1996 850 Recent PNP Switch Replacement, Now Shift Issues

[malvern]

Before delving into my actual predicament, I crave your indulgence. I'm not a gearhead and for the most part I have others (my local Volvo repair shop where I'm paying for the owners' three kids' private school education singlehandedly, and a close friend) take care of the maintenance and repair of my beloved 1996 850. It was the close friend who encouraged me to make the post here on my own since, well, I know what's happening better than anyone else.

About 10 days ago, my friend and I replaced the PNP switch using the great guide to PNP Removal available on this forum. My reverse lights had given up the ghost and after checking that it wasn't an issue with the electrics, we were pretty sure it was a PNP issue. We followed the instructions to a T and my friend did a very thorough job, as always. He tightened everything appropriately and aligned it properly. At the end of the job, my car not only had reverse lights again, it was running better than it ever had before in the three years I've owned it.

4 days ago, things started going wrong. Possibly coincidentally, I hit a huge pothole on my way to work, travelling maybe 10mph at most. As has happened once before, my horn started going off intermittently at very low speeds -- not all the time, and never with any pattern, but only at low speeds. This may be coincidental with what the bigger problem is that started on the same day. I then started having issues with the car shifting through the lower gears from standing. At first, it was just a hesitation I'd never felt before between the gears. Every time I drove, the hesitations got more pronounced. I could feel a clunking as it shifted from one gear to another. Once it got up to what I guess is third, it was fine. No noise, no clunking. Highway driving was as smooth and effortless as always. It was just getting going that was the problem.

This morning, the car did NOT want to go, forwards or in reverse, without me giving it a little gas. Even after I got it going and took it out for a drive around the block it was shuddering. RPM was occasionally dipping below 1000 at idle and then jumping right back up to 1000. Getting from one gear to another occasionally required me getting the RPM up to near 4000, which I have never had to do before in low gears. But once I got it going, everything was fine again after I was travelling above 35mph.

Also, I noticed a small puddle of liquid under the car both at work and at home. I know zilch about fluids, but I did dip my finger in it and it was clear with only the smallest amount of tackiness to it, which I may have just imagined. It had no smell. My car buddy said it is likely to be either water or brake fluid, but since I just had my brakes checked last month I'm hesitant to think it's the brakes. But then again, I know so little about cars relatively speaking I don't trust myself.

My friend says he thinks it's possible that when I hit that pothole it knocked the alignment of the switch (I think that's what he said) and thus the shifting would be affected. Since the car ran so beautifully for five or six days until this happened, I guess it could be possible. I'm taking it into the shop tomorrow morning, and will be prepared for a scolding from my mechanic for not paying him $$$$$$$ to do something I knew my pal -- who's been working on cars as a hobby for 25 years and has rebuilt more classic cars than I have fingers on my hands (and I have a full complement) -- could do for a Chinese takeout in return for payment.

Ultimately, I guess I'd like some input from y'all about whether our guesses are correct, or if we're totally off-base here.

[Ozark Lee]

Welcome to MVS,

The very first thing you should do is check your fluid level. I fear that the pothole may have caused a leak and your description of the problem sounds more like a low fluid level problem than anything else.

The fluid level on the dipstick can be deceptive, it can appear to be OK but you need to check both sides of the dipstick to make sure the level shows the same on both sides. If one side shows fluid and the other is dry then the level is indeed low.

Driving with low fluid can cause permanent damage to the transmission. If at all possible set some white cardboard under the transmission and try to determine if the fluid leak is reddish in color.

If you do determine that the level is low and you do have a leak the next step (after you get the level back to a proper level) is to determine where the leak is occurring. The way the oil pan is positioned it isn't subject to damage however leaks at the axle shafts are fairly common. The good news is that the axle seals are fairly easily fixed and the seals themselves aren't terribly expensive.

...Lee

[malvern]

Thanks so much for the quick reply. I'll pass this on to my car buddy but in the meantime the first thing I'll do is check the levels. Thanks!