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Unless you can find a source of parts other than Volvo, I believe that you will find that the cost to rebuild a manual is prohibitive. Just the bearings and syncros are pricey. If you find that you need the main shaft, junk it. You can buy three or four junkyard transmissions for what the parts can add up to.
I had a 5-speed that self-destructed at 160k. I had recently replaced all the bearings and seals in my Toyota 5-speed for about $100 with no special tools, so I thought I could do the Volvo.
When I saw all the special tools that I needed to do the Volvo, I elected to take it to a transmission shop. They tore it down and quoted me $2850 in parts and $400 labor. I bought another tranny at the junk yard for $600 with a 90-day warrantee. I got a new clutch from Autohause and put it all together in a day. It works GREAT. The car shifts better than it did when it was new.
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