Inspecting / Replacing Solenoids
Inspecting / replacing solenoids
Special tools:
999 5006 LIFTING BAR 999 5006 Lifting Bar
999 5033 SUPPORT 999 5033 Support
999 5460 Lifting hook 999 5460 Lifting Hook
999 5477 JOINT WEDGE 999 5477 Joint Wedge
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5972 FIXTURE 999 5972 Fixture
998 8670 DIAGNOSTIC KEY ST 998 8670 Diagnostic Key ST
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
Opening the control system
Note! Cleanliness:Cleanliness is extremely important when working on transmissions. Before starting work: Clean the transmission and surrounding area, and ensure that the workplace is free of dust and dirt. Components should be dried with compressed air. Under no circumstances may rags or cloths which leave lint or threads be used! Avoid skin contact with transmission fluid! Oil grade:Use only automatic transmission fluid which fulfills both Dexron II E and Ford Mercon standards.
Alignment of steering wheel position
Slacken of the steering wheel adjustment lever.
Press the steering wheel forward into the bottom position and angle it upward as far as possible.
Lock the steering wheel in position with the lever.
Remove:
- The battery
- The battery shelf
Remove:
- The return hose from the control system cover
- The delivery hose at the cooler quick-release coupling. Plug the hose and oil cooler openings with plastic plugs.
- The clamp for the battery negative cable/cable harness on the transmission or the sub-frame. Tie up the cable and harness.
Install:
The lift supports 999 5033 SUPPORT 999 5033 Support on fender edges.
Lifting beam 999 5006 LIFTING BAR 999 5006 Lifting Bar on the supports.
Lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook in the torque rod bracket. Tighten the lifting hook to relieve the load on the engine mountings.
Remove:
- Left front wheel
- The front splash guard. Remove both the screws. Press the splashguard forward to release the guide lug at its rear edge. Detach the front edge of the splashguard.
- The splash guard under the engine. (Early version.)
Undo the carbon filter container from the sub-frame
Cut off the tie strap for the hoses and hang the container in the car body. Unhook the hose from the sub-frame.
Draining oil
Drain the transmission oil. Install the plug with a new gasket
Tighten to: 40 Nm .
Warning! The oil may be extremely hot.
Remove:
- The steering gear nuts
- The screws for the oil pipe bracket
- The screw for the sub-frame-front engine mounting
- The screws securing the mounting for the torque rod on the transmission
- The screw securing the cable conduit to the front member of the sub-frame. Unhook the conduit from the sub-frame.
Right-hand drive models only:
Remove:
- Steering gear collision protection
- The nut for the collision protection-sub-frame.
Remove the control arm/ball joint from the wheel spindle (left side).
Pull the control arm down to expose the ball joint. Install protective socket 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket on the ball joint.
If the ball joint is difficult to insert in the wheel spindle, tap a chisel in the groove on the spindle.
Disconnect and unhook the links from the anti-roll bar (both sides).
Remove the screws from the sub-frame brackets on each side.
Removing the sub-frame
Remove the sub-frame from the car.
Position the mobile jack 999 5972 FIXTURE 999 5972 Fixture under the left-hand side of the sub-frame and raise it into light contact with the frame.
Unscrew the two screws between the frame and body (right side) 10-15 mm . Remove the screws on the left-hand side.
Note! All-wheel drive (AWD) = maximum 5 turns.
Right-hand drive models only:
Lower the sub-frame approximately 100 mm.
Ensure that the five steering gear screws and collision protection screw are clear of the frame.
Remove the screws for the anti-roll bar bearing cap on the left-hand side. Undo the screws on right-hand side until they are held by a short section of thread.
Tie up the anti-roll bar to the steering gear as illustrated.
Lower the sub-frame.
Note! Ensure that the steering gear and the collision protection release from the frame.
Lower the sub-frame to expose the control system cover.
Place a container underneath the transmission.
Remove the oil pipe.
Undo the tie strap securing oil temperature sensor cable, at point where cable is folded.
Pull out the cable and fold it to one side.
Remove the screws for the control system cover (Torx TX40).
Clean any sealing compound residue from the threads (M8x1.25).
Remove the cover.
Use tool 999 5477 JOINT WEDGE 999 5477 Joint Wedge and carefully tap it in between the cover and transmission so as not to bend the seal flange on the cover. Take care that the oil temperature sensor cables are not damaged.
Clean gasket residue from the cover and transmission. Use a scraper.
Note! Ensure that no debris gets into the transmission. Wash the cover thoroughly.
Preparations
Remove:
The connectors for the solenoid valve
The cable harness from the holders on the control system.
Note! Solenoid S1 and solenoid SL have two types of cable harness. See the following four operations.
Information, versions and combinations
Solenoid S1
There are two solenoid S1 variants: early types are connected to the cable harness from the right, later types are connected from the left.
Cable harness
There are two cable harness lengths, one shorter (early type) and one slightly longer (late type).
Combinations
The following combinations can occur:
- S1, early type cable harness, early type, illustration (see operation Solenoid S1 Replacing solenoid , Connecting cable harness )
- S1, early type - cable harness, late type, illustration (A)
- S1, late type - cable harness, late type, illustration (B).
Only the early versions of S1 and late versions of the cable harness are available as replacement parts, illustration A.
Solenoid SL
There are two Solenoid SL variants: early types are connected to the cable harness from the right and later types are connected from the left.
- Early version and replacement parts, illustration (C)
- Late versions, illustration (D).
SL is only available in the early version as a replacement part, illustration (C).
Checking resistance
Solenoids S1, S2, SL:
Measure between the pin in the solenoid connector and the transmission ground terminal.
