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I just installed new diodes to replace the copper rectifier discs on my ZW.

One side was easy and works well.  The other side (right hand) has an issue I cant solve.  The whistle blows as soon as I give it track power.  Measuring the voltage on track, it has about 1.6V DC which is activating the whistle.  Moving the whistle lever give it more voltage until full stroke stops the whistle.  I have taken apart the whistle assembly a couple of times to reinstall thinking the insulator gaskets shifted.  No change.

I have read the instructions on Tranz4mr site and watched the OGR video on the subject so I believe I have it assembled correctly, but obviously something is backwards.   I left the transformer in position on the layout so none of the connecting wires have changed.

Any ideas or diagnostics to try?

Thanks, Bob

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Thanks Jerry

I too had problems with short wires so I extended the wire that goes to the shaft spring.  Right side only needed it.
I checked all the continuity and diodes and everything seems fine.  So I thought what is different from my right hand track and left hand track.  The difference is I have a Lionel sound activation button on the right hand lever track so I can activate bells on some newer engines.
I didn’t think this would have any effect since I did not activate when installing the diodes.
but i pushed it and cycled it a few times.  
The whistle switch now works correctly.  Somehow that activation switch was stuck on sending 1.6v dc to the track continuously.
I don’t understand why but the whistle works now.  I haven’t tried a bell yet.  That’s for another time.

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