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I think, if I had read a little more closely, I would have noticed that this was an early 740. The shift pattern itself should have made me pay more attention...
It's a ZF22 transmission isn't it? You have no "OD lockout" button, but rather D-3-2-1 on the shift lever. Well, I *hope* that your problems are confined to the linkage, or adjustment of the linkage, but in reading over what you wrote, I think there's something much worse. It's bad news, and the fixes for it are both tough choices.
The ZF disintegrates internally- I haven't seen the pieces but its been described to me as a spline on an intermediate shaft stripping out of it's gear teeth. The fix is a rebuild, and people I know with these have been quoted $900 for that work, in addition to the labor of removing and installing the trans. For a Ford Taurus owner, that's a normal occurrence- Volvo people don't expect such problems!
The cheaper fix is to get a good used (junkyard) 88+ automatic, the AW70 (AW71 from a Turbo is fine too) and do the swap. You would also need the complete shifter and linkage, and at least the front section of driveshaft- I'd get the whole thing. You'll need the overdrive relay as well, though that can be bought new or used separately.
Even with all these parts, I do not think you'll come close to the rebuild price of the ZF. The AW should essentially never need a rebuild, and good units are cheap and available, unlike the ZF.
All in all, I'd only consider doing this if the car is worth keeping. If it's very rough, it might be a good parts car for your next one. Sometimes whole cars can be bought for less than one of these repairs...
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Rob Bareiss, New London CT ::: '87 244DL/M47- 234K, '82 245T/M46-182K, '84 242DL/AW70-100K, '89 244DL/AW70- 212K and I miss my: 86 244DL 215K, 87 244DL 239K, 88 744GLE 233K, 88 244GL 147K, 91 244 183K
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