Shift Solenoid: Service and Repair
Solenoid control system, replacing
Special tools:
999 5716 Reading off tool 999 5716 Reading Off Tool
999 5460 Lifting hook 999 5460 Lifting Hook
999 5477 JOINT WEDGE 999 5477 Joint Wedge
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
Replacing and checking solenoids
Note! The operations which affect the cable harness and connectors and mountings for the control system solenoids must not be carried out when replacing the solenoids or the control system.
Removing the control system cover
Cleaning
Carry out an engine wash. Then open the expansion tank cap.
Raise the vehicle.
Note! Position the front lift arms so that they do not obstruct the sub-frame support plates.
Remove:
- the splash guard under the engine
- both the screws for the front splash guard. Press in the catches at the front edge of the cover. Pull the cover backwards.
Place a container underneath the transmission.
Drain the oil. Measure and note the volume of oil.
Install the plug. Tighten. See
Remove the cable harness clamp on the control system cover.
Disconnect the oil cooler return line from the control system cover.
Disconnect the screws for the oil cooler pipe from the transmission. Move the pipe to one side.
Seal the hole in the transmission with a plastic plug.
Position a container under the radiator drain cock. Drain the engine coolant.
Note! Avoid skin contact with the coolant.
Close the nipple.
Disconnect the lower hose for the radiator to provide more space for removing the control system cover.
Remove:
- the screw for the front engine pad and the sub-frame
- the screw for the ground lead bracket.
Note! Applies only to cars with parking heaters:
Remove the 3 screws from the heater on the sub-frame.
Hang or tie up the heater on the left front fender.
Unhook the fuel line from its mountings in the sub-frame.
Lower the vehicle.
Install 999 5716 Reading off tool 999 5716 Reading Off Tool directly above the engine lifting eye. Position the lifting beam brackets as illustrated.
Connect: 999 5460 Lifting hook 999 5460 Lifting Hook to the lifting eye at the rear edge of the engine. Raise the rear edge of the engine 20 mm.
Raise the vehicle.
Slacken off the front mounting screws on the sub-frame.
Remove the left-hand screw.
Unscrew the right-hand screw until it is secured by approximately 5 threads.
Slacken off the rear mounting screw on the left-hand side. Unscrew it approximately two turns.
Insert a spacer between the bodywork and the sub-frame at the front left-hand mounting. There must be a distance of approximately 55 mm.
Cleaning
Use compressed air to blow clean the area around the control system cover. Carefully clean the sub-frame by the cover to prevent dirt entering the transmission.
Remove the screws for the control system cover.
Clean any sealing compound from the threads. Use a tap, M8x1.25.
Detach the cover. Use: 999 5477 JOINT WEDGE 999 5477 Joint Wedge. Carefully tap it in between the cover and transmission so as not to bend the seal flange on the cover.
Slide the cover between the sub-frame and the bodywork. Remove the cover.
Clean the gasket residue from the cover and the transmission.
Note! Wash the cover thoroughly. Ensure that no debris enters the transmission.
Disconnecting the connectors
Disconnect the connectors from the solenoids.
Check the resistance in S1-S5
Location Of Components (Solenoids):
Note! Readings should be taken at approximately 20°C.
Solenoid S1
Measure the resistance between the pin in the solenoid connector and the transmission ground terminal.
Correct value: 12-16 ohms.
Solenoids S2-S5
Measure the resistance between the pin in the solenoid connector and the transmission ground terminal.
Correct value: 11-15 ohms.
If the resistance of any of solenoids S1-S5 is incorrect
Replace the solenoid. See Replacing solenoids S1-S5.
Checking the resistance of SLT, SLS and SLU
Location Of Components (Solenoids):
Note! Readings should be taken at approximately 20°C.
Solenoid SLT, SLS and SLU
Measure the resistance between both the pins in the solenoid connector.
Correct value: 5.0-5.6 ohms.
If the value of any of solenoids SLT, SLS and SLU is incorrect
Replace the control system. See Replacing the control system.
The control system is calibrated together with the solenoids.
Replacing solenoids S1-S5
Location Of Components (Solenoids):
Remove the screw from the solenoid. Remove the solenoid from the control system.
Lubricate the O-ring on the new solenoid. Use automatic transmission fluid.
Install the solenoid. Tighten the screw. Tighten to 7 Nm .
Finishing
Connect the connectors to the solenoids.
Installing the control system cover
Check that the mating surface for the cover is level.
Wipe the cleaned mating surfaces on the cover and transmission.
Note! Ensure that no dirt gets into the transmission.
Apply a bead of sealing compound, approximately 3 mm thick, to the cover.
Also apply sealing compound around the screw holes.
Reinstall the control system cover on the transmission. Tighten. See:.
Stretch the cable up to the oil temperature sensor.
Install:
- the oil pipe on the transmission. Use a new O-ring
- the return line to the control system cover
- the cable harness to the holder on the cover.
Remove the spacer. Install new screws, M14, in the sub-frame. Lubricate the threads. Tighten. See:.
Install:
- the screw for the front engine pad. Tighten to 50 Nm
- the holder for the ground lead.
Applies only to cars with parking heaters:
Install the heater on the sub-frame.
Install the fuel line for the heater in the holders on the sub-frame.
Install the radiator hose.
Install:
- the front splash guard
- the splash guard under the engine.
Lower the vehicle.
Remove the lifting beams and hooks from the engine
Fill with new oil to the volume previously noted.
Top up and check the oil level. See:.
Note! When replacing the transmission oil, the transmission oil replacement counter must be reset. See: Transmission fluid, replacing .
Top up the coolant.
Check any diagnostic trouble codes (DTCs).
Replacing the control system
Preparations
Remove. See: Removing the control system cover.
Remove:
- the connectors for the solenoid valves
- the screw for the oil temperature sensor holder. Remove the sensor from the control system
- the cable harness from the holders on the control system.
Push the cable harness to one side.
Removing the control system
Remove the screws from the control system. Remove the cover from the transmission.
Note! Ensure that there are no cracks on the top of the lever for the gear selector slider.
Replacing sealing rings
Remove the sealing rings from the transmission.
Note! Ensure that no debris enters the transmission.
Install new seals in the transmission
Use petroleum jelly to hold the seals in position.
Checking the gear selector slider
Check that the lever for the gear selector slider is correctly positioned.
Installing the control system
Note! Ensure the lever for the gear selector is set to neutral.
Align the control system on the lever for the gear selector.
Install:
- the screws for the control system
- a new gasket for the cover on the control system. Note that the screws are of different lengths (measured in mm).
Lightly tighten the screws alternately. Then tighten alternately. Tighten to 10 Nm .
Finishing
Install the cable harness. Connect the connectors to the solenoids.
Install the oil temperature sensor with the holder and the screw. Note that the length of the screw is given in mm. Tighten to 10 Nm .
Install the cable harness on the holder. Check that the cable harness is correctly positioned.
Reinstall. See: Installing the control system cover.