Shift Solenoid Inspection/Replacement

SPECIAL TOOLS:
- Lifting frame tool No. 999 5006, or equivalent
- Support rails tool No. 999 5033, or equivalent
- Lifting hook tool No. 999 5460, or equivalent
- Separator tool No. 999 5477, or equivalent
- Protective Sleeve tool No. 999 5562, or equivalent
- Mobile Jack tool No. 998 5972, or equivalent
- Tool No. 998 8670, or equivalent
- Protractor tool No. 951 2050, or equivalent

- Refer to special tool section for additional tool information. Tools and Equipment

PROCEDURE
1. Opening of control system

NOTE:
- Cleanliness is extremely important when working on automatic transmissions.
- Before starting work:
- Before commencing work, clean the transmission and surrounding area, and ensure that the workplace is free of dust and dirt.
- Components should preferably be dried with compressed air.
- Rags or waste which leave lint or threads must not be used under any circumstances:
- Avoid skin contact with transmission fluid:
- Fluid grade: ATF fluid meeting both Dexron IIE and Ford Mercon specifications.





2. Adjust steering wheel position
- Slacken wheel adjusting lever.
- Press wheel forward into bottom position and angle upward as far as possible.
- Lock wheel in position with lever.





3. Remove:
- Battery
- Battery shelf
- Return hose from control system cover
- Delivery hose at cooler quick-release coupling Plug hose and oil cooler openings with plastic plugs.
- Cable clamp retaining battery negative lead/cable harness on the transmission or sub-frame.
Tie up lead and harness.





4. Install:
- Support rails tool No. 999 5033, or equivalent, on fender edges.
- Lifting frame tool No. 999 5006, or equivalent, on support.
- Lifting hook tool No. 999 5460, or equivalent, in torque rod bracket.
Pull on hook to relieve load on engine mountings.





5. Remove:
- Left front wheel.
- Front splashguard.
Remove both bolts and press splashguard forward sufficiently to release guide spigot at rear edge.
Free splashguard at front edge.
- Splashguard under engine. (Early type).
- Unbolt EVAP canister holder from sub-frame
Cut tie securing hoses and hang canister on body.
Unhook hose from sub-frame.
6. Oil, drain
- Drain transmission oil.
Reinstall plug with new seal
Tighten to: 40 Nm.

WARNING: Oil may be extremely hot.





7. Remove:
- Steering gear nuts oil pipe bracket screw
- Bolt securing front engine mounting to sub-frame
- Bolts securing torque rod support on transmission
- Screw securing cable conduit to front member of sub-frame.
Unhook conduit from frame.





8. On right-hand drive models:
- Remove:
Steering gear crash guard
Crash guard/sub-frame nut





9. Remove:
- Remove link/ball joint from wheel spindle (left side).
- Pull down link to expose ball joint. Install protective sleeve 999 5562 on ball joint.
- If the ball joint is difficult to insert in the wheel spindle tap a chisel in the groove on the spindle.
- Disconnect links from anti-roll bar on each side.
- Remove sub-frame support plate bolts on each side.





10. Removal of sub-frame
- Remove sub-frame from car.
- Position hoist tool No. 998 5972, or equivalent, under sub-frame on left-hand side and raise sufficiently to support frame.
- Unscrew bolts (two) between frame and body on righthand side by 1-15 mm (0.4"-0.6 inch).
- Remove bolts on left-hand side.





11. On right-hand drive models:
- Lower sub-frame approx. 100 mm (4 inch).
- Ensure that steering gear studs (five) and crash guard plate studs are clear of frame.
- Remove bolts in anti-roll bar bearing cap on left-hand side.
- Slacken bolts on right-hand side until held by just a few threads.





12. Lower sub-frame.

NOTE: Ensure that steering gear and guard plate are separated from frame.

- Lower sub-frame to expose control system housing.





13. Removal:
- Place container underneath transmission.
- Remove oil pipe.
- Undo clip securing oil temperature sensor cable, at point where cable is folded.
- Pull out cable and place to one side.





14. Removal:
- Remove control system cover screws (Torx TX40)
- Clean sealing compound residue from threads (8 x 1.25 mm).
- Remove cover.
- Use separator tool No. 999 5477, or equivalent.
Tap tool carefully into joint between cover and transmission to ensure that cover sealing flange is not distorted.
Take care to ensure that oil temperature sensor cables are not damaged.
- Remove remains of gasket from cover and transmission joint faces
Use scraper.

NOTE:
- Ensure that no debris enter transmission.
- Wash cover thoroughly.





15. Preparation
- Remove:
Solenoid valve connectors.
Unclip wiring harness from clips on control system.

NOTE:
- Solenoid S1 and solenoid S2 have two types of cable harness
- See the following operations.


16. Information, performance and combinations








- Solenoid S1
Solenoid S1 is in two variants:
Early types with the connection to the cable harness from the right
Later types with the connection from the left.
- Cable harness
The cable harness can be in two lengths:
One shorter (early type)
One slightly longer (late type).
17. Combinations
- The following combinations can occur:
Solenoid S1, early type/cable harness, early type
Solenoid S1, early type/cable harness, late type
Illustration (A)
Solenoid 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).








18. Solenoid SL
- Solenoid SL is in two variants:
Early types with the connection to the cable harness from the right
Later types with the connection from the left.
- Early version and replacement parts
Illustration (C).
- Late versions
Illustration (D).
- Solenoid SL is only available in the early version as a replacement part
Illustration (C).





