 GLT Black/Beige 199k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k

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Re: M56 Swap: The Ultimate Parts List

Post by 850 LPT » Sat Jan 04, 2020 2:49 pm

Wow! Thank you for taking the time to record all this. Much appreciated.

Dirk
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Re: M56 Swap: The Ultimate Parts List

Post by matthew1 » Sat Jan 04, 2020 3:22 pm

Well written, bmwya.

Marked for inclusion in the Volvo Repair Database VRD.

I write the same sentence ^ to mark these so I can quickly find them when I get to work.
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Re: M56 Swap: The Ultimate Parts List

Post by bmdubya1198 » Sat Jan 04, 2020 6:12 pm

If I can help out someone doing a manual swap, my job is done! I love being able to find a complete list that isn't scattered information from 12 years ago.
These users thanked the author bmdubya1198 for the post (total 2):
matthew1Peevarino
2000 V70R Venetian Red/Charcoal M56 Swapped 195k
2000 S70 GLT Mystic Silver/Taupe 253k
2003 S60 2.4T Silver/Black 109k
2007 XC90 V8 AWD Sport Titanium Grey/Black 165k
1993 944 Base Beige/Beige 221k
1991 944 Turbo Dark Green/Beige 172k
1992 245 Base White/Beige 249k
Sold-
1998 V70 GLT Black/Beige 199k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k

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Re: M56 Swap: The Ultimate Parts List

Post by polskamafia mjl » Mon Jan 06, 2020 10:50 pm

bmdubya1198 wrote:
Sat Jan 04, 2020 2:02 pm

-Clutch master cylinder fluid feed hose… PN 9157190. Just a simple rubber hose connecting the brake master cylinder reservoir to the clutch master cylinder. You don’t necessarily need to use the genuine Volvo part here.
That's not just a simple rubber hose, it's a material called EPDM that is resistant to brake fluid. It's difficult to find an OEM replacement, unless things have changed since 2015. It's a discontinued part from Volvo so you can't turn to them. If you have a reliable source please let me know as I would still like to replace mine with a longer piece.
'All my money is gone and I have an old Volvo.' - Bamse's Turbo Underpants

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Re: M56 Swap: The Ultimate Parts List

Post by bmdubya1198 » Tue Jan 07, 2020 8:50 am

polskamafia mjl wrote:
Mon Jan 06, 2020 10:50 pm
bmdubya1198 wrote:
Sat Jan 04, 2020 2:02 pm

-Clutch master cylinder fluid feed hose… PN 9157190. Just a simple rubber hose connecting the brake master cylinder reservoir to the clutch master cylinder. You don’t necessarily need to use the genuine Volvo part here.
That's not just a simple rubber hose, it's a material called EPDM that is resistant to brake fluid. It's difficult to find an OEM replacement, unless things have changed since 2015. It's a discontinued part from Volvo so you can't turn to them. If you have a reliable source please let me know as I would still like to replace mine with a longer piece.
Right, you would want the right material. People don't take that into account... for example rubber heater hose is NOT oil resistant!

In both swaps, we reused the old hose. I agree, it definitely needs to be longer. I'm not aware of a source for a new hose, but I'm sure you can find generic EPDM hose that will work just fine. You would just need the ID measurement, which I don't have handy.
2000 V70R Venetian Red/Charcoal M56 Swapped 195k
2000 S70 GLT Mystic Silver/Taupe 253k
2003 S60 2.4T Silver/Black 109k
2007 XC90 V8 AWD Sport Titanium Grey/Black 165k
1993 944 Base Beige/Beige 221k
1991 944 Turbo Dark Green/Beige 172k
1992 245 Base White/Beige 249k
Sold-
1998 V70 GLT Black/Beige 199k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k

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