I just finished my install into 245.
I had 2 forks, one with hole and another without. And this was their only difference. Length, brearing mating, pivoting place: all same. They can differ only in pivoting as M90 should have that plastic bushing. Can that bring horrible clutching that people have reported before? IMHO not, unless there is third hyraulic fork type. I used the one with hole and made slave cyl adjustable with threaded bar and nyloc nut.
I went for the M47 modified mount as most usual here in TB and
here, although I would have liked the capt. Bondo style. Then again now - after seeing I how steady the setup with M90 gearbox mount is - I am happy. M46 moved and rotated much more with its originial rubber mount. It seemed reasonable to lower the gearbox more than others have done here and I used aluminium spacers found on AW70. With that height it seems that two pieces of propshaft are coincident.
Propshaft came from 940 M47 with its original center support. I will have to take this picture to show my setup there but basically welded 940 support with its piece of sheetmetal to 200 bracket. And bracket is in original 200 place..
Tunnel got quite a lot of smacking. Sadly the place where it needed it most - upper left side of gearbox, where a bolt protrudes - was too strong for our hammer. It has about 5mm on spacing now but as gearbox is almost not moving at all, so it seems OK.
Pedals. The distance between original, cable and new, master cylinder fixing is 10mm. It came as surprise that I needed to mount pedal to higer, luckily existing holes. I didn't like the idea of removing the whole pedal box and manged to take the clutch axle bolt out and put into new place while all the rack was in the car. Needed quite a lot of luck and patience but it was the only way for me as I hate dismantling things that are not directly under work. Clutch pedal is now some 7cm higher as the new placement came as surprise and we didn't have MIG at hand. Lets see if i get used to that.
Also you need different spring. Original hydraulic looks like
this but as this came as surprise we modifid original: reversed it to be pushing upward and bent the ends when red hot.
Its fun to do this kind of tuning on volvos because so many things fit between generations of cars. I used 200 gear stick because I like it more. All bushigs below and in the midde are the same. Its good idea to remove the rear gear slider "button" so that muscle memory woudn't use 1st gear instead of rear.
Then again I feel sorry for volvo engineers who were not allowed to change 20-30-40 year old designs.
My clutch: Sachs 940 TD pressure plate + new NK disk that got new Ferodo linings that were told to be better biting. We'll see about that. M90 thrust bearing. Its mating area is different than M47 bearing but again: side by side to M47 bearing/fork did not show difference in height. My hands were too dirty to handle camera. Anybody can confirm that?
Replaced all seals and oil but the info about the gear selector seal came too late.
Also 3rd gear was left original. Lets see if it breaks.
All new cyl's boots.
Also flexible hose is yet to added to clutch hydraulics.
I am surprised how loud it clicks when changing beween gears. Is it my imagination that it should click less than M46?
But basically it seems to be success and lots of building fun.