... hhmpf ...

See if this helps - https://fifthaveinternetgarage.blogspot.com/2015/10/borg-warner-r-10-r-11-tech-tips.html

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That second wire goes to the kickdown switch, and has something to do with the grounding/ungrounding of the points I think. The manual K posted the link to shows the wiring, but not the contacts in the switch. I never really understood how it worked, it just did. Magic.

Last resort call Mac at Van Pelt Sales. They sell most of the replacement parts, and he’s very good with the overdrives. Maybe he’s seen it before.

http://www.vanpeltsales.com/


miker
55 bird, 32 cabrio F code
Kent, WA
Tucson, AZ

Yes, it seems like the only way to engage the pawl in the trans is to put current to it and extend the plunger while installing it so I know that is not the problem.  It makes no sense that the solenoid will work with the flange loose but not when I tighten it.  There are blue and orange wires coming out from the solenoid.  The only wire which activates the solenoid is the blue wire.  What is the orange wire for?

Alan, are you getting the solenoid shaft properly engaged on the pawl? I know from experience that can be a problem.

miker
55 bird, 32 cabrio F code
Kent, WA
Tucson, AZ

Your solenoid is correct, the plunger should extend when power is applied.

John - "The Hoosier Hurricane"

I have that O.D. Manual but it doesn't specify exactly how the plunger works. 

See if this gives any help -

https://www.oldwillysforum.com/forum/TechData/BWOverdriveManual.pdf

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My '54 Ford is still using 6 volts.   I had a lot of difficulty getting the overdrive working when I first put this car together, but I finally got it to work.    It worked for awhile but then stopped working again.   When bench testing the solenoid, is the plunger supposed to be extended when there is no power to it and retract when powered?  Mine works just the opposite as the plunger extends when I apply power to the blue wire and ground the case and then retracts when not powered.  I saw online that someone was saying that the plunger retracts when powered but mine does the opposite.  Anyway, the solenoid  plunger moves when bench tested but when I install it and tighten the mounting flange nothing happens when I put power to it.  However, if I loosen the two flange bolts to hand tight only, the solenoid clicks when power is applied!  I know this sounds weird but that is what it is doing.  Can anyone help me figure out the problem?  Thanks