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Mike,
I would source a used late model low mileage AW71 with the revised tailshaft bushing (around 1992-1993), and use that with (1) synthetic fluid and (2) a filter in the hose/pipe to/from the cooler and (3) a larger external cooler and (4) the basic shift kit modification outlined by Mike Poulson in the archives at the Turbobricks website (you'll have to search for it but there are even photos).
Running a 14.8 at 90 does not suggest 250 hp. I ran a 14.6 at 94 and calculated maybe 230 hp. There are plenty of formulas available if yo want to search for them and start crunching numbers. Just determine whether they are for wheel hp or crank hp; any trap speed calculation will be based on wheel hp unless it is accompanied by a second calc for either manual or auto trans to obtain crank hp.
If you use a higher stall converter, you will be more likely to make the AW71 slip. In such a case, you need more serious valve body modifications. Someone I communicate with did the basic shift kit mod and still blew a rebuilt AW71 on the dyno at 18 psi with a big exhaust, sport compressor turbo and performance cam. Serious valve body mods might be done by a shop familiar with the older Toyotas, which also used the AW71. I had this done in the US by Level 10 Transmissions (search for the website) in New Jersey for about $600. The shop said that stronger clutches alone would not be sufficient in the long term. They said that ideally both the clutches and the valve body work should be done, at a cost of about $2000 USD, but if only one was done, the valve body work would be the better bet. So far so good. I have had it in for about 3 years with the high stall converter and have run up to 18 psi in daily driving, over at least 50,000 miles.
The next year will be the real test, as I have built a higher performance engine that I expect will push the AW71 to its breaking point. I have not decided what to do then, but I am inclined to go with an M90, BMW Gretrag or Toyota W58 conversion.
For you, I would recommend finding a rod shop in AU. Dick Prince in AU could help you with a manual conversion, as could Dellow. And I am sure that with some searching you could find a Toyota shop familiar with the AW71. Anthony Hyde in AU is another good source. Both have websites and you can find them by searching for their names and Volvo.
Philip Bradley
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