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Discussion Starter #1 (Edited)
I've been prepping my M41 for install with fresh paint and general cleanup...I will order new gaskets and replace. However, I took the OD unit off to cleanup and want to temporarily replace on main tranny body till gaskets arrive and I can't seem to get it back on the housing...it slides over the shaft till the bolts are about to go into the housing and then stops!

Any ideas?



 

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Haven't worked on that tranny. But it can be a bugger to get the splines lined up some times. Have you tried putting the tranny in gear and turning the input shaft? You may have to hold the output while doing this so it doesn't turn.
 

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Discussion Starter #3
Solved....after this post, went back out and twisted and turned till the splines lined up...sorry for the false alarm.
 

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Discussion Starter #4
M41--Install this weekend

OK..think I'm ready

1. new gaskets and O-Rings installed
2. pre-wire with OD relay and indicator light completed
3. have shortened drive shaft
4. checked with PO on clutch condition..>10k miles, so won't change
5. M41 transmission mount
6. transmission cross-members from both the 1800 and my 122
7. solenoid works
8. excellent help from Mr. John Sargent

Anything else I need?
 

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From another thread...

Recently purchased an M41 tranny (out of '68 p1800) for future replacement of my M40...still at PO's garage (he was kind enough to store it temporarily) so I can't confirm if J or D but think is D from the picture I snapped. I've read that I will need the shorter driveshaft from either the m35 or the 1800. The tranny comes with the driveshaft from the 1800...
This thread...

OK..think I'm ready

1. new gaskets and O-Rings installed
2. pre-wire with OD relay and indicator light completed
3. have shortened drive shaft
4. checked with PO on clutch condition..>10k miles, so won't change
5. M41 transmission mount
6. transmission cross-members from both the 1800 and my 122
7. solenoid works
8. excellent help from Mr. John Sargent

Anything else I need?
90-degree fitting on the end of the speedo cable.

If you are planning to use the entire 1800 driveshaft check the center support configuration on your '63 Amazon for compatibility with the 1800 setup.

If you decide to use the Amazon's existing rear drive shaft...

Matching yokes for fitment of OD output flange to (non-1800) shortened front driveshaft.
Correct spline-count on output end of shortened driveshaft to match spline count of existing rear Amazon driveshaft.
New center support bearing/bush, new u-joints, new flange mounting hardware.

Before final assembly the entire driveshaft must be spin-balanced as an assembled unit. Not all axle shops have the correct jig to do this.

If you use the entire 1800 driveshaft and do not intend to balance it be prepared for vibrations unless the shaft is re-assembled in the exact same configuration as when in the 1800 AND if the 1800 had no vibrations.

George Dill

http://forums.swedespeed.com/showthread.php?150663-65-122S-M40-to-M41-transmission-swap

http://www.vclassics.com/archive/odconv.htm

http://www.vclassics.com/archive/index.html

http://www.vclassics.com/contents.htm

http://www.sw-em.com/OD_Retrofitting.htm

http://volvo1800pictures.com/docume...20_140_1800/part_4_41_clutch_120_140_1800.pdf

http://volvo1800pictures.com/docume...gearbox_M40_M41/part_4_43_gearbox_M40_M41.pdf

http://volvo1800pictures.com/docume...40_1800/part_4_43a_overdrive_120_140_1800.pdf

http://volvo1800pictures.com/docume...rdrive_type_J/part_4_43b_overdrive_type_J.pdf

http://volvo1800pictures.com/docume...ropeller_shaft/part_4__45_propeller_shaft.pdf
 

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Discussion Starter #6
Thanks, George. yes I do have the 90-degree fitting and the longer speedo cable and the first thing we'll do is chek the spline count.

And I'll get a tap today for the overdrive switch in my M40 cover. I'll cross my fingers for vibrations and address if needed.

Wish me luck and un-scraped knuckles.
 

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One note: The top two studs where the OD meets the adapter to the gearbox must get copper washers under the nuts, or it will always leak. Very easy to overlook...
 

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Discussion Starter #8
One note: The top two studs where the OD meets the adapter to the gearbox must get copper washers under the nuts, or it will always leak. Very easy to overlook...
the top most stud in picture above, and its mate on the far side?
 

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the top most stud in picture above, and its mate on the far side?
"...tap...for overdrive switch..." - looking at your donor 1800 M41/OD with short-shifter - are you planning to fit the existing Amazon M40 cover to the M41 and use the existing swan neck shifter? Have you ever seen the slick swap of the short-shifter into an Amazon - cool!

