I've got a '96 850glt with about 170,000 on it and I am the original owner and main mechanic. Two years ago I had the pnp fail and put in a new dealer bought switch. No further problems for very little work and money. Now, 30k later it rears its ugly head again with the flashing arrow, third gear only routine. Cleared up the flashing arrow with the "ratchet routine" on the shifter. Last time that bought me about a year of peace and quiet. I expect another year this time.
Is this a regular two year item after the original lasted for so long or am I just having a bit of bad luck with this particular one? No leaks under the hoods to contaminate the switch and I don't pressure wash anything or get in any water other than normal rain. I know it is the grease that gums up the switch but is there any preventative to that problem?
A little labor and about $130 will fix it again with total failure, and it is a good investment in a good car, but can I prolong its life with anything other than the shifter ballet?
Anybody got any ideas or experience in multiple failures of this puppy?

Thanks

Did you check the codes to verify it is the pnp and not something else? I replaced one at about 110K miles and on disassembling the old one it was not only full of grease but the contact tracks were very badly worn too.

Gear position sensors on other cars seem to fail at random times too from what I've been told.

yes, I did get the codes. And lost them. Seems like I remember a little grease, normal amount for electrical contacts, just aged and thicker.

It depends on the heat. That grease solidifies for some strange reason. Autozone also sells a PNP for a lot less money. Supposed to be just as good.

I wonder how long your new one sat on the shelf? Original Volvo parts are guaranteed for a year?

Klaus
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Please answer your responses. We need to know if the advice is good or bad. The 164 has a new home, all I am left with are 2 turbos :)

The operating conditions have not changed significantly from the first switch to the second so I don't think the switch has been exposed to any greater amount of heat.
Will look into the Autozone part. My labor is getting to be more irksome than the price of the part.

I have not had to replace that as yet (110K miles). I wonder if it makes any difference on where you are (high humidity, or salt spray areas)? I live in a relatively low humidity area. I have no idea if this applies.

I'm not sure the location affects the switch much as far as humidity or salt area. I've got family in Boca Raton that have been operation Volvos for years down there and never seen a switch failure in more than 200k on each of their vehicles. Mabye salt exposure is the key to longevity!
I think I just got hold of a short life switch.