Overdrive kicking out by itself

Does your Mitsubishi L300 make a strange noise? Need wheel alignment specs?
sk66
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Overdrive kicking out by itself

Postby sk66 » Fri Jun 01, 2018 12:21 pm

Yesterday while driving after a rain my overdrive kicked out while doing 60mph/100kmph. I was leaving at the next exit anyway so it wasn't a big deal... After slowing down a bit it kicked back in at about 50mph and then several minutes later it kicked out again. The rest of my drive was at 35mph so it would have been out anyway. There was no OD off light on the dash, and the OD button had no affect although it did cause the dash light to illuminate. Driving it today it was fine.

My first thought was moisture at the solenoid, but I don't think that makes sense. The relay has to send the voltage to the solenoid first before moisture at the solenoid could cause an issue doesn't it? So I'm thinking it's probably the OD relay even though there was no corresponding light? Or is that backwards and the OD relay/switch/temp sensor ground out the voltage to the solenoid disabling OD?

I've looked through the electrical manuals and found where the relay is supposed to be located, but no description/test of its function.
Steven
1991 L300
Harrisburg, PA

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Growlerbearnz
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Overdrive kicking out by itself

Postby Growlerbearnz » Fri Jun 01, 2018 3:21 pm

For the O/D wiring diagram and component location, download the complete L300 workshop manual (http://www.delica.ca/forum/viewtopic.php?f=17&t=17809), then look at "Electrical Wiring (1987), page 4-31.

Check out the posts in the Reference Library here: http://www.delica.ca/forum/viewforum.php?f=95 and this Volvo FAQ which has a good section on the OD Solenoid: https://www.volvoclub.org.uk/faq/TransmissionAuto.html#AutoTransOverdriveProblemsSolenoid

The "OD Off" light merely comes on when the OD switch is out, whether OD is actually engaging or not. It isn't triggered by the OD system at all, just by the switch.

I can think of a few likely causes for OD to intermittently drop out, but first confirm that your kickdown cable hasn't come loose at the injection pump.

The most likely problem is with the solenoid failing, or a broken wire to the solenoid. The OD relay is fairly reliable. With the engine running, there should be power at the solenoid all the time, unless the OD switch is off (which turns on the "OD off" light). Turning the switch off and on should cause the solenoid to make a nice, loud, solid-sounding "click". If you don't have a multimeter to check for power at the solenoid, try wiggling the wires going to the solenoid and listen for it to release and re-engage.
Nothing says "poor workmanship" more than wrinkles in the duct tape.

sk66
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Overdrive kicking out by itself

Postby sk66 » Sat Jun 02, 2018 6:20 am

Thanks!

I have the manuals and I read the Volvo FAQ, but missed the other one in my search. Kickdown works normally... if it came loose I would expect the symptom to be it switching into 4th early/staying in 4th rather than disengaging?

Ok, so the solenoid normally has 12v constant and the OD relay/switch interrupts power (opposite of what I thought was probable). That makes the moisture/short cause much more likely and probably(hopefully) easy to fix. It also seems problematic in that it means any failure mode would probably cause a loss of fourth gear. I would much rather a failure resulted in the inability to disengage 4th gear, especially for a vehicle I put through mud/water whenever I can.

Hopefully it's just one of the connections and a good cleaning/dielectric will fix it... I'd much rather maintain the electrical override, but I'm not sure how much trouble it's actually worth.
Steven
1991 L300
Harrisburg, PA

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Overdrive kicking out by itself

Postby Growlerbearnz » Sat Jun 02, 2018 3:46 pm

If it turns out that the solenoid is failing, it's easy to replace. There's really no need to go to the extreme of permanently disabling the solenoid like the Volvo guys do, and I think it would be a disadvantage to our vans: it's useful to be able to turn off OD when climbing a long hill, to let the engine rev a bit without having to floor the accelerator.
Nothing says "poor workmanship" more than wrinkles in the duct tape.

sk66
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Overdrive kicking out by itself

Postby sk66 » Sun Jun 03, 2018 8:53 pm

Growlerbearnz wrote:If it turns out that the solenoid is failing, it's easy to replace. There's really no need to go to the extreme of permanently disabling the solenoid like the Volvo guys do, and I think it would be a disadvantage to our vans: it's useful to be able to turn off OD when climbing a long hill, to let the engine rev a bit without having to floor the accelerator.