Correct value: 10-15 ohms.
Solenoid STH:
Measure between the pins in the solenoid connector.
Correct value: 2-6 ohms.
If the solenoid resistances are correct:
Carry out preparations according to Inspecting/cable harness to solenoids Inspecting/Cable Harness To Solenoids.
Check the cable harness between the solenoids and the connector on the transmission according to Inspecting/cable harness to solenoids Inspecting/Cable Harness To Solenoids.
If solenoid S1, S2 or SL resistances are incorrect:
Replace the solenoid according to next operation.
If solenoid STH resistance is incorrect:
Replacing the control system assembly according to Control system, replacing Control System, Replacing. (Solenoid STH is calibrated together with the control system).
Replacing solenoid
Remove the screw for the solenoid (or the solenoid STH holder).
The illustration shows solenoid SL, S1 and cable harness, early version.
Remove the solenoids from the control system.
Install new solenoids.
Lubricate the solenoid O-rings (S1, S2, SL) with a little petroleum jelly. Install the solenoids Tighten the screws.
Tighten to: 10 Nm .
Installing the control system
Install the gear selector slide in the control system, located as illustrated.
Install new seals in the transmission.
Use petroleum jelly to hold the seals in position.
Install the control system in the transmission.
Locate the arm on the gear selector slide in the hole in the gear selector cam.
Install the screws. Note that screws are of different lengths (measured in mm).
Note! Tighten the screws alternately. Tighten to: 10 Nm.
Install the cover with a new gasket. Tighten to: 10 Nm .
Connecting cable harness
Connect the cable harness connectors to the solenoids.
The illustration shows solenoid SL, S1 and cable harness, early version. See Information, versions and combinations for late versions.
Wiring color codes:
Solenoid S1: white
Solenoid S2: black
Solenoid STH: blue and brown
Solenoid SL: red
Install the cable harness in the holders and check that it is correctly positioned.
Assembling the control system
Sealing the cover
Check that the cover mating surface is level.
Wipe the cleaned mating surfaces on the cover and transmission. Use denatured alcohol.
Note! Ensure that no dirt gets into the transmission.
Place an approximately 3 mm thick bead of sealing compound (P/N 11611409-6) on the cover. (P/N 11611409-6). Apply sealant around the screw holes.
Installing the cover
Reinstall the control system cover on the transmission.
Tighten the screws (Torx TX40) alternately.
Tighten to: 12 Nm .
Stretch the cable up to the oil temperature sensor.
Ensure that cable is correctly positioned. Fold the cable on top of the transmission and secure it with the tie strap.
Install the oil pipe.
Right-hand drive models only:
Raise the sub-frame approximately 100 mm from the body. Locate the steering gear and collision protection in the sub-frame. Install the anti-roll bar screws on the left-hand side. Tighten both bearing caps.
Tighten to: 50 Nm .
Installing the sub-frame
Reinstall the sub-frame.
Use new screws (4 x M14). Lubricate the screw threads.
Begin on the left-hand side.
Raise the sub-frame with the mobile jack.
Note! Carefully locate the steering gear screws in the holes in the sub-frame!
Install the screws for the sub-frame and the support plate. Tighten the sub-frame screws to 105 Nm +120° . Then tighten the sub-frame bracket screws to 50 Nm . Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Transfer the mobile jack to the right-hand side and repeat the procedure.
Remove the lifting hook, lifting beam and support rails.
Install:
The nuts for the steering gear (five). Use new nuts! Tighten to 50 Nm .
The screw for the sub-frame-front engine mounting. Tighten to: 50 Nm .
Right-hand drive models only:
The nut (A) for the collision protection-sub-frame. Tighten to: 50 Nm .
Install:
The torque rod mounting on the transmission. Tighten to: 35 Nm +40° .
Note! Early version M8 screw, 18 Nm +90°
Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Note! Use new screws.
- Both the oil pipe brackets. Tighten to: 25 Nm .
- The cable conduit on the sub-frame.
Right-hand drive models only:
Install the collision protection over the steering gear.
(2 screws) Tighten to: 80 Nm .
Install:
- The carbon filter container and the hose on the sub-frame. Clamp all hoses to the sub-frame with a tie strap.
- The splash guard under the engine. (Early version.)
- The front splash guard. Press into position at front. Press it forward and press upward at the rear so that guide is seated in the channel. Install the screws.
Installing the control arm/ball joint on the stub axle
Remove the protective socket 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket.
Note! Take care that the ball joint boot is not damaged.
Use a new lock nut on bolt. Tighten to: 50 Nm .
Reinstall the links on the anti-roll bar.
Use new locknuts. Tighten to: 50 Nm .
Installing the left front wheel
Lubricate the hub centering lug for the rim with rustproofing agent 1161030-0.
Tighten the screws lightly. Then tighten crosswise. Tighten to: 110 Nm .
Note! See also Tightening the wheel studs Service and Repair.
Install:
- The return oil hose on the control system cover.
- The inlet hose to the oil cooler quick-release coupling
- The clamp for the cable harness/battery cable on the control system cover
- The battery shelf
- The battery
Applies only when replacing the cable harness
Tighten the screws for the air cleaner (ACL) bracket.
Install the air cleaner (ACL) housing with inlet pipe and connections.
Checking the oil level
See Checking oil level Checking Oil Level.
Checking diagnostic trouble codes (DTCs)
Check and erase any diagnostic trouble codes (DTCs).
Note! After replacing the transmission, the transmission adaptation and the "Transmission oil change" counter must be reset. See Resetting the adaptation, AW55-50/51SN Resetting Adaptation.