What are your thoughts on the Over drive solenoid bypass kit available through idp?
http://www.ipdusa.com/products/4793/110397-automatic-over-drive-solenoid-bypass-kit

Mine isn't working and since I don't live in mountainous areas or towing I probably don't need to ever turn my OD off do I? Right now I cringe when driving over 55 due to the high rpm of the motor....I'd just assume this kit would eliminate some of the problems on my aging 240?
Do I still need to keep the OD relay when using the OD bypass plate? I would assume its useless but curious what other 240 owners do here?


Thx...

If you decide to remove the solenoid, contrary to all the reports about how difficult it is, Ive found just the opposite.
Ive removed a couple of them. In each case I elevated the car on the drivers side and used a regular, not modified in anyway(but short), box end wrench. I did not lower tranny at the end.
It would be good idea to visit a car wash and give the area a good cleaning before hand.
I also used an inspection mirror to look at things and watch what I was doing.
You also need sure hands and patience. Dont be in rush.
make sure you have a new o-ring.

Cutting a grove with the dremel is fairly easy. A picture and explanation is found here:

http://www.brickboard.com/FAQ/700-900/TransmissionAuto.htm#OverdriveRemoval

Good luck
Larue

Can I use an "O" ring from the hardware store or do I need to get one at an automotive supply store? I ask because my fav hw store has a nice supply of various size "O" rings.

Hi,

Check here for more info with pic of where to grind groove with Dremel on the solenoid:

http://www.brickboard.com/FAQ/700-900/TransmissionAuto.htm#OverdriveRelay

and here is an even better picture:

http://www.brickboard.com/GALLERY/volvopic.htm?id=9174

A couple years back my solenoid fell apart on my 90 244 and I had the same symptoms you have. Along with the solenoid the wiring was also sheared off. I didn't need the OD function so I bought the bypass plate quickly (before I know that there was detailed documentation on where to cut a failed plate to perform the bypass). Read the above FAQ link for details on removal. Be careful with the two bolts as they are installed at a low torque value. Personally I didn't have to lower the transmission. I just put the front of the car on jackstands, blocked rear wheels and removed the bolts pretty easily-I do have skinny arm however and small hands which probably helped.

Hope that helps,

Travis

Very helpful...thanks. I have big hands but I'm not a stranger to tight places so I'll give this a shot.

Purchasing the plate is a waste of money!
To begin with;if you're going to put a "bypass plate" in, you have to remove the solenoid.Removing thesolenoid is an akward and messy job,and once you get the solenoid out,all you need to do is grind a channel between the O rings,and re-install your solenoid!..In other words, all the bypass plate is, is a flat piece of metal, that has a groove between the two ports...
For the $40 or so bucks they charge for the "bypass plate", you could buy or rent a tool to do it yourself!
Making the groove in your exsisting solenoid is the easy part!, removing and re-installing the solenoid is the hard part!

Have you or anyone else done this modification to the existing solenoid? If so did you take any pictures?

I thought $40 for a metal plate was quite high but its a lot more if I were to buy a new solenoid...What is the groove for? Can the groove be made with a dremel tool?

While my OD solenoid is still functional, my plans are to eliminate it (either with the bypass plate, or through a modification with the judicious use of a Dremel) when it finally gives up. The bigger question, and maybe it has been answered before, is WHY Volvo decided to default the transmission into 4th gear lockout? Seems to me that it would have made much more sense to default it into 4th gear engaged and allow the driver to select a lower gear, as needed, with the shift lever. But that's just me....

B

I have purchased and used this plate as a last resort. You may want to completely diagnose the failure of fourth gear to engage. Test that 12vdc is present at the OD solenoid. If it is then the solenoid is bad and you might as well remove and cap the tranny with the plate, repair/replace the solenoid or modify it to act as the $$$ plate would. look in FAQ. If eliminating the use of the solenoid the relay is useless.