Update on my AW71 OD problem.
As most of you know from my previous posts I had a problem getting my ’93 944T to shift reliably into 4th. Commonly this is referred to as an OverDrive problem even though this is not an over drive. It is an electric controlled shift between 3rd and 4th gear of this transmission. It is not like the over drive I used to have on my 1981 242GT which was a standard box with switch on the shifter enabling me to drop the ratio after you were in 4th, hence dropping RPMs and therefore increasing gas mileage and engine life.
We all know that it can be either the solenoid , the relay tucked away deep behind the center ashtray, or the shifter switch and any wires in between.
I had changed out all electrical components, checked for continuity, flushed professionally and by myself with Mobil I, and all to no avail.
Then somebody mentioned that IPD offers a “blank-off” plate to replace the solenoid for a lot less money than what I already had spent.
I found out that the only thing this plate does is enables the hydraulic fluid to run from the center hole to the aft hole on the tranny. I used a Dremmel (high speed rotary tool) to grind a channel  in my old (still working) solenoid, I had previously replaced this one with a Volvo new one. The steel of the solenoid is pretty hard and it ate up two 1/8” tools quick. If you can mill it or have it milled it would be better, I used a drill-bit also and it works.
I proceeded to take the new solenoid off the transmission on the driver-side but ran into some problem. I took a closed end wrench heated it up and put a 30 degree bend into it in order to reach up as the drive tunnel does not give you much room.
I tried a regular and deep 12mm socket with ratchet on the ‘frozen’ bolt and therefore had to take off the shift linkage . Taking this one nut off to release the linkage made it a lot easier to work the ratchet in the tunnel.
With my luck though, I still could not loosen it and had to drop the tranny center support to get better access.
I also bought a 12mm gear wrench which is the tool of choice for this job especially if you can get one that has a “knee” end. I took the “new” solenoid off and just unplugged the electrical connection just under where the wire enters the top of the tunnel. Took some drill bits the size of each hole in the solenoid and turned them around in the holes of the tranny to make sure they weren’t plugged. (Be careful as the bits can fall in)
Mounting everything is the reverse of the above. Except you don’t have to worry about wires and were to fasten/support them to keep them from chaffing as you don’t need them. I put in a new outer O-ring and opted not to use the inner O-ring as you have to cut that one in order to leave a space for where you cut the channel (C-ring), just leave it out (no problem aligning it)
After remounting everything I started the car and drove her away, she shifted beautifully and smoothly through all 4 gears. Hurray what a pleasure. The car is mine again and the kids has to ask me to drive it when they are home.
I parked the new Town & Country and now use the Brick as my daily driver (40 mile) commute.
My advice to anybody having an OD problem with their automatics; forget about the $140 solenoid, the $45 relay, the Switch, the dashboard light and all the work involved checking/replacing these units. DO WHAT I DID
Take the solenoid out, cut the wire off, grind a channel, and put it back in. From start to finish this is a 3 hour job that saves you a lot of headaches.
Low and behold when I want to pass or accelerate quick I just give some gas and the automatic knows to shift back to 3rd or even 2nd with the kickdown, hence it is an automatic you should not have to shift it to 4th or 3rd .
Sorry about the rambling on but this problem had been bothering me for a long, long time and the solution is so simple and cheap unless you are an aficionado that wants to keep the car in showroom condition and working order. I just want to drive it and see if I can get 465K miles on it like my 123S I used to have.
Thanks to all that gave me input and inspiration the Brick is no longer for sale.
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EJO now a 1994 940T 190K; ex '65 123S; ex '75 245; and ex '81 242GT; also Chrysler 2002 T&C and 2006 MINI Cooper
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