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"I'll have to work my courage to do surgery on the solenoid!"
Let me suggest that before any solenoid surgery, you examine the undercar wire leading to the solenoid. No courage required, and the wire is often found to be the problem.
Regardless of Mr. Scott's over-the-top rant (thanks Norm), the control circuit is dead-simple (not butt-backward), and for all practical purposes is identical to the manual M46 OD he praises so highly.
Here is how the 5 OD control components work:
1) Fuse 11 supplies voltage to items #2, #3, #4, and #5
2) The Shifter button/switch turns the OD relay off and on
3) The OD relay controls the Solenoid and Upshift Arrow light (separate wires)
4) The Upshift Arrow light ON means relay and OD are OFF)
5) The Solenoid allows OD engagement when ON, which is the the "default" Power-On state)
If the Shifter switch makes the Arrow light (#4) go on and off, then items 1, 2, and 3 are OK, and the problem is most likely the undercar wire to the Solenoid (#5) or the wire connector terminal.
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...consider this recent reply to a "check the wiring" suggestion:
"Replaced corroded connector and length of wire with bad insulation. Working perfectly now."
He was having "intermitent" OD failures, was sure it "couldn't be wiring" (that would be "all or nothing"), and was probably on the way to a solid failure.
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Bruce Young
'93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.
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