Classic/Antique Car Repair: Overdrive followup, rattling sound, coil wire

Question
Brad,  thanks for your help previously.  I have replaced my overdrive relay with a *modern* replacement that seems to work well (a 6v VW headlamp relay).

I can engage the solenoid now by grounding the THSW coil wire at any point, on the kickdown switch or right up to five inches from the governor.

I removed the governor and discovered that it was not making internal electrical contact at all. I disassembled it and cleaned up the points. Then it seemed to work properly. I spun it in my hand drill and watched it make and break the circuit as it sped up and slowed down.

I reinstalled the governor (with pretty high hopes!) and took it for a drive.

Well, I still have no overdrive, but am now convinced that I'm electrically OK. It freewheels like it should. However, I seem to hear a light "rattling" sound when the overdrive should be engaged. Since my lockout switch didn't work I put a toggle switch in its place and I can turn that on and off. When its on I can (barely) hear that light rattling sound. When its off I do not.

What do you think?

Answer
Sound to me as if it is time to pull the solenoid out of the car. It sound like the end of the solenoid that engages with the ring gear on the planetary might have worn away or broken off. If that is ok then it is time to pull the unit and open it up.
Brad