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960 Will not start S90-V90

posted by  edhall on  Tue Oct 19 06:13 CST 2004
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last visit: Thu Jun 24 08:51 CST 2010
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Hi,

I am brand new to this forum and desperately need your help to avoid dealer gouging. A few months back my dealer charged me just under $1000 to replace my mass flow sensor, never again. Here is my problem…..

I have a 1995 960 with 135K miles. About 3 weeks ago the reverse lights went out. All bulbs checked out ok as well as all fuses. Now last week the car would not start. If I turn the key on I got nothing. Headlights & dash lights are strong. The battery is fully charged and the terminals very clean. I suspected that the reverse lights and the vehicle not starting may be related to a transmission sensor that tells the vehicle when car is in reverse (backup lights) and when the car is in park for the ignition to be hot, so I stepped on the brake with the key turned on and ran the transmission from park through 1st gear a number of times. Sometimes this takes 10-15 times, but the car eventually starts right up. I have taken apart the transmission console and found one relay that allows the transmission to be shifted when the ignition is on and the brake is being applied. But this appears to be functioning properly. Upon inspection of the transmission from below, I am finding multiple connectors with 8-14 wires in each and no idea which one to check or where to concentrate my troubleshooting efforts. I am assuming that these are related issues, but that my not be the case.

Any and all help or suggestions would be greatly appreciated and welcomed.

Ed







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    Yep! PNP switch, BTDT S90-V90

    uid 19's pic
    posted by  jbowers on  Wed Oct 20 03:17 CST 2004
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    last visit: Sun Jan 22 13:49 CST 2012
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    I replaced mine a few weeks ago. It is tight in there between the exhaust system and the transmission housing but on my '96 there was adequate room so the exhaust system didn't have to be touched.

    A little "liquid wrench" on the shaft will aid in sliding the old one off once you have the mounting bolt off and the clamp nut at the shaft loosened. I used the clamp nut as a pry point to help work the old one off the shaft.

    I had to disconnect the transmission cooler return line on mine to move it out of the way. This is easier if you loosen or take off the end at the radiator and take off the clips that hold the two cooler lines together. Only a little fluid ran out, less than 1/2 cup or so.

    Put a little dialectric greese on the connectors when you put it back together. (It came apart hard!) Have some tie-wraps handy to retie harness back in place. Feeding the harness over the top of transmission only took a couple trys.

    I just centered mine in the range of adjustment and it worked fine in controlling the lights and starting functions.
    --
    '96 965 with 16' wheels at 119K. Had '85 745 Turbo Diesel for 200K.








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    960 Will not start S90-V90

    posted by  eviltwin on  Wed Oct 20 02:01 CST 2004
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    last visit: Wed Jun 20 21:30 CST 2012
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    If it is a problem with corrosion on the PNP switch contacts, you can try "rowing" the gear shift back and forth 30 or more times with the car turned off. This can work to clean them off enough that they start working again. Ususally the car has a limp home mode which I would think would let you start it up.
    --
    97 S90 with 177K miles still going strong








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    960 Will not start S90-V90

    uid 11021's pic
    posted by  dewfpo on  Tue Oct 19 11:57 CST 2004
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    last visit: Thu Oct 23 18:34 CST 2014
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    This sounds like a typical PNP sensor failure. Very common on these cars. The part costs ~$100 and you can replace it yourself or have the dealer do it. Check the FAQ's for instructions, as well I have written up a detailed procedure to replace it if you want to do it yourself. Let me know.

    DEWFPO
    --
    1998 S90 071,245 and 1995 964 154,100








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      960 Will not start S90-V90

      posted by  edhall on  Mon Oct 25 05:44 CST 2004
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      last visit: Thu Jun 24 08:51 CST 2010
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      I would love a copy of your detailed instructions, especially if this can be performed with out removing or loosening the exhaust. I was concerned after reading the procedure available at http://www.brickboard.com/FAQ/700-900/TransmissionAutoAW30.htm#960AW3040GearPositionSensorSwitchReplacement that they may be geared toward the early pre-95 960’s. The local dealer has the part for $125 & want $250 to install. If the procedure is as above for the 95’s, then it is probably worth it, however if easier without messing with rusted exhaust bolts, I’m game for a do-it-yourself.

      Thanks,

      Ed







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        960 Will not start S90-V90

        uid 11021's pic
        posted by  dewfpo on  Tue Oct 26 06:24 CST 2004
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        last visit: Thu Oct 23 18:34 CST 2014
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        Ed,

        I sent you a PM with my procedure and my comments about the exhaust pipe.

        DEWFPO
        --
        1998 S90 068,300 and 1995 964 152,300








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    From the FAQ S90-V90

    posted by  someone claiming to be tjts1 on  Tue Oct 19 08:48 CST 2004 [RELATED]

    http://www.brickboard.com/FAQ/700-900/TransmissionAutoAW30.htm#960AW3040GearPositionSensorSwitchReplacement

    See also

    http://www.brickboard.com/FAQ/700-900/960_90Info.htm#960WontRestartPNPorHarness

    Good Luck
    Justin








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    960 Will not start S90-V90

    posted by  RK on  Tue Oct 19 06:44 CST 2004
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    Ed,

    You are the latest victim of the infamous gear position sensor (a.k.a. PNP switch.) This problem is extremely common among 960/S90 owners. Just do a search in archives with keyword "PNP" and you will get tons of information. It is interesting that symptoms vary a lot from car to car. I had this failed couple of years ago, but I guess I caught it early enough and I never had "no-start" problem. But as in your case, my reverse lights were not working and I had a fat arrow lighted on the dash. Also, I believe I had blinking E/W lights at the transmission lever. The replacement part is about $200 plus or minus $50. A good indy shop should be able to do the whole job for under $400.







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