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Dear Scuba Steve,
Hope you're well. Transmissions used in '92 960s were made by Aisin-Warner, a Japanese firm. Before trying to rebuild the part, I'd seek a salvage yard transmission, with clear, rosy red fluid. You'll have to buy the entire transmission. You do not want the disassembly to be done by anyone, who is not a well-experienced transmission specialist.
What is the Volvo part number? According to Volvo VADIS - the superseded dealer parts/service databate - the control unit for the AW30-40 tranny has three solenoids. Two are part #3515643 and one is #3515644: the latter part (#3515644) is designated in a note as "SL". "SL" may be an abbreviation for "Shift Lockup".
Because these solenoids seem rarely to fail, a salvage yard unit may be a fine alternative versus trying to do a rebuild. If the tranny in your car is an AW30-40 or AW30-43, the solenoid you likely need (see above) was used in 960 trannies up to and including model year 1998. Thus, there should be plenty of 960s in salvage yards, with trannies, from which a solenoid can be had.
Before exploring what's available in salvage yards, I'd try another Volvo dealer. My on-line parts look-up database shows both solenoids are available from Volvo. MSRP on #3515644 is about $200. MSRP on #3515643 is about $150. Not all parts counter staffers are equally skilled. It's possible that the one, whom you consulted, simply did not know how to identify the part. Use one or both part numbers, as a way of confirming that whomever helps you, is "on target".
If none of these suggestions works out, I'd contact Aisin. I've visited their website. They don't want to respond to end-user questions, deflecting those to the manufacturer/dealers. You will need to explain that you've contacted Volvo, and that you were told Volvo no longer supplies the solenoid. If you do not make this statement in your letter, you'll get a form letter telling you to contact Volvo.
Aisin's address: Aisin AW Co. LTD / 10, Takane, Fujii-cho, Anjo City / Aichi 444-1192, Japan . Should You write to Aisin-Warner, be sure to provide full details: Make (Volvo), Model (960), Year (1992), Transmission Model (from data plate on the driver's side of the tranny), and Transmission Serial number. I'd also include the Vehicle Identification Number (VIN). It may take a couple of months for them to reply. But I'd guess they'll reply.
Hope some of this is helpful.
Yours faithfully,
Spook
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