Overdrive Solenoid

Replace the overdrive solenoid in the TR-6060 6-speed manual transmission by accessing the transmission from underneath the vehicle and removing the solenoid assembly from the transmission case.

Warnings

Tools required

Parts

• Overdrive solenoid assembly × 1 — Mopar 68052174AA or equivalent TR-6060 OD solenoid
• Solenoid O-ring seal × 1 — Usually included with solenoid assembly

Fluids

• transmission_manual — 1 qt

Preparation

1. Park vehicle on level ground and engage parking brake.
2. Disconnect negative battery cable to prevent electrical shorts during solenoid replacement.
3. Raise vehicle on lift or securely support on jack stands rated for vehicle weight.
4. Allow transmission to cool if vehicle was recently driven.
5. Position drain pan under transmission to catch fluid spillage during solenoid removal.

Procedure

1. 1

   Access transmission from underneath
   From underneath the vehicle, locate the TR-6060 manual transmission. Identify the overdrive solenoid on the driver side of the transmission case, approximately mid-way along the transmission body. The solenoid has an electrical connector and is retained by 2 bolts to the transmission case.
2. 2

   Disconnect electrical connector
   Locate the electrical connector on the overdrive solenoid. Press the release tab on the connector and pull straight away from the solenoid to disconnect. Do not pull on the wiring harness itself. Move the connector aside to provide clearance for solenoid removal.
3. 3

   Remove solenoid retaining bolts
   Using a 10mm socket, remove the 2 bolts securing the overdrive solenoid to the transmission case. Keep these bolts as they will be reused during installation. Note that some transmission fluid will begin to drain when the solenoid is loosened.
   ⚠Position drain pan directly under solenoid before removing bolts. Expect approximately 0.5-1 quart of fluid to drain.
4. 4

   Remove overdrive solenoid
   Carefully pull the solenoid assembly straight out from the transmission case. The solenoid has an O-ring seal that will create resistance. Twist slightly while pulling if needed to break the seal. Allow transmission fluid to drain into the pan. Inspect the solenoid mounting bore in the transmission case for debris or damage.
5. 5

   Clean mounting surface
   Using a shop towel and wire brush if necessary, clean the solenoid mounting surface on the transmission case. Remove any old O-ring material, debris, or residue. The surface must be clean and smooth for proper sealing of the new solenoid.
6. 6

   Prepare new solenoid
   Remove the new overdrive solenoid from packaging and verify it includes a new O-ring seal. Lightly lubricate the O-ring with clean manual transmission fluid meeting the factory specification to aid installation and prevent seal damage. Inspect the solenoid connector terminals for any shipping damage.
7. 7

   Install new solenoid
   Align the new solenoid with the mounting bore in the transmission case. Ensure the O-ring remains properly seated in the solenoid groove. Push the solenoid straight into the transmission case bore until it seats flush against the case. Do not twist excessively as this may damage the O-ring.
8. 8

   Install and torque retaining bolts
   Install the 2 retaining bolts and hand-tighten. Torque the bolts to 10 ft-lbs in a crisscross pattern to ensure even seating of the solenoid. Do not overtighten as this may damage the transmission case threads or distort the solenoid body.
   ⚠Overtightening can strip the aluminum transmission case threads. Use a torque wrench and do not exceed specified torque.
9. 9

   Reconnect electrical connector
   Push the electrical connector onto the solenoid until it clicks into place. Verify the connection is secure by gently pulling on the connector body (not the wiring). The connector should not separate from the solenoid.
10. 10

    Refill transmission fluid
    Locate the transmission fill plug on the driver side of the transmission case. Remove the fill plug using a 13mm socket. Using a transmission fluid pump, add approximately 1 quart of manual transmission fluid meeting the factory specification to replace the fluid lost during service. The transmission is filled to the proper level when fluid begins to drip from the fill hole. Reinstall and torque the fill plug to 26 ft-lbs.
11. 11

    Reconnect battery and lower vehicle
    Reconnect the negative battery cable at the battery terminal. Lower the vehicle from the lift or remove jack stands. Verify all tools and equipment are clear before lowering.

Reassembly

1. Ensure electrical connector is fully seated and locked onto solenoid.
2. Verify no tools or materials were left in the work area under the vehicle.
3. Check transmission fill level is correct before test driving.

Verification

• Start the engine and allow it to idle. Check for transmission fluid leaks around the overdrive solenoid mounting area.
• Test drive the vehicle through all gears, paying particular attention to 5th and 6th gear engagement (overdrive gears). Shifts should be smooth without delay or harshness.
• Monitor for any check engine or transmission warning lights. If the overdrive solenoid was failing due to electrical issues, codes should clear after successful replacement.
• After test drive, recheck transmission fluid level at the fill plug with transmission at operating temperature. Top off if necessary.

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle