23 replies to this topic

[Ludeless]

So i finally got around to getting the engine/trans back in the car from the manual swap project that's waaay overdue. I'm working on the wiring harness now and am clueless for the most part about which wires to connect to where. I've seen the post on turbobricks but it's not making a lot of sense. Wondering if anyone has some detailed pics or instructions on how to do this.

So far, all i know is that i need to somehow connect into the Reverse lights, Speed Sensor, and PNP switch, but really have no idea where to do this. I'm not very good at wiring or reading wiring diagrams, so any help w this would be greatly appreciated.

Also, what do you guys do about the old automatic harness sheath? The molded plastic case on the harness is shapped to fit and attach to the old automatic... Although with the manual trans in there, it seems to rub against the gear selector switch. It also looks like it is very close to the slave cylinder and throwout fork. I'm wondering if these will cut into over time.

What do you guys do about the harness? Whats the best way to route it?

Here's where it hits the shifter arm




And where it hits the throwout fork.





For the wiring, what do these connect to? I think this is the trans speed sensor.






Thanks!

[Chilled Man]

those wires there Green and Yellow are the reverse wires.

They connect to the Blue white wires on the trans loom

then you connect the green/brown wires together (not 100% sure on color) to jumper the PNP switch

other then that ... dont know

[Ludeless]

those wires there Green and Yellow are the reverse wires.

They connect to the Blue white wires on the trans loom

then you connect the green/brown wires together (not 100% sure on color) to jumper the PNP switch

other then that ... dont know

Reverse wires...got it! Does polarity matter when hooking these up to the blue and blue/white wires

Where do you connect the wires for the PNP switch? Is this done inside the car or still in the hood? No idea where this switch is located

Is there anything else that i need to connect?

[Chilled Man]

dont know never hooked mine up in my car lol

I need to get my lazy ass and do it .

PNP wires are in the same loom as the reverse wires

[turbobrick]

Reverse wires...got it! Does polarity matter when hooking these up to the blue and blue/white wires

Where do you connect the wires for the PNP switch? Is this done inside the car or still in the hood? No idea where this switch is located

Is there anything else that i need to connect?

pnp switch and reverse light wires can be found in the wiring harness that plugs into the automatic.

take off the automatic casing, and route the wiring for TPS / CPS / etc etc up along the side of the engine, you can use the mounting brackets that the sensors mount on with some zip ties.. i believe thats what i did.

just take a moment and look at it all, there's no real by the book; so get creative; make sure you keep clear of the throwout fork though as well as the shifter assembly, you will be able to tell if there's rubbing on either while in the car by depressing the clutch when you have her all bled out as well as the shifting mess.

[Ludeless]

PNP wires are in the same loom as the reverse wires

So there are 2 wires for the PNP right? Looking at the Turbo bricks post it says to cut them at the old transmission connector and then to sodder them but it doesn't say what to soder them to?

So cut this connector out first?



So i cut these wires...green and green/red?, but then what do i do with them? Just connect them together, or do they connect elsewhere to another switch or connector??

[Chilled Man]

I didnt even cut mine I used a fast clip connector thingy and crimped them together .

Thats it .


You can do is run a wire to the dash with a switch and use it as a cut off for the car with the switch open you cant turn the car on

[Ludeless]

I didnt even cut mine I used a fast clip connector thingy and crimped them together .

Thats it .


You can do is run a wire to the dash with a switch and use it as a cut off for the car with the switch open you cant turn the car on

I think i get it! The TB post says that the PNP switch is within the old transmission connector. So you're basically just bypassing that switch by cutting it out of the loop, so that the circuit is always closed??

Is it really that simple?? If so i can't believe i've been racking my head for weeks trying to get my head wrapped around this.

Nothing else to wire up? Just the reverse and pnp wires?

[Chilled Man]

yep that easy

[Ludeless]

Cool, i think i got it! Will try it out tomorrow.

Another stupid question while i'm at it... Where do i fill the manual trans w/ trans fluid? How do you check the level?

[Chilled Man]

Dealer .

I just fully drained it and refilled .

