Volvo 240 estate manual gear box problem

I'm guessing that your GearTronic function (the 'manual' mode) isn't working, nor is the Winter mode working (starting in 2nd or 3rd gear).

The gear selector module under the shifter is most likely the culprit, but using VIDA/DiCE (the Volvo car/computer interface) will tell you more. A local Volvo shop or dealer will have that.
I'm not sure if they're coded to the car, or if you can snag one cheaply from the junkyard from a similar year car and swap them..?!

I'd try disconnecting the battery for an hour first. Turn off the ignition, LEAVE THE CAR ALONE FOR 15 MINUTES and then disconnect the NEGATIVE battery post for 30 minutes.

When you connect the battery again, make sure you FIRST turn the ignition to position II - ignition on. Connect the cable, then turn off the ignition.

It might resolve a temporary problem, or the issue comes back, but at least you know it wasn't something really simple.

Check vacuum lines for leaks.

If the clutch is correctly adjusted, it will start to engage when releasing the clutch pedal at 1 in. off of the floor. When in Heavy traffic shift trans to neutral while at a stop, take your foot off of the clutch pedal to avoid overheating the release bearing

This is just a general answer but there could be several possibilities that come to mind, firstly the clutch could be worn and near the end of it's life or it could be an adjustment issue. If it's a hydraulic operated clutch which involves a Master and Slave cylinder this can be bled to get the air out of it, typically there would be a bleeder screw where the Slave attaches to the transmission. Could be a bent fork (this operates the throw-out bearing) which releases the clutch disk pressure and allows the clutch to spin with no friction.
Check your brake fluid level as this is usually the same hydraulic reservoir for the clutch slave and master cylinder. have someone push the clutch in and out while you watch the movement of the clutch fork to see that it's travelling in and out or back and forth to release the pressure from the clutch.
There is typically an inspection plate at the bottom of the transmission that can be removed for a bit more viewing of the components.
The throw-out bearing could be stuck or going bad, typically this would be like a grinding noise or whirring noise when in Neutral and or when applying the clutch, if this throw out bearing is going bad and they will if they sit for a while but usually will loosen up some or free itself a bit from usage - this is, if it's been sitting for a while and hasnt' been used in a while.
Finally there are brass syncro-mesh gears inside the transmission and if you miss the gears too many times the ends of these gears get worn and you wont get it into gear easily.
Check the fluids on your transmission firstly, there will be a plug on the side, half-way up that you remove and stick a finger in and the fluid level should be level with the check plug that you removed. If you put your finger in and feel no fluid then it is low and be sure to use the correct fluids - see your manual.
Prior to this perhaps there is an adjustment on the shifter linkage that has moved and doesn't allow the full travel of the shifter linkage. This is usually along side of the transmission where the linkage attaches to the transmission - look for a rod with a set-screw on it, sometimes the set-screw loosens or it slides and gives less travel and an easy fix. This is typical of the older Chev trucks but not certain about your specific model.
Hope this helps a bit to try and eliminate some things to get closer to resolving your vehicles issues.
Good luck.

East Coast Canada Rocks!
:)

You will have to strip the box and check the syncro''s on the gears . It sounds like a broken synchro ring.

check your transmission fluid level it may be low.if not get a transmission flush as fluid can be dirty

There is a gear in the speedometer that is stripped and is causing the odometer to stop working. You can get a replacement gear from Odometer Gears (Jeff Caplan) 757-593-3478. You will need special tools to replace these gears, so you may want to take the speedo or the car to a speedometer shop.

It sounds like your clutch isn't releasing properly. Do you need to adjust the pedal free play or bleed the hydraulics? If that doesn't fix it you may need take another look at the clutch you put in.

You have an overdrive relay issue. The tansmission is really a four-speed box, but the OD selector either locks our fourth gear or allows the car to shift normally into fourth. I use the OD on my volvo all the time, because the revs drop in half when the OD is activated, The relay is located behind the glove box, toward the center console. $10 buck on Ebay and your transmission should shift correctly again. I would try that BEFORE more expensive fixes, like OD solenoid $200 or transmission control module. Just for kicks a picked up a spare ECU on Ebay for $10 because these get costly if and when they go. Easy fix, though, a couple of plugs.