Also came across this on another site. All text, no photos. Links were all dead. Not sure if this helps.
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Some of you may recognize this, it's the Audiovox CCS100 cruise control servo module.
I've had 2 quit working in the past 6 months or so. They just quit without warning and appear to successfully pass the troubleshooting tests provided by Audiovox in the manual that comes in the kit. These units aren't made anymore and I couldn't find one to puchase anywhere, so I thought I'd tear one down and see what makes them tick.
Internally, they are pretty simple, with a printed circuit board and 3 solenoids. These 3 solenoids are really vacuum control valves.
I removed the connector access plate:
Then I removed the mounting bracket. The 3 screws that secure the bracket to the housing also hold the end cap on the housing:
This reveals the printed circuit board. If you look near the vacuum hose connection, there are 2 tabs. I used a small flat blade screwdriver to lift the tabs and started to separate the housing. There are 2 more tabs on the back side of the housing. Unhook these tabs, and the 2 halves of the housing can be separated:
Note the tabs on either side of the vacuum fitting:
Separating the housing:
The solenoids are now revealed. You can pull the solenoid assembly away from the housing. There are 6 long pins that pass through the housing into connectors on the circuit board. I removed the circuit board and inspected both sides with a magnifying glass, looking for bad solder joints and failed components. I didn't see anything unusual.
Next, I used a 12v power supply (battery charger) and applied voltage/ground to each solenoid. The two outer solenoids made a nice, solid "click" when energized. The center one made a wimpy sort of buzzing
sound. I figured maybe the center solenoid was stuck.
The solenoids slide off the mount they're on, just use a small blade behind them and they slide right off:
Solenoids, bracket and circuit board assembly:
Each solenoid can be disassembled easily. Pry the metal plug out of the bottom (not difficult, just held in place by an o-ring) and you can get to the spring and plunger. (Note the orientation of the plungers).
This is the disassembled center (vacuum supply) valve:
I used some rubbing alcohol and a cotton swab to clean the internal cavity of each solenoid. I also used a little rubbing alcohol on a rag and wiped the internal parts down as well. I then used a little silicone grease on the o-rings and reassembled each solenoid. I then re-installed the solenoids in the holder they mount to and then slid the black rubber seal down over the pins:
Next, I tested the solenoids again by applying voltage and ground to each set of pins. The vacuum supply solenoid now made a nice "click" when energized. I then reassembled the solenoids, housing plate and circuit
board. If you look at the solenoids, you will see an opening where each solenoid meets the vacuum module (the part of the unit that the throttle cable comes out of):
I did not attempt to tear the vacuum module down, because I was afraid of damaging a seal or something that might cause a vacuum leak. There is a small o-ring that seals each solenoid to a matching port on the vacuum
housing. I lubed each o-ring with some silicone grease and inserted them into the solenoid openings:
I then slid the solenoid/circuit board assembly onto the vacuum module housing, making sure the 4 tabs snapped to secure the 2 halves of the housing:
I reassembled the remainder of the unit by attaching the top cap and the mounting bracket.
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