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1991 740 pickup LR4 V8/4L60e Swap

lookforjoe said:
The problem with PODS - which I did not realize up front - they DON'T ship the pod to you directly. It gets picked up, goes to a local wharehouse, then gets shipped to another storage facility closer to where you moved, then finally gets delivered to you. it's almost 3 weeks between pickup & delivery(!). If I wasn't immersed in house prep, that would have made me absolutely crazy (!) Also - they way they do this, puts you at the end of the month rental, so basically you can expect o pay 2 months rent on the POD, unless you complain (I did) & get a few days grace period.....
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Agreed. You do have to know exactly when you want it and preemptively set it up
 
New kitchen light fixture. Making the Mrs. very happy.
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Drilled the granite & added dish soap dispenser- makes me very happy as I am the dish washer
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Fixed the gas fireplace -turned out it was just the pilot ignitor at issue
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Ordered new lava & embers for it. Those all look pretty ragged
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Another waterfall around the corner from the house
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Going in the pickup to Carlisle PA in the AM for the annual Import Show. I'll get to see a bunch of great Fiat people, along with all the Volvo folks.
Yesterday I fixed the exhaust - just used pieces I had made for the X1/9 K24 - don't want to make a proper exhaust that will only be removed in a month. I found enough tools & the exhaust parts to do the job

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I had made this pipe to bypass the muffler on the Honda K24 install
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Added the piece I made to bypass the cat on the Honda K24 to bring the exhaust back to the bumper
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Jonathan came through for me with a used fogplamp. I do need to sand & polish the glass to get it closer to the clean left side. This is after sanding w/ 120 & 240 grit
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Knowing I have the spare as backup I removed & fixed the foglight I broke by driving into the concrete shelf in our parking area. Superglued all the broken pieces of glass back in place, put Xpel film on the outside, then used clear epoxy from the inside to fill the cracks.
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Got more acoustic tile to finish up behind the air compressor
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Bought another table from the recycling center - $50. I'll probably add a sheet of steel & use it as a welding table. I can actually sit at this one. Typically I've just laid stuff out on the floor or over saw horses, neither of which were particularly comfortable welding positions
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This presented itself - a Volvo 1993 245. So, this will be my next Volvo project after the V8 conversion. Maybe after the V6 conversion in the Datsun, I dunno. In any event it will be a Volvo 240 pickup with a working mid-gate like my 740. I cannot find any examples of 240 pickups with functional gates. Several cool pickups, but none truly functional, so that will be the goal again.
Wagon was garaged unused for the past 10 years or so, back then the driver hit a deer & took it off the road. Pretty much the cleanest 245 I've seen for many years in terms of lack of rust.


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lookforjoe said:
This presented itself - a Volvo 1993 245. So, this will be my next Volvo project after the V8 conversion. Maybe after the V6 conversion in the Datsun, I dunno. In any event it will be a Volvo 240 pickup with a working mid-gate like my 740. I cannot find any examples of 240 pickups with functional gates. Several cool pickups, but none truly functional, so that will be the goal again.
Wagon was garaged unused for the past 10 years or so, back then the driver hit a deer & took it off the road. Pretty much the cleanest 245 I've seen for many years in terms of lack of rust.
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Adding this from the Pie Cut thread I started in 2013 - I may want to make the 240 pickup a little wider - food for thought

 
Speedo on the pickup has been dead for a couple years now - odometer & trip work, just no roadspeed shown. Finally got around to looking at the parts clusters I had - The one speedo I have in good condition is from a slightly newer 940 - the connections are different on the circuit board

I can't fit this speedo into the 91 cluster, and the clock in this is manual adjustment, vs. remote switch in the 740. I tried cutting a hole in this housing for the clock remote adjust connection, however beyond that I found the screw spacing in the circuit board is not the same between manual & remote clocks.
Ultimately, I modded the back side of the manual clock adjuster to clear the '91 fuel gauge, and swapped over the turbo tach/boost gauge to the newer housing.
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Put it in the car like this to check operation & bulbs, Speedo works, so I removed it & reassembled the entire cluster
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Had to drill the cluster & 'glass' to allow the manual clock adjuster to come through (all the way on the left)
Actual mileage 237118
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I've had a vibration at low speed decel - couldn't find any obviously worn, so I removed the driveshaft & checked the ujoints. I had it in my head that that could not be the issue, as I had looked them when I did the carrier bearing. - however I realized that was over 3 years ago now.

