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S40 / V40 '96-'04 General Forum for the Volvo S40 and V40 (Classic) Series from 1995-2004. |
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V40 T4 6 speed gearboxViews : 680 Replies : 7Users Viewing This Thread : |
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#1 |
New Member
Last Online: Yesterday 23:12
Join Date: Aug 2022
Location: Bolho
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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.. Last edited by scorcherimports; Jun 7th, 2024 at 17:41. |
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#2 |
Premier Member
Last Online: Yesterday 21:20
Join Date: Mar 2007
Location: Dublin
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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. |
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#3 |
Non Fragile
Last Online: Yesterday 00:40
Join Date: Apr 2010
Location: Chadderton, Oldham
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Did you need to fabricate new mountings?
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#4 |
New Member
Last Online: Yesterday 23:12
Join Date: Aug 2022
Location: Bolho
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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!! |
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#5 | |
Non Fragile
Last Online: Yesterday 00:40
Join Date: Apr 2010
Location: Chadderton, Oldham
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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? Quote:
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? |
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#6 |
New Member
Last Online: Yesterday 23:12
Join Date: Aug 2022
Location: Bolho
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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. ![]() Last edited by scorcherimports; Jul 12th, 2024 at 15:27. |
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#7 |
Non Fragile
Last Online: Yesterday 00:40
Join Date: Apr 2010
Location: Chadderton, Oldham
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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. |
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#8 |
New Member
Last Online: Yesterday 23:12
Join Date: Aug 2022
Location: Bolho
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About 4,30gbp for 60 miles , or 0,072gbp per mile.
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