so last year i put a volvo 2.3 turbo in my sammi. i used the volvo m45 4 speed manual tranny and the sammi case. recently i was given a blown w56 and a top shift transfer case. my plan is to build an adapter to marry the volvo m45 and the toy case. heres what i have so far......

http://i606.photobucket.com/albums/tt149/levi_456/P4160174-1.jpg
here is the m45 i had to shorten the rail the shifter mounts to so that it is in a comfortable spot in the cab. i also shortened the linkage to shorten the throw. this tranny even fits in the tunnel.

i tore down the w56 and took the female splined output and the female splined m45 output and had them welded and trimmed down to make the coupler smaller in diamiter
http://i606.photobucket.com/albums/tt149/levi_456/IMAG0073.jpg

now the toy case can be driven by the m45

Sweet. I built an adapter for a Toyota T-case for a Volvo automatic, do you know the length?

here is the plate to attach to the tranny side

http://i606.photobucket.com/albums/tt149/levi_456/ThuDec31194913PST2009.jpg

2/1" plate drilled to match the 8 holes on the back of the tranny and torched to fit arround the tail housing.

http://i606.photobucket.com/albums/tt149/levi_456/SunJan03113654PST2010.jpg

now for the transfer case side i cut the back 1/2" off of the donor w56 so that i could use the seal arround the input and to use a a spacer for the bearings.

http://i606.photobucket.com/albums/tt149/levi_456/ThuDec31194616PST2009.jpg

http://i606.photobucket.com/albums/tt149/levi_456/ThuDec31194749PST2009.jpg


then i made a plate to seal it all in, also with 1/2" steel. drilled for the 6 holes on the tcase side

http://i606.photobucket.com/albums/tt149/levi_456/ThuDec31194815PST2009.jpg

i cut a piece of 4" sch 40 pipe at 5" long to tie it all together and a piece of 3/8" plate for a gusset on the bottom.

http://i606.photobucket.com/albums/tt149/levi_456/ThuDec31195037PST2009.jpg

http://i606.photobucket.com/albums/tt149/levi_456/ThuDec31195302PST2009.jpg

the adapter ended up 6" long. that put the toy case as close to the original location as the suzuki case as i could with the length of the coupler. i could cut it down another 3" if i wanted to but i dont want to have to re build my drivelines. here are the measurements from the front of the bellhousing. keep in mind that my motor sits further back than stock so these measurements wont match stock.

rear output-35.5"
http://i606.photobucket.com/albums/tt149/levi_456/SunJan03113906PST2010.jpg

front output-24.5"
http://i606.photobucket.com/albums/tt149/levi_456/SunJan03113840PST2010.jpg

here is the plate to attach to the tranny side

http://i606.photobucket.com/albums/tt149/levi_456/ThuDec31194913PST2009.jpg

2/1" plate drilled to match the 8 holes on the back of the tranny and torched to fit arround the tail housing.

http://i606.photobucket.com/albums/tt149/levi_456/SunJan03113654PST2010.jpg

Wow, nice cuttin'! That's a tight fit.

Looks good Levi. Keep us posted!

This is awesome. Scotty Dingle sent me here. I think i might steal your idea here. Did you blow up the samurai transfer case?

I have a 87 740 turbo that is beat to shit but the motor and trans are damn near perfect. How does the power feel in the samurai? do you street drive it at all?

This is awesome. Scotty Dingle sent me here. I think i might steal your idea here. Did you blow up the samurai transfer case?

I have a 87 740 turbo that is beat to shit but the motor and trans are damn near perfect. How does the power feel in the samurai? do you street drive it at all?

the samurai case diddnt last long at all. the toy case is now duals and 4.7's and going strong.

the power with the 2.3 turbo is almost like a 2stroke plenty of low end and will break loose 35s on a dirt road when the turbo kicks in at 3000rpm. i dont daily drive it (i wish i could but its too cut up) but it has a few road miles on it. the 87 740 is a perfect motor donor, but you will need a m45 trans from an early 80s 240 4speed, a larger radiator than the zuk, and a different intercooler to make it all fit. pm me if you want to go int details.

pretty cool setup..

i like the different powerplant. i dont think i would have put all the effort into a stick shift, but still cool.

nice job

i originaly wanted to go with the aw71 auto trans that comes behind this motor from the factory, the problem is the length. to get the motor to fit i had to set it back further than the 1.3 sits. if i was going to use the toy case it would have ended up 10" longer than my setup. wich means no doubler and an impossibly short rear driveline. there is a huge thread about this trans behind a 1.6 here on pirate. i just stretched the frame 6.5" to make room for my doubler and added 10" to the hood to keep it all covered with a new front mount intercooler.

pm me if you want to go int details.

I'm interested in as much of the details you want to go in to, I think this thread would be a good place for them. A turbo Volvo Samurai is pretty cool :smokin:

there is a long writeup here on pirate about the aw71 auto behind a 1.6. it is the stock volvo auto. there is a lot of info in the thread. the problem with it is the length. my drivetrain was 10" shorter than the auto to toyota setup when i was running a single toy case. there is not room for any more without major stretching.

DO NOT USE THE STOCK T-CASE. i broke 2 of them with a kong bucket and a spine very quickly.

the trans to use is am m45, its a small 4 speed stick found in early 80s volvos. i have bought 2 of them from local wrecking yards for less than $50 the volvo clutch has never slipped with 35's 4.10's and dual cases and lockers.

there is a lot of good info about the motors and what they come in at www.turbobricks.com. any rear wheel drive volvo in about 1980-1995 with the 2.3 turbo (b230ft) should work. i got a beat up '86 760 off of craigslist for $200. i sold my samurai parts and scrapped the rest of the car to make money on the swap.

you wont find much in english about this swap but its common in europe

the volvo radiator and intercooler were too big so i am using a chevy aluminum radiator off of ebay the input and outpus are correct and the all aluminum samurai radiator wasnt nearly enough. and a front mount intercoolcr from ebay. before i stretched the frame i was using a sidemount intercooler off of an eclipse i think.

theese motors last for a long time. most on craigs list have 200,000+ parts are cheap. they have fuel injection, power steering, and 100 amp alternator, and a rear sump oil pan. power upgrades are easy and 200 hp is very easy to get to. with injectors and a boost controller. i also found that it only weighs 40lbs more than a 22re or so i read on some faq somewhere (maybe the toy section)

there are adapter to run a ford t5 transmission out of a 90's mustang. and adapters to use a supra transmission. search turbobricks for more info on this. i would like to see someone find the combination of bellhousings and transmissions to run an all toyota drivetrain behind the 2.3

The m45 has a low first gear. 4.33:1

Duals now eh? where ya been levi? I don't have a zuk to wheel right now, but I did solid axle my 4runner, so it does ok.

just brooke it in the sand last weekend. the splines in the volvo side of the trans to tcase coupler stripped out. looking into an aw71 auto they have a 23 spline output that matches the input of a 23 spline toy case. both male splines but marlin makes a coupler that should last longer than this.

That sucks. So is that going to be longer, so re-doing drivelines again? Stretched the rear out yet?