Ok following up on this thread, I FINALLY found the issue and it wasn't with the BW-35 (although getting the kickdown cable set correctly did help overall). The car is running a pair of HIF6 carbs with a stock Volvo airbox. The holes in the airbox line up with several holes on the carbs and someone in the past actually ending up tapping a hole that matches the airbox holes but is in fact a air input for the "accel pump" mechanism on the side (The device on the side with the "dripper" output). That means my HIF6 carb had 5 tapped holes instead of the correct 4 tapped holes. When I reinstalled the airbox I chased all the threads on the carb with a tap and this sent aluminum shavings into the body of the carb, including the float area and "accel pump" mechanism on the side. Why the carbs ran fine for several thousand miles with these shavings in there is anyone's guess, but definitely cleaning out these shavings from the carb float area solved the issue I was seeing. I guess that goes to show that sometimes the problems ISN'T the last thing you changed! (BW-35 in my case)

Brian

I would totally suspect something with the engine... Keep in mind, with the manual, you rev the engine to 1200rpm or so and gradually let the clutch out, keeping the motor in its power band. With the automatic, you are asking the engine to start working straight from an 800rpm idle.

Maybe turn the idle up just a hair, see if starting from slightly higher helps (temporary measure, it'd be hell on your mileage)

We won't ask the reasoning for the swap :)

--
-Matt I ♥ my ♂

Hi Brian,

I'd only be guessing ...

If you do not have a BW35 service manual standalone or as part of your in-hand maintenance service docs, please try:

http://www.k-jet.org/documents/greenbooks/100-series/

Section for for both 1969 and 1974 treat the transmission here.

Also, here at:

http://www.volvowiringdiagrams.com/?dir=volvo/-%20Service%20Manuals/Automatic%20Transmission

Specifically, see:
TP30868-2 Volvo BW55 AW71.pdf

File URL: http://www.volvowiringdiagrams.com/volvo/-%20Service%20Manuals/Automatic%20Transmission/TP30868-2%20Volvo%20BW55%20AW71.pdf

The other auto transmission service file may be useful, also. I remember seeing Borg-Warner doc on the BW35, yet can't recall where now. Not in bookmarks, either.

And, ha! Found it, for the Borg Warner BW 35. Copy the hyperlink into an new browser window. Mozilla and Chrome and MS browsers may open the file.

Image of title page:



Link to the PDF file:

http://volvo1800pictures.com/document/BW35_manual/bw35.pdf

AND, on the same page:



Link to the PDF file:

http://volvo1800pictures.com/document/mish/Volvo%20Automatic%20transmission%20Diagnostic%20chart.pdf


I found this web site some time ago:

http://volvo1800pictures.com/sweden/Volvo_1800_dokumentation_main_page_en.php

The page is incomplete. You'll find links to the PDF file, yet they are not linked when you look at the page. You have to open the HTML and use search. I mean to write the page owner, yet forget to.


I would guess fluid level, and maybe clogged screen(s), yet if a recently rebuilt BW35, with new (or undamaged re-used) wet clutch discs, there is the service of adjusting the bands (should have been done during the rebuild). Through sounds of something hydraulics .... (I guess) I hope some sort of warranty remains in force on the BW35 rebuild. The BW35 is a durable auto transmission, with care.

If you rev the engine and it does not go, suspect your recently rebuilt BW35.

You have a warranty on the rebuild, I hope?

There would be a host of folks that would want the M40 or M41 transmission, driveshaft, three pedal assembly, clutch cable and sheath, transmission support, and on and on, you removed.

Other board members will provide an actually useful reply to your questions here soon. I though directing you to some service doc may help you with your trouble shooting process.

Hope that helps you,

MacDuff.
--
Give your brickboard.com a big thumbs up! Way up! - Roger Ebert.