Rear joint was seized on one axis. This is a Type 03 driveshaft, 3 x 1209814 (small) ujoints approx 3.25" yoke width. (1340501 carrier, 183265 bearing)
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yoke off
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Joint out
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wire brush the yokes
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New joint in shaft first
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outer yoke on
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I have another complete Type 13 shaft that has 3.5" yokes -
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I think I want to use that with the V8, so I'll get the appropriate ujoints (1220786) carrier (1209820) and bearing (9445857 / SKF 60072RSJ)
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Cut the dead carrier away to get to press the bearing off
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Since I had the driveshaft out, I decided it was time to get the revised torque subframe installed.
Handbrake cable runs through the frame - rather than disassemble the rear brakes, I removed the console, handbrake lever & feed the cable out through the bulkhead
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Stock subframe
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modded one in place - not secured - ran out of time
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Took the subframe back out to work on the rear upper mount, and to pound the floor under the backseat where the wider subframe hits.
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With just the mount in place, I marked & drilled the 2 outer attachments, placed two long bolts through. I will need a tie plate to anchor them
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Put spacers in-between where I will need to add support plates to level the mount area
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Spent much of the day plowing & shoveling snow, and fixing the tractor (with Volvo parts)
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one leg of a Volvo P1 fused positive battery cable (from the C30)
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After that, I needed to relax so I worked on the upper subframe mounting for the torque frame
Made a tie plate for the additional mounts
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Figured out the support plates that need to go behind the mount, to keep it level & supported
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Some more trimming to do, to make sure they sit at 1" off the crossmember, then I'll scrape all the undercoat off & weld them in place
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Had Flu & COVID shots this morning - which slowed me down some, however it was a productive day - I go the torque subframe mounts finished, painted & undercoated - got the subframe back in, eBrake cable routed nicely through the subframe & back in the cabin, and got the driveshaft back in. After that, I had time to get started on the new rear exhaust section intended for the V8. Using 2'5" SS mandrel bends & muffler & resonator

brackets modded, welded & painted here, undercoat applied after
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Area I had to bash to clear the wider subframe - I went a touch overboard, I found, so I tapped it back some from above after
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Torque arms clear all the bracing
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eBrake routed
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cable inside & set in the adjuster, ready to be reached to the lever
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Driveshaft has good clearance off the widened subframe
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Exhaust:
At some point in the past couple years I bought the Solo Performance muffler & resonator, and a set of mandrel bend 2.5" SS pipes to work with.
Cut down the 2 45's & 1 of the 90's to make the over axle section. Everything looks pretty good as far as placement goes. Need to set the rear muffler 1st, then work my way forward. I'm going to add V-bands to make it sectional, although that does make a fair bit of extra work.
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I'll put a V-band in front of this, so when I make the exhaust off the V8, it will tie in here
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All these sleeves are just temporary connection from 4cyl exhaust
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Was able to work on the exhaust this afternoon. Decided I didn't like where I had the resonator set, so I made a dogleg for the inlet side to raise it
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V band will go on the inlet of the resonator
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Overall layout coming along, had the cut each of the over axle pipes to adjust for the shift
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One hanger set on the rear muffler - the other side is really tight against the spare wheel well, so I have to think on that one
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Precision height adjustment
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This will be tailpipes
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Welding V band for the inlet
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Another Volvo I'll be doing a short block replacement on soon
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