Solenoid Wire Harness 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

1. Preparation
- Refer to steps 1 through 14 of Open The Control System. Service and Repair

Inspection/Replacement Of Wiring Harness





2. Preparation
- Remove:
ACL complete with inlet pipe.
ACL bracket.
- Disconnect transmission connector.
Remember rubber seal.





3. Checking of wiring harness
- Use ohmmeter to measure resistance between transmission connector and end of appropriate solenoid cable.
Shake harness gently during measurement to locate possible loose connections.
The ohmmeter should indicate 0 ohms.
- Connector Pin/Wire Color Codes
Pin No: 21
Solenoid/Color: S1/white
Pin No: 22
Solenoid/Color: S2/black
Pin No: 23
Solenoid/Color: SL/red
Pin No: 24
Solenoid/Color: STH/brown
Pin No: 25
Solenoid/Color: STH, ground/blue
- Replace with new harness as described below if ohmmeter indicates value other than 0.





4. Removal of wiring harness
- Remove:
Gear selector cable
Lever
Gear position sensor screw and retainer for harness gland.





5. Demounting of connector
- Remove:
Connector screws
Retainer for grommet for wiring in transmission.
- Remove sockets from connector housing.
- Remove rubber seal from connector.
Insert screwdriver between casing and socket and press catch in.
At the same time slide the sockets out of the casing.





6. Demounting of connector
- Remove socket for wiring to solenoids (5-pin socket).
- Free wiring harness from transmission/control system.





7. Reinstallation of wiring harness
- Install new wiring harness with grommet and O-ring.
- Reconnect solenoid connectors.
- The illustration shows solenoid SL, S1 and cable harness, early version.
See steps 16 through 18 of Shift Solenoid Inspection/Replacement for late version. [1][2]Procedures
- Wiring color codes:
Solenoid S1 white
Solenoid S2 black
Solenoid STH blue/brown
Solenoid SL red
- Reinstall cable harness in retainer and check that harness is correctly positioned.





8. Install:
- Retainer to cable harness grommet.
- Gear position sensor bracket screw.
- Selector lever.
Tighten to: 16 Nm.
- Gear selector cable with washer and retaining clip.
Apply grease part No. 1161241-3, or equivalent, sparingly to lever arm pin.





9. Reinstallation of connector.
- Reinstall sockets to connector.
- Reconnect connector halves.
- Ensure that rubber sleeve is in position.
- Secure harness and rubber sleeve with cable ties.
- Reinstall connector on transmission.
- Reconnect connector.
- Remember rubber seal.
10. Finishing work
- Install control system.
Refer to steps 22 through 38 of Open The Control System. Service and Repair