I have a '91 240 DL that the overdrive is just plain funky, cuts in and out. I got it used, sat for 6 months while jumping paperwork hoops with my state. you can hear the relay click, so it doesn't seem to be a problem. is there any way to get to that d#*^ overdrive solenoid without dropping the trans or expanding my vocabulary? Is the solenoid really the problem or am I just fishig here? TIA for any help ya'll can give.

Try topping of the tranny fluid (if O/D relay and other wiring is good). The O/D can stick if you don't use it regularly and if there isn't enough tranny fluid to lubricate it. Use AT fluid type F (for both manual and auto) and fill it until it start to come out of the fill hole. The fluid from the tranny needs to overflow into the overdrive unit. Hope this helps, good luck.

'86 245 200,000
'87 244 160,000

I had the same problem for my 88 240DL several years ago. I just replaced the over drive relay and the problem was gone.
I think the easiest way is to borrow a good OD relay from your friend and put it on your car and see what will happen.
Relay clicking does not mean it works properly (I heard that sound when I had the problem).

OD relay failure is very common problem for Volvo 240DL.

I have an 82 manual transmission so I am not sure whether your situation parallels mine. What I can say is that on mine the wires and solenoid are easily seen from the driver's side of the car at the aft end of the transmission. My solenoid is yellow in colour. I used to regularly pinch the wire end tabs if the overdrive started to act up. This was early on in my eleven year sojourn with this car. I have never replaced the solenoid, I might add.

Later on I had relay problems that were compounded with a fuse that kept blowing. As your other correspondent noted, the relay is easily found just to the left of the glover compartment box. When I replaced the relay, the overdrive became more reliable and, so far, it seems to be working as expected.

I don't see why you would have to drop the transmission to replace the solenoid but I would follow the advice already given and check the connections, etc., first.

If it is an automatic transmission you might want to check under the vehicle, on the passenger side of the transmission hump. I had some problems with my OD/solenoid when the electrical wire from the solenoid came undone from the wire coming down from the gear shifter. It was an easy fix. All I had to do was resecure the connection. Best wishes.

It is not necessary to remove the transmission to access the solenoid. You should determine that the overdrive relay is actually delivering 12v to the solenoid. The wire to the solenoid (you will see once you are under there) should supply 12v when the relay is activated (arrow on dash will be OFF). Many times the wire suffers from exposure to the rough environment under the car. Also be aware that if it does not show 12v at the solenoid you should then check the relay output that supplies the 12v to the wire as I assume that just because it "clicks" doesn't prove that it is not without fault (you might want to do this first as it is the easier of the two tasks). The relay is located to the left of the opening for the glovebox (which is removed by extracting the screws around the edges and disconnecting the wire for the light). Follow the clicks if necessary to pinpoint its location once the glovebox is out of the way.

Randy