Just finished changing the automatic shifter bushings on a 1991 240 and still have the same problem with the interlock. The shifter has enough play that it sits over towards the driver's side and the pin doesn't engage the plastic lever on the start/inhibitor switch. FWIW the bushings were not that bad so replacing them hasn't changed anything. Bentley doesn't address this that I can see, just the adjustment of the switch fore and aft and the lever free play fore an aft. Any thoughts on this excess side to side play in the shift lever??

I've wondered about this for a long time. Since there's the bypass lever under the shifter housing, couldn't a resourceful owner just pin the lever or permanently fasten the switch, or grind off a tab, or do something to override the lock-out? I can't fathom that someone here hasn't found a simple fix for this, no?

B

The bypass lever is for operating the solenoid to allow lever movement in a case of a dead battery. I think mine's OK but it seems a bit flaky. Your question has me thinking of another idea I had which is could the PnP switch be moved over towards the shift lever? If the 2 screws that attach it were replaced with longer ones, and washers used to shim it over, it would move the plastic shift lever over and onto the tab on the shift lever??

This car is an extra vehicle that I am planning to sell soon so I would like it to be operating safely when sold.

It's been a while but we got the shifter from a pre-interlock car. The covers were a bit different but we were able to use the original. I don't remember anything particularly hard about the procedure.
Gary

Hey Gary,

I'm guessing the "hard" part is getting at the bolts above the tranny securing the shifter assembly into its pan or removing the entire pan if that's the way you went. Easier, yes, if the transmission or driveshaft is out. Or if one is already fairly familiar with what's down there....





The bolts are UNF up to some year; not sure when, but this is an '89.



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Art Benstein near Baltimore

Crusin' and playin' the radio... With no particular place to go.

Thanks Art, was hoping you would chime in, that's not quite as simple as it sounds. Any thoughts on shimming the selector switch over towards the gear shift lever, or adjusting the play in the shift lever to get it over towards the selector switch? Thanks, Jim.

Jim,

I'll have a look tomorrow. Never saw one with play side-to-side.


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Art Benstein near Baltimore

"Charlie, you're outta da bar!" -Special Hal

Thanks Art, yes the side to side issue doesn't come up in any threads I have searched?

Jim, I spent the afternoon boiling down a 91's shifter to evaporate all the mysteries I could name. My conclusion, if the side-play is enough to pull the pin from the pizza switch, is the three screws holding the shifter assembly in the bucket are loose, or something is sadly rusted down there.

Also, I was unable to find a way to withdraw the assembly from inside the car without at least disconnecting the shifter's arm from the linkage below. And for my shortcut, that involved making carpet incisions.

Even getting the shifter assembly out of the bucket was a tight squeeze after removing the arm from it.

And, extracting the solenoid without doing the above looked possible at first, when I discovered that someone in the past had attempted this by prying off the retainer ring on the top pin, and breaking the bottom pin. Couldn't do it.

So, if you don't find those screws loose above the transmission output flange, I'd sure like to learn what you do find. Any other explanation for the side play you feel is beyond my imagination.

By the way, the 91 I tore down has metric hardware holding the shifter assembly to the bottom of its bucket. Bring a 10mm wrench. The locknut retaining the arm (the bent bar stock with holes in it) is a 5/16-18 size -- use a 1/2" wrench.


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Art Benstein near Baltimore

Hospitality: making your guests feel like they’re at home, even if you wish they were.

Art, WOW, thank-you for taking the time to do all of that investigation, it is greatly appreciated!! Sorry for taking so long to reply as I had company for the long weekend and rain since then.

I had a look at the shifter assembly and can't see anything that looks rusted or otherwise out of place, still doesn't explain the play in the shifter. I know it's a poorboy solution but I am going to look for a couple of longer screws and some washers to shim the "pizza switch" (that's a good one BTW) over so it engages the pin on the shift lever. The last few days I have made a point of holding the lever over slightly when shifting and have not disengaged the pizza switch. It's not the proper solution, but the lever is just far enough over to lose the switch so it doesn't have to go far. I'll post back after I get it done with a report.

Thanks again,
Jim

Hi Jim,

Of course I can't recommend any fix that could compromise the safety Volvo intended, which would depend on fully understanding the cause of the side play you are experiencing.

There should not be any side-to-side play at the shifter capable of unpinning the switch. Something is wrong. It will likely get worse.

I would feel much better if you gave it one more greasy arm attempt from under the car: Grab the end of the arm of the shifter's lever (where you installed the grommet) and feel the side play that would reflect to the shifter knob. It should be solid. It isn't, I suspect, and at that point you will see what is moving.

Bring along a 10mm wrench and see if those three bolts are loose. Like I mentioned in the last post, if they are tight, I cannot imagine any reason for side play in the shifter beyond bent-up or disintegrated metal. Give it this one try before resorting to modification.






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Art Benstein near Baltimore

A bus station is where a bus stops. A train station is where a train stops. On my desk, I have a work station..

Hi Art, I was thinking you would respond as above, and as usual you are correct. I will give it another go and report back, may be awhile as other projects on the go competing for my time and energy. Thanks again for all the help, much appreciated. Jim.

Take your time, Jim. I'm sure the nice sunny morning will come along when your curiosity will get the best of you. It did me, and I thank you for that.


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Art Benstein near Baltimore

He who smiles in a crisis has found someone to blame.

I have thought of doing this as well, my issue is that the nearest PnP is a 4 hour round trip and 240's are not plentiful there. It would definitely be the simplest solution though.