First of all, thanks to all of you who responded with information at various
sites, pdf.files, manuals and your own experiences.
WE HAVE SUCCESS!!!! Yes after 9 hours of fun garage time, I finally have it
where it runs and switches in and out of overdrive.
The oil pressure was fine, the relief valve was fine, the relay was fine.
After finding the right spot for the operating valve to be set, ( a little
further than the 3/16th hole, I worked on the solenoid side and found some
issues.
1) The plunger was too long, so the lever would not travel very far or far
enough.
2) The solenoid lever was binding ever so slightly on the upper red bolt
head and it would not work the plunger smoothly.
3) The new solenoid it self was iffy.
Action taken
I ground off the plunger down 1/16 inch. I lapped the plunger.
I reshaped the solenoid lever so the plunger moved more freely.
I rebuilt the new solenoid with some of the parts from the old original. The
original was made in England and the new one was made in China. I used the
original plunger, (heavier that the Chinese one) and reused the original
internal plastic cap. The Chinese one was held together with machine screws
that did not fit (too small) and the inside of the plastic cap where the
insulator walls are, was way to tight for the two brass point plates to
activate properly. Thus causing sporadic results.
Once I sorted all that out and reassembled the transmission tunnel, cover
pads and carpet, along with re installing the carpets, seats and checked to
make sure it all still worked. Then I checked that I could reverse, because
it mentioned in one of the articles or manuals that this could be disastrous
if it stayed in OD and I tried to back up. All is well.
I am super tired and overjoyed, that I finally have a working OD.
Thanks everyone again. Go 6pack autox team!!!!
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