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No Problem! First, do you have a Volvo shop manual? A Haynes manual? Both give almost step by step instructions for dropping one out and putting the other in. DON'T bother getting a Chilton's. Are you certain that you have the rear mount/cross member - for the straight stick? It is totally different than the BW35 rear mount/cross member. Also, be certain that your flywheel bolt pattern matches the crank shaft the older engines are 6 bolt, the newer 8 bolt. And the drive shaft is different between the two.
Yes, you can do the switch without taking the engine out. You will need to get you car at least 20 inches off the ground though, in order to slide the transmissions in and out. I used jack stands and cement blocks - I'm kind of a belt and suspenders guy. (I figure my wife would take off with the pool guy, if the old 164 fell on me.) It is also going to be handy to have either a floor jack, or a couple of people to help, when it comes time to lower the BW35, and also raise the M410 into place. The trannys aren't that heavy, but trying to match up the splines on the transmission shaft, hold the transmission in place, and start the bell housing bolts is really impossible without the jack or friends.
Tell you what, if you email me your fax number, I could copy and fax the pages from the manual. Plus, if you have an email I could let you know some of the little things the manual neglects to tell you about. For instance, when you disconnect the exhaust headers, you have to use a very long extension with a swivel. Then you have to be extremely careful about snapping off the bolts or studs. Use plenty of penetrating oil well in advance of this operation. Also, when you disconnect wires - label them! Some of the connections you won't use again, but... And zip lock sandwich bags are great to put bolts in with a label, that you won't be using again for a couple of weeks (months) if you get to work on your 164 as I do - infrequently.
Even though it sounds like a big job, if one could work at it non-stop, and one had all of the proper bits, a good mechanic could do this in a day - or so.
Last but definitely not least - there is this Board and Walrus3.
Let me know if I can help further.
Kent
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