Volvo 960 Lock Up Solenoid

[schicksal]

Diagnosis of the 960 suddenly driving like crap found the lock up solenoid resistance as being well out of spec. Does anyone know its part number and where it could be purchased online? It would be great if it could be found in North America but it seems these things are like hen's teeth and if I have to pay a crazy amount in shipping to get my hands on one so be it.

Also replacements for the little flexible insulators used in numerous places on the wire harness would be great. Mine were crumbling to bits on the main harness to transmission solenoid connector causing a bad connection for solenoid #2.

[mjk164]

The lock up solenoid is a known failure with this gearbox but only after some considerable time. My 1993 960 has done about 360,000 miles now and I replaced the solenoid at about 270,000 and it be fine ever since. The symptoms are generally remaining in lock-up until the revs and speed are right down and various similar issue related to that. The job is not that difficult to do and well described on this website and if you look at my posts about Nov 2013 you will find what I did. The solenoid is still available from Germany but if you get in touch with Steve at Braydons he will source the part for you; its not that cheap but brings the car back to as new. I will look through my invoices and see if I can fine the Volvo p/n.
Good luck!

[Laird Scooby]

You could try : https://www.fcpeuro.com/Volvo-parts/...55&m=20&page=2

Once you're on the site, you'll have to enter the correct details, year, model etc as i tried guessing and came up with nothing.

Good luck with it anyway!

*** EDIT ***

You could also try : http://www.pioneerautoinc.com/catalogs/

Most of the AW boxes are listed under Toyota and the Volvo part numbers are included where the parts differ from the Toyota spec.

[schicksal]

Originally Posted by Laird Scooby

You could try : https://www.fcpeuro.com/Volvo-parts/...55&m=20&page=2

Once you're on the site, you'll have to enter the correct details, year, model etc as i tried guessing and came up with nothing.

Good luck with it anyway!

*** EDIT ***

You could also try : http://www.pioneerautoinc.com/catalogs/

Most of the AW boxes are listed under Toyota and the Volvo part numbers are included where the parts differ from the Toyota spec.

FCP didn't have any solenoids, unfortunately. The shape of the Volvo SL solenoid is very different from what Toyotas used. It's long with some channels cut out. Part number 3515644 (pics available on Skandix). The only thing I can figure is that the entire subassembly they're installed into is different even though it is an AW30-40LE transmission. The catalog you linked to shows it on page 307 (assembly E), and it makes me wonder if those bits from a Toyota would be a direct swap over to a Volvo along with the internal wire harness. It looks about as large as a sheet of paper.

[schicksal]

Originally Posted by mjk164

The lock up solenoid is a known failure with this gearbox but only after some considerable time. My 1993 960 has done about 360,000 miles now and I replaced the solenoid at about 270,000 and it be fine ever since. The symptoms are generally remaining in lock-up until the revs and speed are right down and various similar issue related to that. The job is not that difficult to do and well described on this website and if you look at my posts about Nov 2013 you will find what I did. The solenoid is still available from Germany but if you get in touch with Steve at Braydons he will source the part for you; its not that cheap but brings the car back to as new. I will look through my invoices and see if I can fine the Volvo p/n.
Good luck!

Sad thing is I'm the proud owner of two failed SL solenoids. I bought a second gearbox for next to nothing but S2 and SL tested out of spec. It isn't completely dead - in the rare event it locks up it will release as intended instead of shuddering when coming to a stop. Resistance is 192 ohms but should be between 10 and 15.

As luck would have it I managed to find one for a great price on ebay out of Taiwan of all places!
https://www.ebay.com/itm/NEW-OE-3515...-/331685549377

Otherwise I would have gladly called up Steve since this is the only bit in the entire car besides the Nivomats that isn't like new.

Any thoughts on the little pieces of the electrical connector that are crumbling apart? I haven't seen any sources for those but don't exactly know their part number. Surely I'm not the only one who's experiencing that problem, it looks like nearly every plug uses them.

[Laird Scooby]

Originally Posted by schicksal

FCP didn't have any solenoids, unfortunately. The shape of the Volvo SL solenoid is very different from what Toyotas used. It's long with some channels cut out. Part number 3515644 (pics available on Skandix). The only thing I can figure is that the entire subassembly they're installed into is different even though it is an AW30-40LE transmission. The catalog you linked to shows it on page 307 (assembly E), and it makes me wonder if those bits from a Toyota would be a direct swap over to a Volvo along with the internal wire harness. It looks about as large as a sheet of paper.

If you have a closer look, you should find the relevant Volvo parts listed separately to the Toyota bits in the parts list but i have to confess i couldn't. Perhaps a phone call to Pioneer Auto?

If you look at Pg309 it lists the solenoids and a solenoid kit part number 771050.

As for these plastic crumbling parts/insulators/plugs, any chance you can add a photo please? I might recognise them as something easily available then and be able to point you in the right direction.

[schicksal]

Originally Posted by Laird Scooby

If you have a closer look, you should find the relevant Volvo parts listed separately to the Toyota bits in the parts list but i have to confess i couldn't. Perhaps a phone call to Pioneer Auto?

If you look at Pg309 it lists the solenoids and a solenoid kit part number 771050.

As for these plastic crumbling parts/insulators/plugs, any chance you can add a photo please? I might recognise them as something easily available then and be able to point you in the right direction.

Attached is the plug in question - the white bits are what keep the female terminals in the actual plug. They've degraded enough so I could just pull the plastic bit off and just plug the five wires to their mating end individually.

It's not the end of the world if the parts aren't available anywhere, I can always cut both ends of the plug and use a generic waterproof one as a replacement.

[Laird Scooby]

I know the plugs you mean now, if there is wiring to each side then you have two halves of the same plug so could easily replace it with a Supaseal type plug or similar.

Can't remember if i ever knew where to source those plugs now but definitely don't know at the moment! This is what i mean about Supaseal type connectors :

http://www.ebay.co.uk/itm/1-Kit-8-Pi...IAAOSwPgxVMMf1

You can probably find them on ebay.com as well, often the suppliers in Hong Kong, China etc supply multiples at a much cheaper rate so you could possibly get 10 sets for not much more than a single set. I recently bought some 1 pin and 2 pin similar connectors in packs of 10 for not much more than buying 2 or 3 sets singly.

[schicksal]

Ah, that's about what I was expecting. I was looking at that exact connector on Amazon just a few days ago. There's an excess of wire in the harness and my soldering skills are good, so no worries fitting one of those at least!

[Laird Scooby]

Soldering skills?

not with the ones i linked to - they use crimp connectors that push into the plug/socket housing.

Handy if there is no power where you are going to to the job.