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The only thing that I can think of, and I hated to say anything before this because I don't have my car nearby right now (still don't), but in post #22 you stated that you couldn't see terminal #3 on the solenoid when it was installed. I recall that #3 was right near the bottom. Is it possible that the solenoid was in upside down????

At least you know the solenoid and electrics are good so far. That's one less worry.

Getting the solenoid in the pawl is tricky but the procedure is in the manual. Basically you have to energize the solenoid to extend the plunger and then go in at an angle to capture the slot in the pawl.

Not sure how much troubleshooting or access you have with the unit in the car. The pawl has to slide in a groove opened when the balk ring moves out of the way and then slide into the sun gear hub. I don't think there is a way to check general condition of either item or see if there is a clear path or damage preventing free travel with the unit fully installed. West brings up a good point and worth looking into. Not sure if that would cause the problem or not. Would have thought the mechanic would have got it right though.

Maybe someone has an idea on how to mechanically troubleshoot in the car??

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Possible-#4 is at the bottom/#7 left of it/#6 between 4 and 3. I am pretty sure spacer has 2 holes facing the rear of the car. I guess I will reinstall. Like I said the thing fell out when the last bolt was removed-like it was not connected to the pawl.

We will see

The solenoid did appear to be upside down and sounds as if the spacer might have compounded it. The solenoid side with 3 terminals faces the rear.

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The spacer could have been backwards on the solenoid itself, which would force the solenoid to go in backwards as you try to put the unit in correctly.

The 2 holes in the spacer are facing the rear of the car-#4 lead is as I said almost in my face(toward the ground) and #3 is slmost 180 deg from it. I put the thing back together-when I ground #5 relay same as before-relay comes in/green light on in dash/solenoid may be making more sound than before. When I put the solenoid back in-tilted it toward the rear and pulled out on it to insure it had caught the pawl which it felt like it did.


I thought the space was unsymetrical part/I thought the solemoid was symetrical

Well I guess I will take it for a ride.

Hopefully it will work but something still doesn't sound right.

If your solenoid is the same as I have, orientation per the illustration and photo would put 3 not quite on the bottom but lowest toward the ground and 4 on top or about 11:00. 7 is about 2:00 toward front of car and 6 pointing straight back at 9:00. If the spacer is oriented as others have mentioned, then I would think that would put the spacer 180 out on the solenoid.

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mine is about 180 deg from the illustration-that would put the spacer 180 out in relation to the solenoid Could that keep it form going into OD?

thks

David

Just to confirm-with solenoid out of the car-the solenoid is working correctly?

Per your post 40, solenoid sounds as if it's working. Goes out half inch, stays out, and dash light goes out.

An improperly aligned spacer is one of a list of things mentioned that could prevent OD engagement. A sticking or damaged pawl requiring removal and cleaning or repair are others.