Service Information

Orlando

Control Solenoid Valve and Transmission Control Module Assembly Solenoid Performance Test

Special Tools

•	DT-48616 Control Solenoid Test Plate

•	DT-48616-10 Adapter Harness

For equivalent regional tools, refer to Special Tools .

The purpose of this procedure is to test the functionality of the control solenoid valve assembly solenoids for a gross stuck open or stuck closed condition. DT-48616 test plate is bolted to the control solenoid valve assembly on the valve body mounting surface. Pressurised air is passed into the aluminium test block, through the control solenoid valve assembly solenoid passage and back to a pressure gauge on the test block. The pressure gauge indicates open if air pressure is passed through the solenoid, or closed if the solenoid is unable to pass air through. A scan tool is used to command the solenoids ON and OFF. While watching the pressure gauge, one can determine the valve functionality. The recommended shop air pressure for this test is 90-100 psi.

Remove the control solenoid valve assembly from the transmission.

Note: Drain the TCM of excess transmission fluid before attaching to test block and use caution when attaching air to test block air inlet.

Bolt the DT-48616 test plate to the control solenoid valve assembly on the valve body mounting surface. Use the bolts and washers supplied with the tool to attach the test block. Tighten the bolts to 5 N·m (44 lb in) using a centre out alternating torque sequence.
Install the pressure gauge to the affected solenoid air port. Reference component to air port table.

Note: If air pressure greater than 345 kPa (50 psi) is applied, an accurate test of the shift solenoid cannot be performed.

Regulate the shop air pressure to 310-345 kPa (45-50 psi) and connect the line to the DT-48616 test plate air inlet port.
Connect the DT-48616-10 harness to the vehicle harness and the control solenoid valve assembly.

Note: The TCM limits the time the solenoids are commanded on to prevent overheating of the solenoids. Once the time limit is reached, the TCM prevents the test from being continued for 5 minutes. The ignition must remain ON during the 5 minute countdown period.

Ignition ON, use a scan tool to command the solenoid in question On and Off. Watch the air pressure gauge and look for the change in pressure as you command the valve On and Off. The valve should change the flow through the valve port with a result of a change in the pressure reading on the gauge. If the valve is stuck closed, no pressure change will occur. Command the solenoid valve On and Off several times to determine the state of the solenoid valve in question. Release the air pressure in the gauge between pressurisation tests.

Control Solenoid Valve Assembly Solenoid Performance Test Plate to Component Identification

Component	Port On Test Plate	Commanded State
Component	Port On Test Plate	ON	OFF
PC Solenoid 2, 35R	F	Full pressure to gauge	No pressure to gauge
PC Solenoid 3, R1/456	G	Full pressure to gauge	No pressure to gauge
PC Solenoid 4, 2-6	B	Full pressure to gauge	No pressure to gauge
PC Solenoid 5, 1234	C	Full pressure to gauge	No pressure to gauge
Shift Solenoid	D	Full pressure to gauge	Below full pressure to gauge
Line Pressure Control Solenoid	A	Command to highest setting, full pressure to gauge	Command to lowest setting, below full pressure to gauge
TCC PC Solenoid	E	Full pressure to gauge	No pressure to gauge
Note: With the key on engine off (KOEO), the TCM will normally cycle some of the transmission solenoids On and Off to facilitate keeping the ports and solenoids clean and free of debris. This dither function is a normal activity and will cause the valves to cycle open and closed quickly when the TCM is powered up. This can cause the psi gauge to flicker high and low as the valves open and close. This may cause some air to exit the ports where the psi gauge is not connected as those solenoids cycle on and off.