I think the swap would be a bolt-in. You'd need to bolt in quite a bit of stuff, including front crossmember, front springs, fuel system, and do some wiring (not much, mostly taking stuff out from the B6304's FI system and electronic tranny control system).... but I see no reason why it would not work. The only thing that might require some fabrication will be the driveshaft, since a 96 960 will have an independent rearend. You might be able to mate the front section of the 2-piece driveshaft from the D24T car (which has a live axle) to the rear section of the 960's current driveline to make one that mates the ZF tranny to the independent rear, but if it were me I would have it done by a shop to ensure that the balancing, phasing, etc were all correct. Otherwise the vibes can be nasty.
Some point in the next few years the D24T+manual trans from my '83 is going to find a new home in a '92-'94 965 (the last years of the live rear axle being used). I think the combination of the diesel engine in a really nice later body would be a great result.
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86 745 D24T/ZF 345k lifted 2.5"
83 764 D24T/M46 155k
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