Guys,

I was on my way back to school from a weekend at home. 75 miles into the trip I hear a fuse popping type noise and my tach shoots to 4K.

Damn! That OD relay that I should have replaced over the summer finally came back haunt me. Sometimes the light would come on when I started the car on I hot day. So I would give the dash a whack and things would be good.

I pulled over first chance I had and looked in the fuse box. They were fine, so now I pretty much have it narrowed down to the relay. Prob is the OD light did not come on when this started. 4th just went away w/o the light coming on. The light would come on if I hit the OD lockout, so it was not a bulb failure on the dash that caused the light to be out.

So can the OD fail w/o the dash indicator coming on? I have no tools, 100 miles from home, and need to have this fixed tomorrow. There is a local garage that has some Volvo business, so I can get a relay there if that is the problem, but I am going to need some guidance to fix this if we are talking more than swapping relays.

Thanks so much.

Hi. My name is Les and I have OD troubles.

As a variation to the theme, I resoldered my relay (per the Daun de Solderdum) and viola! -er, uh, no change. Then I replaced the switch on the gear shift knob and viola! OD works! It engages and disengages on command (my command, not its own . . .) But wait, all is not well in Mudville - the stupid dash light works only sometimes. Actually, when the OD is disengaged, it works all the time (it's OFF). I know the bulb isn't burned out or disconnected - it comes ON (when the OD is engaged), but only about 10 - 20% of the time. So my car is operational, sort of, but clearly there is still something that needs to be fixed.

Les,

I have an 89 240 automatic, and have been in volvo hell because of overdrive related electrical problems.

I found this board too late for saving some big $. But my problem persists. In short, I am now replacing the OD solenoid. In case this doesn't do it, how much did that switch go for and what was involved in replacing it? If it is not a big cost, I might want to try replacing it first, and possibly returning the solenoid.

Thanks in advance.

b-v-g

Let me ask again. For an '89 240 automatic,

1) how am I supposed to access and replace the OD switch on the gear shifter

2) how am I supposed to access and replace the OD solenoid

For the OD switch on the gear shifter, it looks like it should be accessed from inside the car. What needs to be removed/peeled back, and in what order? Is there a way to open up the plastic housing around the shifter and peer in for wire problems?

Likewise, for the OD solenoid, do I need to remove anything to access the "shelf" it sits on? For example is there a plate protecting the underside of the housing? Also, somebody mentioned that the connector-lead from the solenoid needs to be run through an existing wiring sleeve, is this right?

Thanks if you can help.

B-V-G,

(kinda sounds like "BVD") (but it kinda looks like "BUG")

Ok, sorry. I got the switch in a salvage yard. Because I was purchasing a number of other items, the guy didn't charge me for the switch.

Replacing the switch on my car was a snap because I have an M46 (manual) gear box. I don't know what kind of contortions you'd have to go through; maybe none at all.

Make sure the wires from the switch on top, down through the shifter and out the side, under the rubber boot, are ok and not frayed. Look under the car as well to make sure the wires are not frayed or broken.

And if the wires are frayed, just tell them, "Don't be afraid, little wires, all will be well soon!"

Ok, sorry. A cheap shot, I admit, but I just couldn't resist.

"Never walk past a sick dog without giving it a good swift kick."

Could be intermittent bulb (not likely), intermittent connections at the bulb socket or to the cluster (also not likely), intermittent wiring or connections to the relay (also also not likely), or some undefined mysterious relay problem (likely).

Tell ya what. I'll send you a repaired and known-good relay, you send me your suspicious relay (I suspect it).

Don Foster (near Cape Cod, MA)

Great! I accept your magnanimous offer. Would you prefer to exchange address info on or off the Brickboard?

Jonathan --

"...can the OD fail w/o the dash indicator coming on?"

Sure.

As I've said about a gazillion times on the BB—maybe more than a gazillion times—RESOLDER THE DAMNED THING.

Meanwhile, remove the relay, pop off the plastic cover, and examine the backside of the printed circuit board. Look carefully (using a magnifying glass) at the larger solder connections.

If you see cracks, push into them (or "stake" them) using a sharp tool, such as an awl or a thumb tack. Because solder is soft, you'll deform it enough to make contact 'til you can resolder the connections.

Don Foster (near Cape Cod, MA)

......but this time I have to listen!

First thing on the list of things to do Tuesday when I get home? Bust out the soldering iron!

Things work for now, I cleaned the connections and put it back in. I had OD on a short test drive, but I do not trust it for the trip home. Tomorrow I will get a used relay from one of the shops parts cars, just in case. I will re-do this one as well and keep it as a spare.

Listen to Don, listen to Don, listen to Don.......

"Listen to Don, listen to Don, listen to Don..."

Ok, listen to me!

Resolder your fuel pump relay, too. When its solder connections let you down (and they WILL let you down) it'll be far more troublesome than the OD relay.

we decided to rename him "dan, dan, the resolder man", but

being that his name isn't dan, it didn't work out too well.

Don Don, the resolder Mon. I guess you have to be from Jamacia.

How about Don-Son?

Geez.

Good thing my name's not Dick. Or Kirk.

Don Foster (near Cape Cod, MA)

Don, the SOLDER DON

The DON of soldering

Soldering since the dawn of man, DON

He'll stick his hot tip in anything, here's DON....

OK OK It's all Don hill from here.....and I wouldn't want to Foster another wickedly funny and eutectically correct pun run....

Your puns are a-paul-ing. All those synthetic fumes must be corroding your brain connections.

Fear not — I can resolder them all!

But for your hard head, we'd need the oxy-acetylene torch with a #10 tip, extra gas and extra oxygen.

Just remember this: Before you solder with your hot iron, ya gotta tin it.

Don Foster (near Cape Cod, MA)

I like that, John. Glad my name isn't Dick.

But since it costs $0 to do and results in a better than new relay, I think it's worth the money.

Don Foster (near Cape Cod, MA)

Yep that's what i call him.

Knowledge gained from his his resolder rantings saved me a 200 mile drive home in third gear on one occasion and helped me correct a no start on another occasion.

I bow to you sir.