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'90 240 will not shift to 4th gear. 200

posted by  paganm1255 on  Sat Dec 29 12:13 CST 2012
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last visit: Sun Dec 30 17:27 CST 2012
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1990 240DL AW70 4-speed automatic transmission w/OverDrive(OD). 189K. I am 2nd owner since 1995 at 41K. This is now my daughter's daily driver. I had opportunity to drive it on 12/27 (first time I have driven it in 6-8 weeks and noticed the car does not shift from 3rd to 4th gear. My daughter drives locally so really has no occasion to drive over 45-50 mph, or for extended periods of time/miles (trips less than 10 mi one way. She said it's been "doing that" for several weeks, probably for the last few hundred miles. So, yesterday I removed the transmission pan and replaced the screen/filter and the transmission fluid, and added about 8oz of Sea Foam "Trans Tune" and took it for a 12-15 mile test drive to let it warm up, not exceeding 50 mph. It still does not shift from 3rd to 4th gear. All other gear selections work fine when I shift manually (P, R, 1, 2, D, N). All gears shift automatically smoothly: 2nd at about 15 mph, 3rd at about 25-30 mph. The car would usually shift to 4th just past 40 mph, but no longer does so. It just hangs in 3rd gear even to speeds up to 50 mph. Letting up on the accelerator after achieving 40+mph does not cause it to shift. "Kick-down" cable is fine and the transmission downshifts when I sharply depress the acccelerator. OD button switches on-off w/orange arrow as usual, however it does not "down-shift". I assume this is because the car needs to be in high (4th)gear in order for the OD switch to command the down-shift. Would appreciate any advice on what is causing this and what I can do to remedy and get 4th gear operational again.
(BTW: My daughter reminded me that she "told" me the car "sounded loud" back when this all started (but she never made comment to me about shifting). She said "You know,Dad, if the car had a tachometer, I would have known right away it was related to the transmission." (That's my girl.)
Thanks again. Marc







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    '90 240 will not shift to 4th gear. 200

    posted by  chup on  Sat Dec 29 17:39 CST 2012
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    last visit: Tue Sep 9 14:02 CST 2014
    [RELATED]

    Make sure the kickdown cable is functioning properly. It should be sliding in and out of its sheithing smoothly.








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      '90 240 will not shift to 4th gear. 200

      posted by  paganm1255 on  Sat Dec 29 20:15 CST 2012
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      last visit: Sun Dec 30 17:27 CST 2012
      [RELATED]

      Thanks for the tip. I checked and the kickdown cable is functioning smoothly and properly.








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        '90 240 will not shift to 4th gear. 200

        posted by  stoney on  Sun Dec 30 06:25 CST 2012
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        last visit: Wed Oct 22 17:48 CST 2014
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        Double check the wiring where it comes out of the bottom of the shifter stalk. This is a know olace for wire chafing and the short that results can mimic a ground and the relay will trip and say I' working.

        Check the fluid level, one thing not listed in your troublrshoot list posted, this can cause a funky OD/Solenoid issue.

        Does sound like the OD Solenoid though.








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          '90 240 will not shift to 4th gear. 200

          posted by  paganm1255 on  Sun Dec 30 16:35 CST 2012
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          last visit: Sun Dec 30 17:27 CST 2012
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          Thanks for your tips. I checked and found no wire chaffing at the base of the shifter stalk. Also just changed ATF, screen, gasket, and pan gasket as part of this advetnure (needed to do it anyway). Fuid level is good.

          The problem turned out to be the white solenoid wire was broken. About an inch of the insulation had toasted away over time as it rubbed against the top of the transmission housing. The bare wire chaffed until the last strand broke. I unplugged it (the remaining insulation disintegrated in my fingrs) and replaced it with a plug and wire from an old 240 wiring harness I keep on hand for just such needs. Fed it up through the gromet in the gear selector box and joined the ends. Test drove with excellent results; fully functional again.

          Thanks fellow brickboarders for your advice and sharing of resources.
          Marc








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            '90 240 will not shift to 4th gear. 200

            posted by  Onkel Udo II on  Sun Dec 30 16:40 CST 2012
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            last visit: Fri Oct 24 08:50 CST 2014
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            For me, second most common cause of failure for the OD. That being said, belt and suspenders are in order. Coat said wire with a protective loom or acres of liquid electrical tape while it is still clean enough to do so.








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              '90 240 will not shift to 4th gear. 200

              posted by  paganm1255 on  Sun Dec 30 17:24 CST 2012
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              last visit: Sun Dec 30 17:27 CST 2012
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              One step ahead of you my friend; slid said 14 guage replacement wire through about a 8 guage protective sleeve from grommet to plug. Then wrapped the connector plug in corrugated plastic tubing, electrical taped the ends. All is now well protected.








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              '90 240 will not shift to 4th gear. 200

              posted by  pageda on  Sun Dec 30 16:46 CST 2012
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              last visit: Fri Oct 24 13:18 CST 2014
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              It happened to me once, the insulation was gone and the wire shorted to the transmission. I sleeved the bare wire and it is still running fine.
              Dan








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          '90 240 will not shift to 4th gear. 200

          posted by  jwalker on  Sun Dec 30 08:01 CST 2012
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          last visit: Fri Jun 6 08:39 CST 2014
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          I agree. Do recheck the wiring. It is a lot cheaper and easier than a solenoid. That is the exact location where the wiring on my 1990 went bad. The shifter tunnel lip does it in. Look for corrosion there too.
          --
          95 855 GLT Sportwagon 214k, sold - 90 244 DL 300k








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            '90 240 will not shift to 4th gear. 200

            posted by  stoney on  Sun Dec 30 09:22 CST 2012
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            last visit: Wed Oct 22 17:48 CST 2014
            [RELATED]

            I actually usd a section of gas line hose to line the bottom of the shifter tube so I didn't have to do this twice.








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    '90 240 will not shift to 4th gear. 200

    posted by  trichard on  Sat Dec 29 12:30 CST 2012
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    last visit: Fri Oct 24 05:52 CST 2014
    [RELATED]

    4 factors can cause this

    1. the od relay is bad
    2. the od switch on the shifter is bad
    3. the wiring to thew od solenoid has broken
    4. the od solenoid has failed.

    when you switch the orange light ON do you hear a faint click in the glove box area? yes means the relay is good. so go to # 3 and or 4
    if you do not hear a click replace or resolder the relay and retest.







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      '90 240 will not shift to 4th gear. 200

      posted by  paganm1255 on  Sat Dec 29 17:59 CST 2012
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      last visit: Sun Dec 30 17:27 CST 2012
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      Thanks for the tips. I removed glove box located the relay and took her for a test drive;
      1. When I switch the orange light ON while driving, I hear a click; same when I switch light OFF. To be sure, I swapped out with spare od relay I happened to have. Same result, clicks orange light "ON" and clicks light "OFF" with no change in gear shifting.
      2. I believe the od switch on the shift lever to be good because it turns the relay & light on/off.
      3. I jacked the car and inspected the od selenoid. The wiring looks good from the solenoid as it goes up over the transmission. I used a mirror and flashlight to view over the top and everything I looked OK for as far as I could "see" the wire. No cracked/broken/grounded wire. Where does that wire go/connect? Where should I trace/follow it to?
      4. The od solenoid does have a diagonal crack on the side of the black plastic dome. I don't know how long it has been like that.
      5. Also replaced the #11 16A fuse in the fuse box, just to be sure.

      Next steps?







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        '90 240 will not shift to 4th gear. 200

        posted by  pageda on  Sat Dec 29 18:11 CST 2012
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        last visit: Fri Oct 24 13:18 CST 2014
        [RELATED]

        Now you need to see if power is going to the solenoid, if it is you will need to replace it.

        But first check the 700 / 900 FAQ's.

        http://www.brickboard.com/FAQ/700-900/TransmissionAuto.htm#OverdriveRelay

        Dan








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          '90 240 will not shift to 4th gear. 200

          posted by  paganm1255 on  Sat Dec 29 20:18 CST 2012
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          last visit: Sun Dec 30 17:27 CST 2012
          [RELATED]

          I followed your link to the OverdriveRelay FAQ and reviewed it this evening. Good prep for more trouble-shooting tomorrow. I need to verify whether the solenoid is getting power.








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      '90 240 will not shift to 4th gear. 200

      posted by  pageda on  Sat Dec 29 13:21 CST 2012
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      last visit: Fri Oct 24 13:18 CST 2014
      [RELATED]

      The transmission is 3 speed unless the overdrive is working. Check items as trichard suggested.

      Also check the fuse and make sure the white wire going to the solenoid is not shorted out against the transmission or body.
      Dan







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        '90 240 will not shift to 4th gear. 200

        posted by  paganm1255 on  Sat Dec 29 17:23 CST 2012
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        last visit: Sun Dec 30 17:27 CST 2012
        [RELATED]

        Thanks for the clarification. I checked the #11 16A fuse and it is not blown. To be sure, I cleaned the holder and replaced with a new 16A fuse. Same symptoms persist.
        Marc








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          '90 240 will not shift to 4th gear. 200

          posted by  pageda on  Sat Dec 29 17:44 CST 2012
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          last visit: Fri Oct 24 13:18 CST 2014
          [RELATED]

          I would check the relay, when you push the OD button you should hear the relay click? If it does not replace or re-solder the circuit board on the relay.
          Dan








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            '90 240 will not shift to 4th gear. 200

            uid 27's pic
            posted by  Art Benstein on  Sat Dec 29 18:12 CST 2012
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            last visit: Fri Oct 17 20:10 CST 2014
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            Also note, that even though the relay clicks, it may not be doing its job. In fact, the most common fault with the relay, a cracked solder around its armature contact on the printed circuit board, does not keep it from clicking. Just keeps it from delivering the voltage to the solenoid in the transmission.

            http://cleanflametrap.com/#links
            --
            Art Benstein near Baltimore

            I used to work in a blanket factory, but it folded.








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              '90 240 will not shift to 4th gear. 200

              posted by  paganm1255 on  Sat Dec 29 21:31 CST 2012
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              last visit: Sun Dec 30 17:27 CST 2012
              [RELATED]

              Thanks for chiming in, Art. Always interested in what you have to say. I checked out your link to cleanflametrap and read up on Automatic OD diagnosis and failure analysis this evening. Great photos. I'm ready for more trouble-shooting tomorrow. The wiring to the solenoid is loomed, so I'll need to verify with a sharp probe whether or not the solenoid is getting power.








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                '90 240 will not shift to 4th gear. 200

                posted by  volvo426 on  Sat Dec 29 23:24 CST 2012
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                last visit: Thu Oct 23 13:44 CST 2014
                [RELATED]

                Get rid of the solenoid altogether and put on one of the bypass plates and you will always have 4th gear.








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                  '90 240 will not shift to 4th gear. 200

                  posted by  Onkel Udo II on  Sun Dec 30 03:12 CST 2012
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                  last visit: Fri Oct 24 08:50 CST 2014
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                  Unless you want to tow, ever drive in the mountains, etc.

                  The most common reason to you use a the bypass method (and I argue that the plate is a waste of money when you can just use a dremel) is when the solenoid itself fails.

                  The relay is a quick fix. It take the iron longer to heat up that it does to make the repair.







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