'93 240 automatic - where is the relay/switch for the fifth gear?

I've yet to ever see a solenoid fail, it can happen, but it's unlikely.

As I've said before, check the wiring under the car to the solenoid, if the
relay is ok then that's almost certainly where the problem is. You can test
the solenoid while you're down there too.

 

We had a solenoid fail. The wiring was also crap, but the solenoid
was bad.

 

Well, my dear James, you are right (again?). The wire above the
electrical connector for the overdrive solenoid is cut. I haven't
started to take things apart to see were that wire goes to on the
inside of the car, but I'm sure I'll find out soon enough...

P.S. An overdrive solenoid (I know I don't need one) sells for $95 at
FCP and $390 at your friendly Volvo dealer...

 

The wire goes up through a rubber plug into the passenger compartment and up
into the center console to where the relay is. You can get heat shrink butt
splices to make waterproof joints, or you can solder the wire together and
cover it with a piece of heatshrink tubing. In a pinch, a normal butt splice
with a good coat of electrical tape will work.

 

Forgive my ignorance, but where can one usually find "heatshrink
tubing"? Thanks.

Btw, I find this whole thing pretty dumb. This overdrive thingy could
be removed entirely and the car always able to reach 4th gear. I
don't see any use for this thing which has caused me a good deal of
aggravation and worries.

 

It's handy if you're hauling a heavy load or towing a trailer, it prevents
the transmission from hunting, which newer computer controlled automatics
usually don't do.

You can get a bypass plate from IPD, or just wire the solenoid to switched
12V. Heatshrink tubing can be found at an electronics store, Radio Shack
carries it. Heatshrink butt splices are sold at any autoparts store in the
electrical section.

 

Update: I soldered the two wires and use heatshrink tubing. Btw, the
insulation around the wire is crumbling into dust.

In retrospect, I believe the wire broke in two as a result of driving
in 10-12 inches of snow for 10+ miles. I must have hit something
hard, like ice and it broke the wire.

Everything is fine now. I must not be normal for worrying so much
about my 240...

Thanks to all for your help. You've got a nice group in here.

 

The heat and oil do nasty things to that wire over time. Last time I worked
on an auto 240 I replaced the whole wire from about an inch from the
solenoid to where it goes up into the car. New wire got two layers of
heatshrink tubing over the whole thing.