19. Checking resistance
- Solenoids S1, S2, SL:
Measure resistance between pin in solenoid connector and transmission ground terminal.
The correct resistance should be: 10-15 ohms
- Solenoid STH:
Measure resistance between pins in solenoid connector.
The correct resistance should be: 2-6 ohms
20. If solenoid resistances are correct:
- Perform preparations as per step 2 of Solenoid Wire Harness Inspection/Replacement. Service and Repair
- Check wiring harness between solenoids and-connector on transmission as per step 3 of Solenoid Wire Harness Inspection/Replacement. Service and Repair.
- If solenoid S1, S2 or SL value is incorrect:
Replace solenoid as outlined in the following steps.
- If solenoid STH value is incorrect:
Replace complete control system as per step 2 of Control System Replacement. Service and Repair
(Solenoid STH is calibrated together with the control system).





21. Replacing solenoid
- Remove solenoid retaining screws
- The illustration shows solenoids SL, S1 and cable harness, early version.
- Remove solenoids from control system.
- Install new solenoids.
- Lubricate solenoid O-rings (S1, S2, SL) with a little Vaseline.
Install solenoids and tighten screws to: 10 Nm





22. Reinstallation of control system
- Reinstall gear selector slide in control system as illustrated.
- Install new seals in transmission.
Use Vaseline to hold seals in position.





23. Install control system in transmission.
- Insert arm on gear selector slide in hole in gear selector cam.
- Install screws.
Note that screws are of different lengths (measured in mm. see illustration).

NOTE:
- Tighten screws alternately.
- Tighten to: 10 Nm

- Install cover with new gasket.
Tighten to: 10 Nm





24. Connection of wiring harness
- Connect wiring harness connectors to solenoids.
- The illustration shows solenoids SL, S1 and cable harness, early version
Refer to illustrations for steps 16 through 18 for late version.
- Wiring color codes:
Solenoid S1 white
Solenoid S2 black
Solenoid STH blue/brown
Solenoid SL red
- Reinstall cable harness and check that harness is correctly positioned.





25. Assembling of control system
- Tightening of cover
Check that cover mating surface is level.
Wipe cleaned joint faces on cover and transmission with methylated spirits.

NOTE: Ensure that no dirt enters the transmission.

Place approx. 3 mm (0.12 inch) thick bead of sealing compound part No. 11611409-6, or equivalent, on cover.
Also coat face around screw holes.





26. Reinstallation of oil cover
- Reinstall control system cover on transmission.
Tighten screws (Torx TX40) diagonally to: 12 Nm
Stretch cable up to oil temperature sensor.
Ensure that cable is correctly positioned.
Fold cable on top of transmission and secure with clamp.
Install oil pipe.





27. On right-hand drive models:
- Raise sub-frame to approx. 100 mm (4 inch) from the body.
- Position steering gear and guard plate in sub-frame.
- Install anti-roll bar bolts on left-hand side and tighten both bearing caps to: 50 Nm





28. Reinstallation of sub-frame
- Reinstall sub-frame.
- Use new bolts (4 x 14 mm).
Lubricate bolt threads.
- Commence on left-hand side.
- Raise sub-frame on hoist.

NOTE: Ensure that steering gear studs are located in holes in sub-frame!

- Install frame and support plate bolts.
- Tighten sub-frame bolts first to 105 Nm +120° and then support plate bolts to 50 Nm.
Use protractor gauge tool No. 951 2050, or equivalent.
- Transfer hoist to right-hand side and repeat procedure.





29. Remove liking hook, liking beam and support rails.
- Install:
Steering gear nuts (five).
Use new nuts!
Tighten to: 50 Nm
Bolt securing front engine mounting to sub-frame.
Tighten to: 50 Nm
- On right-hand drive models:
Guard plate/subframe nut (A).
Tighten to: 50 Nm





30. Install:
- Torque rod support in transmission.
Tighten later version to: 35 Nm + 40°.
- Tighten early version with 8 mm screw to: 18 Nm + 90°
Use protractor gauge tool No. 951 2050, or equivalent.

NOTE: Use new bolts.

- Both oil pipe brackets.
Tighten to: 25 Nm
- Cable conduit on sub-frame.





31. On right-hand drive models:
- Install steering gear guard plate.
Tighten the two bolts to: 80 Nm





32. Install:
- EVAP canister holder and hose on sub-frame.
Clip all hoses to frame with a band clamp.
- Splash-guard under engine. (Early type)
- The front cover.
Press into position at front.
Press forward and press upward at rear so that guide spigot is seated in slot.
Install screws.





33. Reinstallation of link/ball joint to wheel spindle
- Remove protective sleeve.

NOTE: Take care that the ball joint boot is not damaged.

- Use new lock nut on bolt.
Tighten to: 50 Nm
- Reinstall links to anti-roll bar.
- Use new lock nuts.
Tighten to: 50 Nm





34. Installation of left front wheel
- Lubricate the hub guide for the rim with rust inhibitor part No. 1161030-0, or equivalent.
- Tighten the studs lightly.
Tighten alternately to: 110 Nm





35. Install:
- Return oil hose to control system cover
- Inlet hose to oil cooler quick-release coupling
- Wiring harness/battery lead clip on control system cover
- Battery shelf
- Battery
36. Applies only when replacing wiring harness:
- Tighten air cleaner bracket screws.
Install air cleaner with inlet pipe and connections.





36. Checking oil level
- See Checking/Adjusting Oil Level. Testing and Inspection
38. Checking DTCs
- Use a suitable scan tool to check for and erase any Diagnostic Trouble Codes (DTCs). [1][2][3]Initial Inspection and Diagnostic Overview