Engine/Trans alignment problem

[TestPoint]

I am in the process of installing a 5.0L '00 Mountaineer engine/transmission in an old Volvo.

Found a 10k mile engine/trans in a wreaking yard warehouse from the same vehicle, one of the infamous Firestone rollovers. When assembling everything lines up, flex plate holes to converter bolts, pins in engine to trans holes, converter hub to crankshaft and bolts together.

Tried to turn engine when assembled. Locked up tight. Loosened bolts and engine turns. Disassembled, pulled converter. It appears to fit fine on its shaft and pump and turns freely.

Reassembled. Engine turns until I close the last 1/8" of the lower bolts and then locks the engine. Neither flex plate nor steel plate behind appear to be bent. I cannot see anything interfering nor any marks on any parts. I did clean converter hub and crankshaft socket and lightly oil.

Any thoughts would be appreciated. Probably won't be the last time I am here asking for help.

 

[99SportX]

Awesome project dude! I have a 5.0L Volvo on my list of things to do someday. It has always seemed like a cool project to me since I like the older RWD Volvos. You picked a great drivetrain to use for it. What model Volvo is it going in?

The problem you described sounds unusual, but I experienced the same issue when I changed out my V6 transmission. The torque converter wasn't all the way in. I thought it was, and tried numerous times to get it in farther so I thought it was ok......but it was hitting the input shaft that wasn't in all the way. The trans housing did not fit up to the block easily and when I tried tightening the bolts to pull it closer, the engine would not turn. Once I corrected that, there were no problems and the thing just about installed itself.

When I did my V8 conversion I had no problems with the trans at all and I had very little knowledge about cars compared to now. You should be able to get the transmission casing up to the block without any trouble. If it has any gap, then there is a problem with the torque converter fitment.

 

[TestPoint]

That's what I thought too but took it out and reinstalled and still no go. I'll try again tomorrow.

The Volvo is a '82 diesel (or was) wagon with the GL interior. I bought it new and wore it out in 180k miles but the interior and paint are still in very good condition. It always lived in a garage and has been in dry storage for the past 13 years. Of course the tires need a little air.

I suspect the 240 hp Ford is going to feel somewhat different from the 83 hp diesel.

Thanks for the response.

 

[jetfiremuck]

Alignment

Good luck with the swop. The converter needs to be recessed in the trans 1" from the converter to the bellhousing face. The trans input shaft will bind or the converter tangs will not engage the pump. Are you interested in selling the trans bell housing from the diesel volvo if it is an automatic, Thanks Jerry

 

[TestPoint]

Jerry,

It is an automatic. The Volvo engine/transmission has already gone to a local scrap yard but I can probably recover it. I gave it to the yard guy for coming to get it. Tell me what you are willing to pay and I will get in touch with him. Located in north Georgia.

TestPoint

 

[TestPoint]

Got side tracked for a few days but thought I would wrap up my question with a resolution for someone searching in the future.

When installing the torque converter onto the transmission shaft there are three teeth engagements you have to align. The final one will position the front of the converter hub in alignment with the bell housing.

Without that, you are never going to get the engine/ transmission to bolt up (and work).

Incidentally, I was working with an engine on an engine crane and manually trying to align the transmission. Went to ACE hardware and bought a couple of MUCH longer (SAE) bolts to match the assembly bolts and that made all this much easier for a one man operation.

 

[99SportX]

Great work man. The longer bolts are definitely a helpful method. I found myself doing that as well when I was struggling with the 5r55e transmission from the V6 explorer.

Please post some pictures of the install when you are done, I am curious to see it. How much fabrication was involved to get it mounted in there? Did you remove the AC compressor? If so, what did you do about that? Steering pump? I am just curious what was involved in putting a newer engine into an older vehicle.

V8 Volvo wagons are just too cool.

 

[TestPoint]

Putting a V8 into a Volvo is a very common project. Both the engine and transmission fit easily. I had the straight 6 diesel sitting on the floor next to the V8 5.0L Ford engine and the V8 was shorter both in length and height. The '95-'01 5.0L Explorer engine/transmission appears to be the engine of choice at the moment.

Lots of transitions like the PS high pressure hose has to be Ford on one end and Volvo on the other. And yes, I plan on using the Ford AC compressor to drive the Volvo system. That too will require strange hoses to make the transition.

Having a 240 hp V8 in a 28 year old Volvo station wagon is going to be a great new experience. I drove it for 180k miles with that 83 hp diesel.

The only fabrication is the motor mounts, and of course all the hoses and wiring. No welding or cutting. Even the rear end ratio is perfect for the V8 and auto transmission.

Based on other converter's input I expect to get 20/28 mpg when complete.

I plan on setting up the car to be completely exhaust emission compliant including the OBD II connector.

Keeps me out of trouble otherwise.