Installing a Volvo 240 Rear End into an Opel Manta A/Ascona A

Installation

As detailed in the previous post, I picked up a rear end from a 1990 Volvo 240 with a 3.73 ratio for $200 and will be putting it in my 24 valve Ascona wagon.

The axles were drilled out to a 4x100 pattern (5x108 is stock) and an Eaton G80 locker carrier installed.

Eaton G-80 Locker

 The drivers side axle needed to be shortened 1/4 inch for the locker.

Locker Installed

Easy way to remove Opel rear end when working alone.

The hub to hub width of the 240 is very close to the Manta/Ascona A's.

Volvo in place

The brake system on the new rear end needed replacing. The Volvo e-brake uses brake shoes on the inside of the rotors and both were in real rough shape. I priced out the cost of replacing the, calipers and rotors vs. using (and then replacing) the VW/BMW rear disc setup I had set aside for my Opel GT and the replacement cost was twice that of the Volvo parts. New parts were ordered from Rock Auto and FCP Euro

Trailing Arms

A test fitting showed me that the Volvo trailing arms can be used and any welding needs for this swap can be on the Volvo trailing arms only. This means that those who do not have access to a welder can bring the two arms to a welding shop for the work and no Opel rear ends will be harmed in the process.

Trailing arm with wheel centered

Alignment with arm mount

After installing poly bushings at the rear of the trailing arm, they were attached and with little alignment, adjustable rod ends will line up with the Opel mounting location. The springs will line up in front of the axle and with spring hats installed on the arms top, they will sit ~1 inch higher than original. I'll need to either use a shorter spring or cut one down.

Adjustable Rod End

Eyelet will be cut off arm and rod end welded

Spring hat in place

An alternative would be to drop the springs into the trailing arms and use the stock springs.

Lower shock mounts will be welded on the back of the trailing arms.

Shock Location

Used Opel lower brackets

The wheels were put on and the axle centered in order to get accurate locations for the rod ends and spring hats.

Stopping Power

Adjustable links will go from the axle mounts to the body frame near the factory sway bar mount brackets and a new adjustable panhard bar made up. The end of the left side trailing arm was cut to clear the panhard bar

Adjustable Panhard Bar end

One and one half coils were cut off of Manta/Ascona front springs to get this ride height:

Ride Height

The upper links of the Volvo 4-link suspension were attached to the frame after the Opel sway bar brackets were removed. A sleeve and plate were added for support and to prevent crushing of the stamped frame.

Frame Sleeve

Upper link

Upper link

The floor under the rear seat area was cut to allow for link movement. It will be boxed in from above.

The pinion angle and rough alignment will be set once the driveshaft is in place.

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