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Hello:
It could easily be the case that the used relay was also bad. Another thing to check is the wiring from the shift tunnel to the solenoid-- on my 240 the back section of the wiring was bare and shorting out intermittently on the tailshaft housing of the transmission. I replaced the relay, which had been cooked by the short and used a new wire to the first connection on the line to the OD. It has worked great ever since.
If you are worried about melting of the OD relay base, have a look at it. If it has overheated it will be easy to see.
You can check the electronics out with a simple test light with the ignition on but not started. You should be able to measure 12V at the solenoid and switch it on and off with the shifter button.
I believe I have seen instructions in the archives on how to jumper the OD relay to leave the OD on all the time-- that would be a useful way to sort out whether the problem is electrical or hydraulic. My money is on electrical.
Good luck!
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Herb Goltz, Aurora, Ontario, Canada '92 245 w/130K mi, '92 945T w/200K mi
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