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Yup that is a possible cause how ever you would think after AS many clutches and look sees this unit has under gone someone would have at least mentioned the shaft had some wear to it, but also knowing the lack of caring ( don't give a shit attitude) a lot of society has today ! I guess its possible it has been overlooked! Like I said I'm confused!

You said the clutch shafts are fairly new But How old is your Clutch cable ? If its old replace it!!! At this point if it sounds like a slipping clutch it likely is a slipping clutch In my mind the only things you haven't changed here are the clutch pedal and the cable Never seen a clutch pedal siezed to the shaft anything is possible I guess ! I have seen clutch cables cause grief And we are Grasping At straws At this point! Also a thought here! Have you tried locking out the power divider? Is there a possibility that there is a striped axle gear and it is grabbing and slipping intermittently! When this post first started when were focusing on the engine cause it happened all the while the engine ran ? Now we are looking at the frame? and under power? I am Officially confused ! 😣

I also Kev ! It must mean ! They had Fake news back then too I guess! !🙄 (In jest!)

Yup me too how ever he should be smelling the un mistakable smell of heated clutch/brakes

The bell housing is part of the trans you will need to fab mounts as for the tone ring that will be tough as there were very few built with electric speedo you may fine one thru chassis records of some MH cab over chassis!

The cross shafts were OK on the Clutch fork?

Good to see the reman center is keeping its bulldog reputation as well! Same old same old!😣🙄

YUP An d You Said It out LOUD! 😂

Don't kid your self! The owner of our dealership is also A gravel pit owner He bought into the Volvo equipment line back when he took over the Mack Dealership here we have had our fair share of repairing this junk too! The quality and design is somewhat better than the truck end. Still kind dollar store ish however! He has switched back to Cat for the pit end of the business ! I'm sure it has a lot to do with economics as well never the less he switched back! lehbier would not even be in the thought process !

No I'm positive of sure your mistaken Its the Volvo/88800352 Tool A Bargain @ $1,338.18 ! 😣 A lot of R+d Went into building that unit ya know!🙄 One thing about the Volvo Group , They Are equal opportunity Gouger's ! They gouge the customers and they gouge the dealers ! If they were as good at fixing injector cups as they are at gouging these trucks would be perfect! Money For Nothing Shit For Free! Nope! They sell That too!

Un plug the round fuel pump connector take it apart an put it together several times then try start it! By several times I mean at least6

Drive by wire started 1993 400 hp! they offered mech in the lower HP for about 2 years beyond 93 ! by 95 / 97 I believe everything would be DBW Either or were Quite reliable !

Yup ! The Harness! this is another on going issue that seems to never got dealt with, Coolant push and oil push is quite common on these ! Oil or Coolant can be pushed up the wire from various failed or failing dollarstore sensors used on the engine and expansion tank right back to the ECU! However in your case the it looks as thou there was no coolant evidence or oil Did you clean it out?

GOOD CALL Swishy!!!

Should be a non egr engine! 2004 was the anniversary Of EGR Celebrated daily/ weekly / monthly/ yearly at a shop near you! 😣 I would have your fuel pressure checked Also if it has a waste gated turbo it may be sticking !

From My observation the DOT make their own rules! They also have a spin the wheel Game they use when they start the week! last week it was licence plate lights this week its mud flaps have to be 8 inches from the ground important shit like that!😖

The pto gear is still engaged to the counter shaft if set to tight it will will whine all the time! you don't have that problem with 99 percent pto! it runs off the center section (Main Box) the only suggestion I have for you is to drain the oil remove the pto cover and look inside the back section and see if you can see anything odd!(shift fork rubbing the gear teeth or anything like that ) when the split is in hi! as paul said there are needle / roller bearings on the counter shafts however the sound would likley be there all the time They tend to whine somewhat in hi but not as bad as your describing!

Is the pto mounted on the side of the trans? Did u shim it correctly

Well if they can drag it out long enough maybe the warranty will be off then you can buy the new engine or better still you can by a fleet of trucks and maybe they can spend a month or two fixing this one atleast you may have half a chance of getting some work done! While they change out the engine ! 🤔

I have one other thought and question is your clutch brake working? If not. Check to see it hasn’t broken and taken out the timing sensor on the flywheel just something to look for

First off year of the vehicle helps to identify closer what we’re dealing with! Second if the engine is a red engine your dealer is likely correct. 2 options 6000 in repairs or set fire to it and collect the insurance.😠

Mack Tech is correct in my opinion ! how ever It is possible he could have nicked an oring but with even one missing I believe the engine would be fuel of fuel in short order if it would run at all . This also may be unrelated to the oring job ,the fuel transfer pump seals can leak past the shaft ( its not uncommon !)

It will work fine!

I beleive shut the engine down turn the the key back on soon as the engine stops running!