Inspecting/Cable Harness To Solenoids

Inspecting / replacing the cable harness for the solenoids

Special tools:
999 5475 GAUGE 999 5475 Gauge

Preparations




Remove:
- The battery
- The air cleaner (ACL) housing assembly, see Replacing the air cleaner (ACL) Replacing Air Cleaner (ACL).
- The battery shelf
- Separate the 6--pin connector for the cable harness.
- Slacken off the cap nut for the oil pipe on the control system cover.

Preparations, continued




Raise the car.
Drain the transmission oil. Install the oil drain plug. Use a new sealing ring.
Torque: 40 Nm.
Disconnect the oil pipes. Push them to one side.
Seal all openings with plastic plugs.

Opening the control system




Remove the Torx TX40 screws for the control system cover.
Remove the cover.
Use tool 999 5477 JOINT WEDGE 999 5477 Joint Wedge. Tap the tool carefully into the joint between the cover and the transmission to ensure that the cover sealing flange is not distorted. Take care not to damage the oil temperature sensor cables.
Clean the gasket residue from the cover and the transmission. Use a scraper.

Note! Ensure that no debris enters the transmission. Wash the cover thoroughly.

Disconnecting connections




Disconnect the connectors for the solenoid valves (S1, S2, SL, STH).
Remove the cable harness from the holders on the control system.

Checking the cable harness




Use an ohmmeter to measure the resistance between the transmission connector and the end of the appropriate solenoid cable. Shake the harness gently during the measurement to identify any possible loose connections. The ohmmeter should read approximately 0 ohms.





Replace the cable harness if the ohmmeter displays any other value. See Removing the cable harness and Connecting the cable harness to the control system.

Removing the gear-shift position sensor




Remove:
- The transmission cable from the lever
- The lever
- The nut, the locking washer and the rubber washer for the gear shift linkage rod
- The dip stick pipe. Lift up the pipe and turn it to one side.
- The mounting screws for the gear-shift position sensor (two)
Carefully lift the sensor from the gear shift linkage rod.

Caution! If the metal tongue on the gear-shift position sensor gets stuck on the transmission cable bracket: Remove the bracket and put it to one side.

Removing the cable harness




Remove the holder / spacer for the cable harness grommet in the transmission.
Remove the cable harness grommet from the transmission.
Remove the cable harness from the transmission.

Connecting the cable harness to the control system




Install the new cable harness with grommet and an O-ring. Connect the connectors to the solenoids.
Connector / cable colors:
Solenoid S1: White / white
Solenoid S2: black / black
Solenoid SL: black / yellow
Solenoid STH: black / brown, blue
Install the cable harness in the holders. Check that it is correctly positioned.

Installing the cover




Install the control system cover according to Replacing control system, AW50-42 Service and Repair and Replacing control system, AW50-42 Service and Repair.

Connecting the cable harness




Install and connect the cable harness connector to the bracket.
Ensure that the cable harness is correctly positioned.
Clamp the cable harness with tie straps.

Installing / adjusting the gear position sensor




Install:
- The holder / spacer on the cable harness grommet.
- The screws for the holder / gear-shift position sensor. Do not tighten the screws.
- The rubber washer, the lock washer and the nut for the gear shift linkage rod. Lock the nut with the washer.
Adjust the gear-shift position sensor according to Checking and adjusting the gear-shift position sensor, AW50-42 Adjustments.

Installing components




Install:
- The dip stick pipe. Ensure that the O-ring is in position. Tighten the nut
Torque: 25 Nm
- The lever on the gear shift linkage rod.
Torque: 16 Nm
- The transmission cable on the lever with a washer and retaining clip. Apply a small amount of grease (P/N 1161241- 3) to the lever shaft journal.
If the transmission cable is removed it must be adjusted according to Adjusting the transmission cable Adjusting The Transmission Cable.

Installing other components




Tighten the oil pipe cap nut on the control system cover.
Install:
- The air cleaner (ACL) housing assembly, see Replacing the air cleaner (ACL) Replacing Air Cleaner (ACL).
- The battery shelf
- The battery

Filling and checking oil
Top up the transmission with oil. Check the level according to Checking oil level, AW50-42 Checking Oil Level.

Checking diagnostic trouble codes (DTCs)
Check and erase any diagnostic trouble codes (DTCs).