Its not that big of deal if your over/ under alittle

[AverageVolvo]

Dealer .

I just fully drained it and refilled .

Its not that big of deal if your over/ under alittle

Go to your local auto store and get one of those funnels with a flexible hoses on it. or buy some hose and fit it over an existing funnel. need to be apprx one foot.

The fill plug, is on driver side(Usa) in wheel well area there are two plugs look carefully it is the top one,, best to remove tire and use a 3/8th driver with I believe a 19mm socket(scratch head)
you may need leverage from top engine bay. Fill it to the top of the fill hole. Use only volvo brand gear oil(2L I beleive so 2 bottles they are 18$ a piece.., and a new copper crush washer or at least sand the groove out of the old one and clean it.

[Ludeless]

Reverse wires...got it! Does polarity matter when hooking these up to the blue and blue/white wires

Going to do some wiring tonight... anyone know if the polarity of the reverse wires matters or not? Not a huge deal to change it around if i get it hooked up backwards...just trying to save myself some work if i can get it right the first time.

Thanks!

[Chilled Man]

? dont know let me know I might actually get mine done then

[lookforjoe]

Fill the trans through the rev light switch hole - it's easier - just don't rush.

wiring

Splice green & green/red starter feed. In other words, just connect these two together.

Splice blue/grey (pin 9) & blue (pin 5) from trans connector to manual rev. light harness. No polarity, it doesn't matter which contact they go to on the switch.

[Dan2286]

Fill the trans through the rev light switch hole - it's easier - just don't rush.

Shouldn't he have the fill plug out so he knows when the trans is full?

[I hate haters]

Shouldn't he have the fill plug out so he knows when the trans is full?

Not if you measure how much you put in. It takes 2.2L of Volvo synthetic transmission oil p/n 1161645.

[Ludeless]

Got most of the wiring bundled up...wanted to post a couple pics to make sure i'm not overlooking anything.

First question...is this the correct routing for the clutch cylinder hard line? Goes up and over the transmission, nearby where the battery tray and air box will sit. Then there is a section of rubber hose back into a hard line which runs under the cylinder.









Second is the wiring... For the reverse lights, those seemed to be on a different breakout from the harness as most the other sensors which run on top of the tranny (O2 sensor, Camshaft pos sensor, BCS connector, etc...) I have the brake wires going underneath one of the shift cables, but it looks like it could also route around the outboard side of the trans



And the main harness is still very close to the shift fork when the clutch is pressed... i tried ti get it as far away as possible, but when the clutch is pressed in all the way, it just barely makes contact w/ the wire wrapping.





thoughts....suggestions???

Thanks!

[lookforjoe]

Got most of the wiring bundled up...wanted to post a couple pics to make sure i'm not overlooking anything.

First question...is this the correct routing for the clutch cylinder hard line? Goes up and over the transmission, nearby where the battery tray and air box will sit. Then there is a section of rubber hose back into a hard line which runs under the cylinder.

And the main harness is still very close to the shift fork when the clutch is pressed... i tried ti get it as far away as possible, but when the clutch is pressed in all the way, it just barely makes contact w/ the wire wrapping.





thoughts....suggestions???

Thanks!

Reverse the clamp so that it offsets the wiring loom a little further away from the fork.
a
You can also clamp the clutch hard line with a similar sleeved clamp, using one of the holes previously used for the air box base, just to prevent it flexing.
Looks good overall!

[Ludeless]

Not if you measure how much you put in. It takes 2.2L of Volvo synthetic transmission oil p/n 1161645.

So which one the correct fluid to use? I got 1L of this pn 1161645 about 2 months ago from volvo...parts guy he said it was only 1 L, but i went back today and picked up 1 more L and the guy gave me PN 1161745, which is different.

1161645 saiys it's more Model:1995 and lists a bunch of transmissions influding the M56 and is good to -48C

1161745: says SAW 75W-80, SPI-GL4, and only mentioned XC90 6 cylinder AWD 2003, and says its good to -60C

I told the guy i needed the one for the 850...wondering if this is a just an updated gear oil that's ok to mix w/ the other, or if i need to take it back and get the same stuff as the first time?