Solenoid Valves

Solenoids, Checking/Replacement
Special tool: 9995477

NOTE: Cleanliness is extremely important when working on automatic transmissions. Clean around the filler tube and drain plug. Always use clean containers and ensure that the workplace is free of dust and dirt.

Resistance Measurement
- Disconnect battery ground lead.
- Remove plug and drain fluid from pan.

Caution: Fluid may be extremely hot if car has recently been driven.

- Disconnect HO2S lead clips from pan.





- Remove pan.
- Remove fluid dipstick screws.
- Remove pan mounting bolts.
- Tap in blade of joint wedge 999 5477 all around joint between transmission housing and pan.

NOTE: Take care to avoid damage to pan flange.

CAUTION: Risk of fluid spillage, pan may contain residual fluid.





- Detach cable bracket from control system, and solenoid connectors from solenoids.
- Remove screws (two) and bracket.
- Detach connectors from solenoids.
- Open solenoid connectors on transmission.





- Check resistance of solenoid leads.
- Connect between transmission connector and end of each solenoid lead. Shake wiring gently during measurement to locate any points of loose contact.
- Instrument should indicate 0 ohm.





Replacing Solenoid Wiring Harness





- Figures in illustration denote solenoid connections as shown in table.
- When replacing wiring harness, remove cable bracket on transmission housing.
- Reconnect connector at transmission after checking and replacing wiring harness.





Checking Resistance Of Solenoids S1, S2 And SL
- Connect ohmmeter between solenoid S1 connector pin and ground terminal on transmission. Instrument should indicate 10 - 15 ohm.
- Repeat measurement for solenoids S2 and SL. Instrument should indicate 10 - 15 ohm.
- Solenoid in question must be replaced if instrument indicates different value in any of above measurements.





Check Resistance Of Solenoid STH
- Connect ohmmeter between two pins in solenoid connector. Instrument should indicate 2 - 6 ohm.
- Solenoid must be replaced if instrument indicates different value.
Replacement Of Solenoids





Removing solenoids S1 and S2
- Remove solenoid retainer.
- Withdraw solenoids S1 and S2 from control system.





Removing Solenoids SL and STH
- Remove fluid strainer (3 screws).
- Remove solenoid retainer.
- Withdraw solenoids SL and STH from control system.
- Install new solenoids SL and STH.
- Install solenoids SL and STH complete with retainer and screws. Tighten to 10 Nm (7.5 ft lb).





- Clean fluid strainer carefully
- Inspect strainer and seals. If required, replace strainer and seals as a unit.
- Install strainer.
- Tighten screws to 10 Nm (7.5 ft lb).





Installing New Solenoids S1 And S2
- Lubricate new solenoid 0-rings lightly with Vaseline. Install solenoids S1 and S2 with common screw. Tighten to 10 Nm (7.5 ft lb).





- Install solenoid leads and wiring harness bracket.
- Install solenoid connectors (four). Connect gray wiring connector to gray solenoid connector (solenoid SL.)
- Of remaining connectors, one has two pins and fits solenoid STH only. Location of last two connectors is clear from length of wiring (solenoids S1 and S2.)
- Install bracket with two screws. Tighten to 10 Nm (7.5 ft lb).

Installing Fluid Pan
- Clean remains of gasket from fluid pan and transmission sealing faces. Use bakelite scraper.
- Clean sealing faces with methylated spirits.





- Install particle magnets (four) in fluid pan recesses as shown.
- Apply liquid sealing compound (liquid gasket), P/N 1161409-6, to parts as illustrated. Apply bead approx. 3 mm thick to faces and around screw holes.





- Install and tighten fluid pan and dipstick screws diagonally to 7 Nm (5 ft lb).
- Install drain plug with new seal.
- Tighten to 20 Nm (15 ft lb).
- Clip HO2S lead to fluid pan.
- Fill system with fresh fluid. Grade of fluid: ATF fluid that complies with the specifications for Dexron II E and Ford Mercon or Dexron III and Ford Mercon.
- Reconnect battery ground lead.
- Erase DTCs.