Hello All,

I have a 1996 850 GLT wagon (non-turbo) with a 5 speed manual. It has 330,000 miles. Recently, I have noticed it takes more effort to place the car in first gear and sometimes I cannot get it into reverse unless I put the transmission in first, ease up on the clutch pedal slightly and then put the transmission into reverse.

I described these symptoms to my mechanic and he told me the synchronization gear is worn. The same synchronization gear is used for first and reverse gears. He told me it would cost over a $1,000 to take apart and replace the worn synchronization gear and I would be better off looking for a used transmission to install. By the way, I did have the clutch replaced a few months ago prior to the difficulty in the shifting developing.

I called my local Volvo Dealer and was told the part # for the transmission is # 36050245 and when it was available it cost retail $2,227.52. Of course it is no longer available.

Any thoughts or suggestions in how to fix this problem? I really like the car and esthetically it belies its age and everything works on it. The transmission still works, but I have been advised by my mechanic that over time the condition of the transmission will get worse. Thanks to all who reply.

Hugh

It would be well worth your while to have another mechanic check your clutch adjustment. Perhaps even at a dealer.

Your new clutch stands to be thicker than your old one - a careful adjustment was in order.

Jim,

Thanks for your suggestion. I will have the adjustment on the clutch checked as you suggested.

Hugh

Hugh,

Did you have difficulties before the clutch was replaced? If not, check the brake fluid level in the slave master. Then get under the car and take a look at the slave and see if it is leaking.

Then check the end of the piston where it connects to the throw out arm and see if the bolt came loose. You can also visually check that the bolt is still in the same position (before the clutch work) by gauging the amount of rust before and after the rod connector.

To me, it sounds like the clutch does not disengage far enough. The syncros are quite robust.
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Keeping it running is better than buying new

Klaus,

I did not have this shifting issue with the clutch/transmission prior to its replacement of the clutch. However, prior to the replacement of the clutch, I did have the master cylinder replaced. To my knowledge it was not leaking or failing. It was the original unit, and my mechanic was trouble shooting a “rubbing noise” I kept hearing at the time every time I let up on the clutch pedal. He said the boot on the master cylinder was torn and it made sense to replace it while he had the pedal assembly apart.

I will show your post to my mechanic. I hope you are right and spare me the expense and headache of replacing the manual transmission.

I confess I am a little disappointed that I am having problems with the transmission. I don’t beat on the car, and I replace the transmission oil every 100,000 miles even though it is not called for in the owner’s manual.

Thank you for your response and suggestions.

Hugh

Hugh,

You might want to find a different mechanic if yours doesn't want to readjust the clutch slave. It is so easy to adjust, especially with a lift, that it shouldn't take more than 15-20 minutes.

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Keeping it running is better than buying new

Yeah, I don't think its your transmission at all. I think its your clutch. even if it is your transmission (which I don't believe), I would keep my car numbers matching and get my transmission rebuilt. That is if I'm keeping the car.

enjoy

Minorl,

Thank you for your comment. At this point, I don't think the problem is the transmissions. The difficulty in shifting seems to have "gone away". On the rare occasion I will have difficulty putting the transmission into reverse. I remedy the situation by putting the transmission into first, let up on the clutch pedal slightly (not all the way) and then the transmission will easily slide into reverse.

My car has 330,000 miles on it. I like my 850 very much, especially because it is a manual transmission. I do plan to hold onto it as long as I can. I know the likelihood of finding another manual Volvo wagon is nil. I have owned the car for almost 20 years (I bought is used in 1999 with 50,000 miles). The more I drive it, the more I appreciate it. The idea of swapping out the transmission doesn't appeal to me.

Hugh

Hugh,

Going with a used transmission seems to be your only financially viable option if you would like to keep the car. However, it may be very difficult finding one. Rebuilding the transmission with either your mechanic or a transmission shop would be much more expensive. Doing that would far exceed the value of the car.

Another option would be to continue driving it as is. Meaning drive it into the ground.

Good luck,
Jim

Jim,

Thanks for your reply. I do like driving this car. It does a lot of things right: very utilitarian, gets decent gas mileage, very safe and of course, it’s a Volvo!

If I need to replace the transmission (See Klaus’ comment below), a used unit is the way to go. However, they may not be cheap either. I contacted Erie Vo-Vo and was told they have been out of manual transmissions for 850s for a while and don’t expect to get in anymore any time soon. The representative told me, if they did have one, it would cost $850 plus $100 for freight shipping. Almost half the cost of a new transmission (which of course is not available).

However, I may have caught a break. A few days prior to my discussing this transmission issue with my mechanic a friend called him wanting to sell him a used transmission out of an 850 for a $150. He had removed the manual transmission to install an automatic (usually it is the other way around). Anyway, my mechanic has put in a call to see if the transmission is still available. His friend told him someone else has expressed interest in the transmission so we will see. I don’t know how many miles are on this transmission. I have 330,000 miles on my transmission and I don’t want to put another transmission with equal mileage just to have the problem resurface again. My hope, if I really need a replacement transmission is to find one with under 200,000 miles on it. But of course all potential 850 donors are nearly 20 years old now, so high mileage may be unavoidable.

My 850 wagon is still very drivable. I will follow your advice and continue to drive it as long as I can. As I said, I really like the car and the longer I hold onto it, the more I like it. I will post the outcome of this issue.

Hugh