- Subject: Repairing a broken solenoid wire
- Unit: VW 02E
- Essential Reading: Rebuilder, Diagnostician
- Author: Wayne Colonna, ATSG, Transmission Digest Technical Editor
With the increase in manufacturers forcing the purchase of subcomponent replacements rather than enabling you to buy only what you need, it’s great to get a break every once in a while. Such is the case with Volkswagen’s 02E Direct Shift Gearbox. The solenoids mounted on the valve body are not available individually, so if you needed just one solenoid you would have to buy the entire Mechatronic assembly (valve body, solenoids and TCM) for about a thousand bucks.
However, when a solenoid electrical fault occurs, there are times when a simple little fix is all that is needed. Upon a careful look at most of these solenoids (Figure 1), you will discover that the coil wires pass through a hole in their respective blades. Each of these wires has an interference type of fit as it passes through this hole in the blade in lieu of being soldered to it.
Despite the plastic base to assist in securing these wires, in time they can work their way loose or break (Figure 2), causing erratic or consistent solenoid electrical codes. Usually there is enough wire for a person who can solder to join this wire end to its respective blade without it interfering with the blade’s contact to the structural conductor plate – a desirable alternative to spending a thousand dollars!
Many thanks to Juan Carlos Molina from Taller Molina in Argentina.