Agreed.
Steven
1991 L300
Harrisburg, PA

sk66
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Overdrive kicking out by itself

Postby sk66 » Wed Jun 06, 2018 2:09 pm

Well, it was running fine for several days so I hadn't gotten to poking around. But today it went out again, apparently for good.

I did some checks:
Drop down cable is still connected.
I get 9.8v at the solenoid with the key in the run position.
I get less than 1v (.78) to the solenoid with the engine running (vehicle in park).
The OD switch doesn't cause the solenoid to click in either case.
The rubber insulator top of the solenoid is cracked/falling apart, but that would be secondary if the voltages aren't right.
I cleaned the contacts at both connectors near the solenoid and applied dielectric grease hoping that would make a difference, but it didn't... the contacts all looked good to start with.

I was going to jumper the relay, but it's not located where the diagrams say it should be... I'll try to locate it tomorrow, guessing it might be with the fuse behind the glove box.

Any other suggestions for me at this point? If I can't locate the relay or sort the issue quickly I'll probably attempt temporarily bypassing the solenoid by removing the inner o-ring. At least I'll be able to drive it on the highway while I keep looking for the issue.
Steven
1991 L300
Harrisburg, PA

sk66
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Overdrive kicking out by itself

Postby sk66 » Thu Jun 07, 2018 12:35 pm

Instead of going on an egg hunt looking for the O/D relay I decided to just try directly jumping the solenoid with lengths of wire off of the battery... I got nothing. Then I pulled the solenoid and jumped it again using proper jumpers/clips, no joy again. So now I've done the bypass mod to the solenoid and I'm looking for a replacement.

I think I found the part (no pic) on Amayama, MD609455 or replacement part MD919150... price is $267 + sh. I also found one at a US importer (no part # listed)... for $475 + sh!
I also found a Volvo replacement solenoid (pt# 1239928) for about $45 delivered... I'll have to splice it into the harness, but that's no big deal.

Can anyone verify the part #'s/prices? Thanks!
Steven
1991 L300
Harrisburg, PA

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Overdrive kicking out by itself

Postby Growlerbearnz » Thu Jun 07, 2018 3:33 pm

Yup. Part number is MB919150, price is US$270. Ouch.

I'd go for the Volvo unit and see if it works. The same gearbox (Aisin Warner 03-7X) was also fitted to a bunch of Toyotas, where it was called an A43D or A43DL.
Nothing says "poor workmanship" more than wrinkles in the duct tape.

sk66
Posts: 155
Joined: Thu Oct 06, 2016 3:24 pm
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Vehicle: '91 Delica L300
Location: Pennsylvania, USA

Overdrive kicking out by itself

Postby sk66 » Fri Jun 08, 2018 5:29 am

The volvo solenoid should be here next week... I'll update after it's installed.
Steven
1991 L300
Harrisburg, PA

sk66
Posts: 155
Joined: Thu Oct 06, 2016 3:24 pm
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Vehicle: '91 Delica L300
Location: Pennsylvania, USA

Overdrive kicking out by itself

Postby sk66 » Fri Jun 22, 2018 9:31 am

The Volvo solenoid works like a champ... everything is functioning correctly again.
Interestingly, when I originally pulled the failed solenoid there was no fluid leakage. But when I pulled it for replacement the transmission leaked quite a few ounces... I don't know how much would have leaked out because I didn't wait for it to stop. I'm guessing the modified solenoid allowed fluid somewhere the failed solenoid did not (it kind of acted like it was under slight pressure).
Steven
1991 L300
Harrisburg, PA


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