CCS100 cruise control **REPAIRED**

[cactusjack]

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.

I will have to test this later when I have more time, and will report on whether or not I successfully fixed this unit. I thought I would post this write-up now, because I know a number of you have these units and some of them have had problems. I hope this tutorial may help you out.

[blowndodge]

Very professionally done write up Scott!

I'm wondering if the fully electric cruise control (someone had a posting here) would last longer albeit it's more expensive. Toasting 3 of the Audiovoxs is excessive to me even if you know how to fix it.

[oldbikers]

I don't know what the problem is with this unit it must have something to do with it being on a motorcycle because I have used them in my hot rods for years with no problem I have one in my 65 Olds now but then the one on my bike is still working it just doesn't hold the correct speed.

[rickyboy]

Thanks Scott. Nice write up. I'll bookmark this thread on the chance that mine goes. I hope it all checks out good.
BTW.....were you at home working when you did all this? ??? ??? ???

[macmac]

And that's how you do it. Nice workin' Cj. I don't have that unit, never saw one either, but this is more or less the same way I fix relays with a dollar bill. Nicely done.

[cactusjack]

Originally Posted by rickyboy ... #00722

Thanks Scott. Nice write up. I'll bookmark this thread on the chance that mine goes. I hope it all checks out good.
BTW.....were you at home working when you did all this? ??? ??? ???

Uh...what's your point? ::)

[coacha]

Nice write up and pictures. Hope you got it figured out.

[cactusjack]

Originally Posted by CoachA

Nice write up and pictures. Hope you got it figured out.

I do, too. I'm on call this weekend, so I won't be riding. I should have time to hook up my "fixed" unit and find out if I really did fix it.

[macmac]

I think it will be fixed.

[Top Cat]

Very nice write up CJ,
But apparently you don't realize this is a throw away society.
Something quits working you toss it and buy a new one. If they don't make it anymore you buy the closest thing to it. ;)

[fatrat45]

nice job great info for future problems. and i agree with TC nothing is made to last anymore, and that real bad for a lot of people.

[AlabamaNomadRider]

Good job Scott, very well written. I think it will work when you reinstall it.

TC you are so correct in nothing being made to throw away. You can't find a safety razor that isn't disposable. Once upon a time there was some fine craftsmanship in the old razors. I do own several and still shave with an old metal razor.

[macmac]

Gene you said that backwards. I know because I speak backwards. It made sence.

[mac]

The same unit I installed in my car (Miata) quit working for some unknown reason, this may help me fix it. Let us know how it all turned out.

Thanks for the write-up!

[Cajunrider]

Very well done Scott.