240 AW/M46 gas to diesel swap: Which Clutch Cable???

Grubby · #1 05-30-2010, 05:23 AM

Does anyone know which clutch cable I have to use for an auto to manual/gas to D24T swap in a 240? The diesel cable is different from the gas. There is a difference in the connectors at the pedal: one is split, the other is a "T" cable end....I have a clutch pedal from a gas 240, which takes the split one. Is there a length or strength difference for some reason??
Thanks for any input...

Jason · #2 05-30-2010, 06:19 AM

I don't think there would be a difference in strength, and for length it would have to be the same as the transmission is in the same position relative to the car. Granted the mount on the bellhousing may be slightly different, but the cable is adjustable. If you have the cable that goes with the pedal you have, you should be set. I'm not sure if the end at the clutch release arm is the same on the gas and diesel bellhousing though.

Jason

Grubby · #3 05-30-2010, 06:39 AM

Thanks Jason. Your thoughts are in line with mine: it would have to do with the position of the tranny relative to the firewall. Since everything in my d24t/240 swap lines up like a 240 in a gas configuration (intake, eng. mounts, oil pan, all have been modified to fit the D24T into a 240 correctly) I should be able to use the gas cable, which is what fits my pedal. I have already swapped bell housings, and it looks like everything is the same except the housing shape and the bolt holes. By the way, how's that T5 swap doing? Solid, I bet. I will probably put one in if this M46 doesn't hold up...
Thanks,
Abe

Jason · #4 05-30-2010, 07:58 AM

Its done, take a look in the garage section. I put up the rest of the pics of the swap.

The trans has to be in the same place, since he shifter obviously has to still come up through the tunnel in the same hole. I think you should be fine.

I wish I would have done the T-5 swap in the first place, since the longevity of the M46 was pretty crappy (3 days worth of abuse and it blew lunch!!). Part of the reason I didn't do it right off was the lack of clear info on the internet. I'm going to make a new thread that I'll make into a sticky with all the pertinent info and pics, and stick it up in the performance/aftermarket section. Honestly its a cheap swap, the transmissions are cheap, strong, and readily available. I sure as hell wouldn't install another M46 if yours blows up, unless the car is just a stock cruiser... But what fun would that be?!

Jason

Grubby · #5 06-01-2010, 05:02 PM

Congrats on the swap.
The motor I am putting in is NOT stock. It was built by a volvo tech who also built dragster motors, and had pictures in his shop of drag raced volvos! It was a serendipitous find...just waiting for me in the back of his garage next to a bunch of sweet looking 16Valves. This is his 3rd D24T build that he has modified to fit in a 240. He likes the 240s like I do. We'll see how long the M46 lasts behind it...I will be looking for that T5 swap sticky. How are the ratios in the T5 when coupled with our motors? I hope 1st is longer. BY THE WAY:::::do you know if the clutch release fork is the same for gas and diesel M46s? The bearings are different. Thanks again for your help and this great site!

Jason · #6 06-01-2010, 07:16 PM

I'm not sure about the fork, according to the listings at work, the bearing is the same though. I would expect the fork is the same as long as its for a cable clutch. The ratios of the T-5 are better, 1st gear is taller, the spread between gears is good, and the 3rd to 4th gear rpm drop is only about 600rpm so its really right there for the "top end" pull. 5th gear is f'in awesome. With the automatic rear end in my car (3.70 axle ratio) I cruise at 2500rpm doing 65mph. Its only doing 3100 or so at 80! The redblock guys over on T-bricks bitch about how tall the 5th gear is, but thats becuase their sissy ass red blocks don't have any low end torque. 2500 is purring for our engines... It cruises at that rpm easily.

What does your engine have done to it? Any head work, NA cam? There isn't a whole hell of a lot you can do to the engine itself, but I would be interested to know what he did. My "built" engine is going to be with a ported and polished head, NA cam, and arp engine hardware...

Jason

Grubby · #7 06-23-2010, 05:50 PM

Quote:

Originally Posted by Jason

I don't think there would be a difference in strength, and for length it would have to be the same as the transmission is in the same position relative to the car. Granted the mount on the bellhousing may be slightly different, but the cable is adjustable. If you have the cable that goes with the pedal you have, you should be set. I'm not sure if the end at the clutch release arm is the same on the gas and diesel bellhousing though.

Jason

Jason, back to that gas to diesel m46 build: I measured the tubes that the throwout bearings run on, in the gas vs diesel, and there was a centimeter or more difference in the position of the tubes relative to the plane where the bell housing mates to the block. I think this relates to the different thickness of the diesel clutch and flywheel compared to the gas. Also, the diesel cable has a longer length of cable coming out of the bell housing end. I am guessing this is also related to the thickness of the flywheel and/or clutch. So, it looks like I'm going to have to use a diesel cable and clutch pedal after all. Anyway, thought I should let you know for future reference. I'll post again if I discover something different. I am hoping I can use a 740 clutch pedal, because the diesel cable cross references with all 700 series manual shifts, gas and diesel, at least according to a parts supplier I looked it up on. So, as long as that pedal fits in my sheet metal pedal carrier, I'm golden. If not, its might be hard to find a 240 diesel clutch pedal.

Jason · #8 06-24-2010, 05:46 AM

Interesting... I can't say for sure on the 2 series, as I've got a 760... My clutch pedal assemly came out of a gas 7 series though, as did the clutch cable. Thats why I was expecting that it would work.

Jason

Grubby · #9 12-09-2010, 04:32 PM

Just a quick follow up: The gas clutch cable worked! I was wrong. It is all together now: tranny, clutch, driveshaft. Just have to run all the lines and mount the accessories! I'm excited to get it going! Thanks again for your help.

Jason · #10 12-10-2010, 04:43 AM

Good to hear... These cars are so much more fun with a manual!

Jason