the 096/01m internal harness DIY...enjoy!

[jljohnson85]

Ok well I have an issue with my 01m and I figured I might ask it here because I think it might be related.

My car stays in third gear 95% of the time. It will shift into fourth very very rarely. I can never seem to find the exact conditions and its never reproduce able. When it does shift into fourth it will kick down into third when I slow or mash the accelerator. It WONT shift down into second or first though. When I come to a stop my trans will slam and all the lights on the gear selection will light up.

When I unplug my TCM I can get 1st and 3rd if I manually select gears but it will never go up into 4th and the shifts are very rough.

I it scanned by a generic OBD2 scanner and got code P0763 Shift Solenoid Circuit C Electrical. Is this a symptom of a bad wire loom or solenoid? How can I test the solenoid wires without dropping the pan?

[rychas1]

none of my documents show generic codes for the transmission, so i dont know for sure which solenoid that is. run vag-com, then we can talk. but it sounds typical frayed harness/solenoid stuck.

[Dorin18]

You can unplug the male wire harness plug from the top of the transmission and measure the resistance between the exposed pins.
You should see the plug that it is pointed with an arrow below (called case connector in the manual):

Below you should see the top view of the connector and the way the ribbon cable attaches to the solenoids (observe their position inside the valve body in case you need to change one):

And here is the table with the solenoids resistance:

It is a little hard to bend over and use both of your hands to measure resistance between two pins... To free one hand, I used one wire with a small connector at one end, connector that I adjust a little bit to fit over one single pin. You can find something like this in toys, computers or other electronics. Let me see if I can make a picture...

Well, it is a little blurry, but you can get the idea.
Good luck!

And one more thing. If you need to change a solenoid you will probably reuse the old harness. If you manage to break some clips (like I did), the plug will not stay on by itself. You have to help it stay.
Here is a picture of my solenoids



Modified by Dorin18 at 6:57 AM 9-22-2008

[divineVR6]

wheres a simple question, on those trannys where do you Refill them? i see where you can drain but at what point on the tranny do you put the fluid in?

[rychas1]

the plug on top.

[jljohnson85]

Thank you Dorin18, that is EXACTLY what I needed.

[divineVR6]

Quote, originally posted by rychas1 »

the plug on top.

havent noticed a plug yet. havent really dove into it yet. i do see where the tranny cooler is on top, i suppose its near there?

[rychas1]

no. its near the front top edge. it easiest way to see it is to look from underneath. once u see the tranny near the left (drivers side) front. its right there. red cap.

[divineVR6]

thanks

[diesel-up]

So on my 1994 passat when I start it there is no tranny pressure and after it runs for a few seconds it squeels as if it has to much pressure and the tranny wont shift correctly only 1st and 3rd. Just bought Hex-usb+CAN Vag-com and no codes.Unplug a connector and codes show. But the ATF temp keeps rising the longer the car runs.Got another AD TCU for it and still nothing. Any ideas?

[divineVR6]

if the temp keeps rising could be a possibility that your tranny cooler is clogged. it sits right there on top of the tranny. i dont know what else it could be although im sure there's many other posibilities

[rychas1]

the internal harness hoses the ATF temp sensor. if temps are just stupid for the conditions (say, idling), then its the harness

[Dorin18]

I would add 200-400 ml of ATF to see the reaction. If you don't see an improvement just remove the exact amount of fluid.

[rychas1]

just changed out the n90 solenoid on my 02m tonite...shifts perfect!! will redline each gear and downshifts with no clunks. upshifts are smooth and precise. i love it!!!!!!!!!!!! didnt take pics, but it was so easy t20 for the bolts to remove solenoid holding bracket.

[divineVR6]

is n90 the 3rd gear solenoid?

[rychas1]

yes. 4th back from front. that was keeping me in limp mode. not anymore

[diesel-up]

So I pulled the codes and this is what came up,
00638 Engine/transmission electrical connection 03-10 No signal intermittent
00545 Engine/transmission electrical connection 31-00 open or short.

Any ideas......Thanks

[herb2k]

Check/replace the solenoid wiring harness...

Can anyone let me know the "trick" to unlocking the locking ring for the harness? I tried squeezing two sides of it but it just doesn't seem to budge!

