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Your description doesn't make any sense. Read this:
"If the OD is engaged (the light is on) and i slow down to 55-60mph the rpm drops to 1200rpm. On the other hand if i shift into OD, the rpm increase to ~3000rpm when i press the gaspedal without any acceleration"
Pray tell, how exactly do you shift into OD if the OD is already on? Kind alike a light switch man... if the light is on then hitting the switch probably doesn't turn it on, right?
Besides, there isn't any way to shift into OD since its electronically activated... unless of course you are shifting out of fourth gear with the OD light on and it remains on AFTER you shift out of fourth gear. The OD can't engage in any gear BUT fourth by design; shifting out of fourth while the OD is active drops the OD out.
So your description sucks, but from what I cna piece together it sounds like you have bad o-rings or old style pistons. Basically you are getting seepage past the rings and the OD is kicking out, causing the tach to jump up to fourth gear levels, but you are still in OD meaning it bounces around a little. I would surmise that if you disengage the OD, wait a second, and then do a clean engagement (clutching each time when you shift in and out) it will engage with little issue.
No, I don't have a source for the pistons unfortunately. I think Volvo sells them, but that they are a little pricey for what they are. I have my indy guy do all my tranny work, and I can't remember if he buys them from Volvo or has a metal guy he goes to to get them done. They are fairly simple items to have someone make, and you could probably just pull yours and have the groove routed wider by a metalshop if you were so inclined.
The PITA is that you have to drop the tranny and pull the OD to do the swap, which means time and effort.
good luck,
-rt
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