V40 T4 6 speed gearbox

[scorcherimports]

Hi everyone!

Finally got my van running again and this is the result:



The gearbox installation is a lot more tricky than the internet advised.. it was possible yes.. but far far away from a easy or direct job.. did in fact anyone have done it or this is indeed the world unique V40 T4 6 speed?

Btw, the six gear is a speed ticket bait..

[Volvophile]

I have only seen one person put an M66 into an S40 T4. It's a red car that is online somewhere and is mainly used for track days. I was curious to know about the swap recently myself, even though I sold my T4 years ago. At the time I owned it, transmission conversions seemed to be very scarce and rarely performed. It might have been down to the S40/V40 T4 being less popular, or indeed as global a model as any of the T5's.

My T4 was the Aisin five speed auto and if I had kept it, I would have definitely looked at an M66 manual swap.

[canis]

Did you need to fabricate new mountings?

[scorcherimports]

Originally Posted by canis

Did you need to fabricate new mountings?

Yes, all of them!


To start, installing a 6 speed gearbox implies a new clutch plate due to M66 gearbox primary shaft being 25mm diameter vs 20mm M56




Then the rear mount won't fit..




Need custom template with new bolt pattern:











Some plasma cutting:








New clutch plate isn't compatible with original dual mass flywheel..




Needed 3mm clearance workout:




There was no place to mount the side gearbox mount.. Need o custom made one..














[YOUTUBE]https://www.youtube.com/shorts/2Y9zMC8OsoI[/YOUTUBE]


[YOUTUBE]https://www.youtube.com/watch?v=VgCcN2WcvH4[/YOUTUBE]

All done!!

[canis]

A tree stump! Why didn't I think of that? That's it - I'm getting a tree stump for my garage, and I'm doing it today!

I like your thinking though. Years ago I wondered if I could put a five speed box from a Sierra onto my Cortina. But Sierras were new in those days, and out of my price range. I never obtained one to make the attempt.

This project excites me because I always felt my diesel V40 lacked gears. The jump from 2nd to 3rd was annoyingly large for a diesel engine. Do you know anything about the gear ratios? Does a six speed have a higher top gear, or better selection of ratios within?

Originally Posted by scorcherimports

New clutch plate isn't compatible with original dual mass flywheel..

None of us are...

I can't believe you're running that axle live on a scissor jack. Man, that's bravery right there! Thanks for sharing those pictures. I love how customisable the original V40s are but even I never attempted anything like this. Great job, well done.

What are those four black boxes before the injector rail? What do they do?

[scorcherimports]

There is literally some wood stumps under the chassis haha, so no worries.. and petrol engine idling in 6 gear will stop right away if anything happens.


The 4 boxes are individual LPG injectors, don't ask me how but this van can do now 6 liters on LPG, meaning 5 euro per 100km driven.

[canis]

Haha, yes I see the stumps under the car now. So it's the same gears but with an faster one on top, that's cool.

I dunno what 5 euros is, but it's sounds like peanuts for 100km. I daren't say what I'm paying per mile, it's too frightening.

[scorcherimports]

About 4,30gbp for 60 miles , or 0,072gbp per mile.