[rychas1]

Quote, originally posted by herb2k »

Check/replace the solenoid wiring harness... Can anyone let me know the "trick" to unlocking the locking ring for the harness? I tried squeezing two sides of it but it just doesn't seem to budge!

o yes, i remember that sucka. squeeze harder!! and try to lift one side at a time.

[dansXR2]

I'm getting a code for the #7 Solenoid. I'm new to automatics and find this post VERY informative. I'm gonna try testing the resistance of the #1&#10 pins and see if I have a short. I hit a bump when it was okay for a while, and the bump kicked limp mode back in... Probably a messed up ribbon?

[rychas1]

broken ribbon, bad connector connection (main to internal), tcu, or something else. start with the basics. check codes, connections, and resistance. go from there.

[godutch]

easiest way to remove the wire harness is to use a butter knive - which is wider than a flathead screwdriver, put the knife between the valve body and the plug - so in essance the knife lays on top of the wire, and then slightly angle the knive toward to plug - and the plug will just jump out. One at the time. Easy as slicing pie. I have done it more that 15 times sofar without damaging the wire. Valve bodies are pieces of crap. Difficult to isolate the problem.

[crazeehorse]

this post is awesome, & the valve body teardown is too. i have the harness, & the printed circuit foil ordered. i should have it by the end of the week. i have'nt read the whole post yet, but thanks ahead of time. they told me at the dealer, the harness, & the pc foil come in two parts. mine was soldered,(the damaged one) but the tech said it should plug together.

[dansXR2]

http://forums.vwvortex.com/zerothread?id=4118194

Where should I start? Power/Ground? Where are their locations?

[crazeehorse]

i have a 2001 bettle, i am replacing the same parts as in this post. when i'm done with the repair, will i be able to reset the 01M transmission, by turning on the key, holding the gas pedal to the floor for 5 secs. ? or, will i have to have software, or take to someone that does?

[Thumper1044]

I am sorry to hear that you feel people do not appreciate posts here. I have printed many of the posts and am assembling my own version of the Vortex Bentley. Yes, I do have the Bentley manual also, but I so often often find that the posts here are much more detailed and actually done by mechanics. I haven't needed the DIY cleaning of the valve body yet, but I truely appreciate having the info if and when I do. Many on this site have helped me and that is what keeps my VW running. Here is my thank you to all for their time and efforts to create their technical posts.

Thumper

[rychas1]

u can do the mechanical reset too. and its more like 10 sec.

[YYeahoo]

This Post is awesome ....... Just what I was looking For. I wanted Pictures and good info and you have provided it. I'm about to tear into A 2001 Cabrio. I have rang out the Solenoids coils from the external connector and found EV-7 (N94) Pins 1 and 10 (spec 55 to 65 Ohms) ringing 291 ohms.... way out of spec. I have the Solenoid resistance spec I can email to anyone who is interested. I'm not a VW fan but I'm a fan of saving a few bucks for my daughter. Great info buddy and thanks so much for your effort and willingness to help others.

[Z-Raddo G60]

Quote, originally posted by dansXR2 »

...code for the #7 Solenoid... I'm gonna try testing the resistance of the #1&#10 pins...

Did you test out the resistance on the "suspected" solenoid?

Quote, originally posted by dansXR2 »

...hit a bump...was okay for a while and the bump kicked limp mode back in...

Could this be a faulty or loose connector? What came of the replacement cable?

[rychas1]

im glad it was useful.

[rinux1]

i check all the pins and the sensor temp is with 280k ohms, do you thing this could do the transmission to be in limp mode?, i have a golf 97, and only get third gear and reverse, somethimes reverse kills the engine, but with out the tmc i get fisrt and third and reverse with no problems at all


Modified by rinux1 at 2:30 PM 4-23-2009

[rychas1]

100% in limp mode. reset it and see.

[rinux1]

do i need to change the wire harness first, and reset or reset and see whats going to happen? how do i reset manually ?

[rychas1]

reset before anything. tuen key on, press gas to floor for 15 sec, turn key off, release gas pedal, start car while touching nothing, let sit for 5 min, enjoy

[rinux1]

mmm... i did the reset but din't work, now i have codes p1613 (mill call up / short to b+), p0730 incorrect gear ratio, and p0440 evaporative emission system, any sugestion???