Hi, it sounds like you have a nice example of a D24 powered 940.
Over here in the UK I've known people to have their M90s rebuild by specialist transmission shops.
A lot of the lads on here are based in the US which I believe had very limited numbers of the M90 and maybe none with the D24 bellhousing, therefore it maybe difficult to find M90 specific advice on here although I do believe the petrol version will be very similar so maybe some more advice could be found on the Turbobricks forum.
From my knowledge the M90 is a strong gearbox especially at stock horse powers and providing the gearbox isn't abused. Perhaps a previous owner of your car was a little rough?
The other important thing about the M90 to bare in mind is the oil which you may already know, The oil that Volvo made for the M90 I think I'm right in saying has been discontinued and therefore it is important to get the right equivalent. More info on this should be available on the UK Volvo owners forum or again Turbobricks.
If memory serves me correctly I've seen several second hand Volvo parts on UK eBay that are coming from Lithuania so it maybe the best option to try and find a second hand gearbox to swap yours with?
Hope this is helpful
Many thanks Tristan
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