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Figure 1
Do you honestly he fact is that they are not all Im gonna replace them all!
COUN
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Posters also the complexity of todays
available for automatic transmission
$15 each.
and its related components.
Figure 2
hand if you are doing a 4L60E you can believe solenoids wear out and should pushes the ball against the seat thus cut-
win $240.48 Thats the local GM deal- be replaced. After all they contain ting off oil flow. The entire process
ers list price. moving parts and can get contaminated takes a fraction of a second with total
Some of you will probably say I with metal. The pulse width modulated movement of approximately .050 thou-
pay less than that. This is just an exam- ones really get a workout being pulsed sandths of an inch.
ple. Only you can determine the actu- million and millions of times. With only a small amount of move-
al costs and savings. However you It is important for you to really ment and with the constant flow of oil
look at it there is absolutely no denying take a hard look at how a modern sole- its easy to see why these solenoids can
it is a significant part of the job. It real- noid operates. You really need to last so long. Probably the most suscep-
ly doesnt take a rocket scientist to see understand what moves and what tible part of this solenoid is the nozzle
that the numbers keep adding up and wears. With that thought in mind I have and O-ring.
up. chosen the 4L60E as an example. How can you judge when to
But how does this help you? Think replace one of these solenoids? Do you
about it. Say your shop does 20 jobs a Types of Solenoids: start by checking the cars speedometer
month and only 1/3 of them need Lets take a look at 3 types of sole- or perhaps look in the sump for metal.
replacement solenoids. Now take the noids. Sticking with the 4L60E we will Thats ok if you want but there is
average cost of solenoids per job lets examine the simple on/off shift sole- always that gray area, isnt there? You
call it $150. 20 jobs at $100 savings noid, the 3-2 solenoid which is a pulse can tell some things just by looking at
each (2/3rds of $150). Thats $2000 per width modulated type solenoid and the them, but how can you be sure?
month. Thats the prize! Imagine force motor which is a balanced spool Assuming there is no obvious dam-
$24,000 per year! Out of the trash can valve type solenoid. age to the nozzle and O-ring. I would
and back into your hands. start with a simple on/off test measur-
Whoa! You say. Solenoids wear Shift Solenoids ing leakage (to make sure it works at
out! I gotta worry about warranty and Simple on/off solenoids: Figure all), flow (to check that it isnt clogged)
when should I replace them. Besides 1 shows a GM 4L60E SHIFT solenoid. and the ability of the solenoid to ener-
we use new solenoids and mark them They have a GM list price of about gize under pressure (to make sure the
up. Good point. $23.91 each and are extremely simple solenoid mechanically can hold pres-
in operation. Apply current and the sure when energized). Its that simple.
Lets see. . . solenoid stops oil flow. Take away cur-
New Solenoids: $150 marked up, rent and the oil is allowed to flow. GM 3-2 Downshift solenoid
say 30% thats $45 you make each job. The moving elements of the GM Next lets take a look at the 4L60E
Your happy but is the customer? 4L60E solenoid consist of a plunger, solenoid in figure 2. This solenoid is a
Used Solenoids: You charge the spring and metering ball. It is actually normally closed PWM type solenoid
customer $95 to flush and test their the action of the metering ball against and lists for $25.58.
solenoids. You save the customer $100 the polycarbonate nozzle seat that con- Examining figure 2 the moving
and you make $95 dollars! trols the oil flow. This particular sole- elements consist of a spring, plunger,
Thats enough about the prize. noid is a normally open solenoid. Oil diaphragm and metering ball. In oper-
Now some serious discussion about constantly flows through the nozzle and ation the metering rod is drawn from
Solenoids. around the ball while the solenoid is the sleeve allowing the metering ball to
It is no secret that some of you open. When the solenoid is energized it move. This allows more oil to get by it.
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Solenoids: How Big Is The Prize?
Figure 3
This solenoid is electrically pulsed at First inspect the solenoid physically. has some similarity to the 3-2 solenoid
50 cycles per second. The PCM oper- Pay particular attention to the O-rings, we just discussed. It is also a pulse
ates the 3-2 valve at 90% duty when the nozzle, connector and screens. This width modulated solenoid, however its
transmission is in 2nd, 3rd and 4th solenoid depends upon oil and careful- coil operating frequency is 292.5 cycles
gear. During a 3-2 downshift, the sole- ly controlled electrical energy to oper- for second. It also controls oil flow
noid duty is reduced to control the ate, so you will need a tester to check it. through the variation of pulse width.
exhaust of 3rd accumulator fluid The following tests should be conduct- Unlike the 3-2 solenoid the Line
through the 3-2 valve. This action ed: Pressure Control solenoid utilizes a
helped by the spring and diaphragm and Solenoid Off: Leak test under spool valve to control oil flow and pres-
accompanied with signal oil causes the pressure. sure.
ball to move smoothly in and out of the Solenoid On (90%): Output The way this solenoid works is a
seat (again the nozzle serves as the pressure = Input Pressure small amount of actuator feed limit
seat). It is this smooth and almost Output Flow check (AFL) fluid is allowed to flow through
motionless action (the entire travel is Dynamic Test: Carefully step a small orifice into the spool valve.
approximately .035 inches) that strokes the solenoid from 90% duty to This fluid passes through the center of
the much larger 3-2 control valve in the 0% duty monitoring the the spool valve and is either applied
valve body and ultimately exhausts the change in output pressure. against the solenoid armature or
3rd accumulator. By changing the Pressure should diminish in a exhausted. Actuation of the armature
length of time the solenoid is actually smooth fashion as the meter- by increasing the coil current causes the
pulsed (pulse width) the metering rod ing ball moves in and out of spool valve to move smoothly up and
and ball can be moved in varying the seat. down floating in a constant wave of oil.
amounts thus changing the 3rd accumu- The entire spool valve is held in bal-
lator exhausting times and ultimately Hint: Try comparing the used one ance via an ingenious combination of
the downshift feel. to a new one. They should both behave oil pressure, spring action and electri-
Remember, the maximum total the same. cally induced magnetic force. The GM
movement of the metering ball is only 4L60E Line Pressure Solenoid also
.035 thousandths of an inch assisted by Line Pressure Control Solenoid contains a damper spring (actually a
both spring and a cushion of oil. (aka:Force Motor, EPC) diaphragm) that serves as a dashpot for
Operation is smooth and lubricated by a Figure 3 shows a 4L60E electronic the armature to move against.
wave of oil. line pressure control solenoid. This Its easy to see all the moving parts
How can you check a 3-2 solenoid: solenoid, which GM lists for $119.29, in an EPC solenoid assembly that with
ONLY $59.95
LIST PRICE: $159.99
when purchasing tools
separately
PART #
TK900
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#T700-311 #T700-307 #T 700-308 440T4 GM 4L30E,
3/8-10mm 700R4 Servo Capsule Servo Capsule 4L60E & 4L80E
Universal Slide Servo Capsule Driver for 700R4 Remover Harness
Hammer Remover & 4L60E Qty 1 Removal Tool
Pump Adapter Qty 1 Qty 1 Qty 1
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S - 19 0 O - 19 0
Ford Cooler Line
Ford Cooler #K-190 # T 760
Line O-Rings Ford Cooler Line AOD Shift Valve #T350-302 # K T 3507
Retaining Clips 440T4 Internal Yoke Seals & Installation Tool
Qty 10 Installation Kit Bore Sealing Tool
Qty 10 Metal-Clad Seal Puller 350, 700R4
Qty 1 Qty 1
Qty 1 Qty 6 0042