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Bypassing the solenoid restored proper engagement of the OD

1992 250K

This 1992 745 was failing to engage the OD prior to 7 or 8 miles of driving (it would engage after reaching temperature). Traced it down to the solenoid failing.

The FAQ's provide lots of support on the work around of grinding a groove between the two holes in the solenoid with a dremel.

I had adequate working room by removing the crossmember and lowering the transmission with a jack under the oil pan. I made sure the area was exceptionally clean by using a small wire brush, compressed air and carb cleaner before removing the solenoid. I also did the suggested quick start up and run through the R and D positions (yes, messy for sure).

I found a proper size O-ring at Lowes in the plumbing department. Danco was the supplier, 96734 #17 O-ring. 1 1/16"OD x 7/8" ID x 3/32"

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Any twenty minute job is just a broken bolt away from a three day ordeal







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