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Riverol,
First, don't discount the abusiveness of trained (middle aged) engineers. I worked with several a few years back and they were more abusive to our company cars and equipment than any other employees. Even after my warnings about stopping first before throwing a car into reverse .... they would tell me, "I'm sure the engineers that designed the trans. took people like me into account." They kept saying that even after the rear seals on the transmissions began leaking and the cars had to go into the shop to get them changed..... one twice. They still abused the cars. Of course they weren't paying the repair bills, the company was.
Anyway....
The first trans going bad makes sense. Coolant in the atf will destroy the internals of the trans. No dispute there.
The second trans overheating the fluid right away points to an internal trans. fault, wrong atf, bad atf temp sensor (possible if the first one was reused after a bad overheat) or the atf is not getting cooled by the radiator. The very fact that you installed a Volvo ATF cooler AND have used synthetic atf indicate to me that there is an internal problem with the existing trans that is generating excessive heat. Unless a VERY experienced Volvo transmission rebuiler looks at this trans, I would not rebuild it. There appears to be an internal problem that may be very difficult to diagnose by anything less than an AW30-40 expert. Perhaps have a Lexus tranny expert check it out.
The AW30-40 we'd seen here in the US are really very stout. I have not heard much of the overheating problems you are experiencing. You may want to consider getting one from the US.
I live in the mountains, 7,200 feet in elevation to be exact. There's a 4.5 mile, 6 percent constant grade up to the area where we live. That's 35-40 mph, 2,200 rpm. constant uphill load with the A/C on in the summer. We have two of these cars and they both have M1 ATF with the stock radiator tranny cooler and they we have experienced no transmission problems. I do always let the engine cool (until the fan shuts off) before I shut it down. The last 250 ft(driveway) is a 12 percent grade so I get the trannies good and hot, especially in the summer.
Sorry I'm not more help.
DEWFPO
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1998 S90 071,245 and 1995 964 154,100
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