George Dill
 

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Discussion Starter #11 (Edited)
"...tap...for overdrive switch..." - looking at your donor 1800 M41/OD with short-shifter - are you planning to fit the existing Amazon M40 cover to the M41 and use the existing swan neck shifter? Have you ever seen the slick swap of the short-shifter into an Amazon - cool!

George Dill

George...I'll use the M40 cover (but with a short shifter) How's that possible, you ask?! Well the PO wanted a shortshifter but did not want to cut the car, He fashioned a shift linkage that sits on top of the tunnel, based on a product that IPD used to sell and also used in some old-school muscle cars. Though its kinda rough, it is fairly unique and I think I'll keep it. I may have a picture of it posted in some of my other threads? Maybe one day I'll get one professionally built, based on POs design, but with machined parts and nice welds!


 

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Discussion Starter #12
Ok...my help had the sense enough to take some measurements of the M41 and the short drive shaft and check for fit/length before we removed any of the M40. It appears that the short drive shaft that came from the 1800 is too short to reach tha back axle...I thought this was a straightforward swap!?

I think I'll shorten my long drive shaft by 11 and 1/16th " unless someone can point out the error of my ways with the short shaft.
 

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Discussion Starter #13
Do I just use the front half of my 2 pc short shaft and connect this front piece to the rear piece of my existing 122 shaft?
 

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Ok...my help had the sense enough to take some measurements of the M41 and the short drive shaft and check for fit/length before we removed any of the M40. It appears that the short drive shaft that came from the 1800 is too short to reach tha back axle...I thought this was a straightforward swap!?

I think I'll shorten my long drive shaft by 11 and 1/16th " unless someone can point out the error of my ways with the short shaft.
Do I just use the front half of my 2 pc short shaft and connect this front piece to the rear piece of my existing 122 shaft?
One option is to shorten the existing Amazon front drive shaft to include welding on the front flange/yolk connection cut from the front of 1800 front shaft.

This will allow you to bolt the modified front shaft directly onto the 1800 overdrive output flange while keeping the Amazon center support and rear shaft as-is.

You will still need to balance the entire driveshaft as a single unit off the car which is a good time to install new center support bearing/bushes, all-new u-joints and flange mounting hardware.

George Dill
 

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C'mon, Dill! Yolk is part of an egg, not a driveshaft!
I woulda said if he can put it together and get it to fit, go for it! That is what I did on my 66 wagon in Panama (where nobody knew how to balance a driveshaft).
 

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Discussion Starter #16
Here is my 1800 front short shaft. How do I get the bearing off and then fit this shaft into my 122 center support?

 

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Here is my 1800 front short shaft. How do I get the bearing off and then fit this shaft into my 122 center support?

The 1800 front shaft will not mate with the 122 rear shaft unless the spline count is identical.

Count the "grooves" in the 1800 shaft visible here...

http://i1067.photobucket.com/albums/u431/JohnDouglas2/1963 Volvo 122/2012-07-01_20-49-34_590.jpg

...then safely get under the 122 with the rear suspension in full-drop and count the splines on the 122 rear shaft near the center support...

http://www.flickr.com/photos/mathrock/6623575675/

George Dill
 

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You unscrew the nut on the end of the shaft and the bearing comes right off. If you have the rubber bearing mount the bearing will fit into it. Then you can put the nut back on.
 

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OD M41 into early 122

I'd think you could use the 1800 front drive shaft section and the rear half of the one already on the wagon.

Issues:

Your 1800 front section uses the late donut bearing support bracket (surrounds the bearing and is captured by a bracket that is the bolted to the tunnel). I guess you could use this bearing and donut if you had the capturing bracket and welded nuts into your wagon tunnel, but more likely you'll use...

The original center support bearing native to your '63 body is held by a bracket with 2 pins; the pins live in 2 grommets that are popped into a piece of sheet metal that's part of the tunnel.

You can swap the piece with the pins from your original front section onto the 1800 front section.

Find both driveshaft breakdowns so you can see how the parts are meant to be arranged behind the large nut.

The bearings are different.

Also note that there is a lock tap that is bent up on one of the flats of that large nut. You'll have to bend that down prior to removing the nut. There is a dust boot not shown in your photo that goes on the lip of that nut and over the sliding member (splined front end of rear section)
 
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