SONNAX Catalog Transmission

Quality Engineered Products
TRANSMISSION SPECIALTIES
VOLUME 4 2001
SPRING SPRING
On-line Action
he Sonnax Transmission Specialties site at www.transmissionspecialty.com has been redesigned and is one of eight distinct and affiliated sites. The main site at www.sonnax.com serves as a portal for webpages that focus on the following product lines: TS (Transmission Specialties), Torque Converter, SonnaFlow, Sonnax Information, High Performance, Ring Gears, Manual Clutch, and a site for our other products (which includes Allison Replacement Hard Parts, Friction Papers and Band Linings, and Harley Davidson Replacement Bearings). We will be adding more sites in the future, including a web site that focuses on technical questions. Because of the new site, we will be able to better serve our customers by providing the information pertaining to the Transmission Specialties product line and our customers area of expertise and interest without items not relevant to their business. The site is revised weekly with listings of recent updates. Our dynamic menu that allows the user to search by part make (GM, Chrysler, etc.), application (4L60, 41TE, etc.) and part type (boost valve, front pump bushing, etc.) has been redesigned and is more userfriendly. We also have on-line instructions for products, making it easier to install our products if instructions are lost. These instructions provide more detailed information, allowing for additional helpful information such as Wet Air Test (WAT), wiggle test, additional photos, reaming instructions, general tips, and other problems to look for as well. The Information page contains numerous technical articles, the 2001 Seminar Schedule, our Sonnax Spanish site and a Featured Parts section. New articles, on many different topics and written by various industry experts as well as Sonnax engineers, are added regularly. The technical articles are
From the main portal site hundreds of pages of information can be accessed with the click of a button.
organized by product line, and listed from the most recent date to the oldest. Each article has a synopsis under the title. Customers have downloaded a number of these technical articles every day since they were placed on the site and over 10,000 times to date. Additional articles will also be added to this page regularly. The Seminar Schedule enables customers to know which shows we will be attending, where they are being held, and who is sponsoring the seminar. The Spanish site contains TS announcements and technical articles and is continually being developed to mirror our TS site. The New Featured Parts Section includes brief product summaries, and links to the announcements and additional information. The new site also makes it easier to contact a Sonnax Salesperson and receive technical help. Customers can fill out a form to request catalogs, our newsletter, or email updates on new TS products. Please be aware that to view the individual parts announcements, a password is required. To get a password, complete the password request form at http://www.sonnax.com/account_request.htm. Due to a high volume of password requests, it may take a few days for your password request to be processed. Come visit us at www.sonnax.com for each of your aftermarket product needs!
APPLICATIONS
8 52 General Motors Ford
100 Chrysler 118 Foreign

HONDA TOYOTA MAZDA KM/JATCO ZF
132 High Performance
TECHNICAL DISCUSSIONS
IFC On-line Action 4 50 60 78 98 Valve and Bore Inspection GM Friction Materials and Applications Transmission Gerotor Pumps Sonnaflow: Cooler Flow Sensor Bushings Take a Beating
108 Designed for Durability 115 Converter Code Blues? 116 So Wheres the Connection? 124 Restoring the Valve Body: Reamer Technique 150 Sealing the Seals, Bore Prep is More than Elbow Grease and Sandpaper
PRODUCT CHARTS AND LISTINGS

2 Sonnax Valve Family Chart 123 Sonnax Precision Reamers 140 Sonnax Small Parts Program 142 Shims, Allison and Bearings 146 Transmission Replacement Parts Showcase 152 Complete Sonnax Transmission Specialty Product Listing
Symbols used in this catalog: :Sonnax featured part :Sonnax part also available
O TO L
:Tool required for installation

E
D
QUIRE
R
R
QUIRE
INI
CH

:Machining required for installation
:New Sonnax part introduced in this catalog
2001 SONNAX INDUSTRIES
:New Sonnax part soon to be available
DESIGN BY SONNAX CREATIVE DEPARTMENT
SONNAX FAMILY VALVE CHART

PR BOOST PR VALVE TV BOOST/CONTROL
75918-01K 8 65754-Series 9 84754-12K & 17K 42 84754-12K, 17K 42 84570-30K 44 34910-03K 11 77917-06 33 77917-07 33 34910-01K 11, 34910-05K 11 77917 Ser. 18, 77968 19, 77966 Ser. 20 77898E-K, & 77898E-4K 32 77898E-3K, & 77898E-6K 32 84754-16K, 22K 41 84754-01K,08K,16K ,22K, 97K, 98K 40-41
TCC/BYPASS
GENERAL MOTORS
125 200, 200C 4T60 4T60-E 4T65-E 350 400 4L60 4L60-E 4L80-E 77805-K 28 77754-03K, 04K, 29 77805E-K, 77805-K 28 34994-01K 49
FORD
C6 E4OD A4LD 4R44-E, 4R55-E AXOD AXOD-E, AX4S AX4N AOD AOD-E, 4R70W ATX CD4E 36424-01K, 03K 56 56947-02K,03K,04K,05K 66 56947-06K 67 37947-01K 71 96201-01K, 08K,12K,13K 87 96201-01K, 08K,12K,13K 87 96201-01K, 08K,12K,13K 87 76990K, 03K 73 76948-02K 81 76948-01 & -09 81 73480-RK, MK 94
96201-06K 86 96206-01K 89 96206-03K (AX4N), 92 96206-01K 89 76989K & 03K, 72 76970 75 76948-04K 80 86940-01 & 03 83 73840-BK, MK 94
CHRYSLER
A904/42RH A727/46RH 47RH A404, A413 A470, A670 41TE 42LE 12229-01K 109 22229-01K 109 22771-01K 110 22771-01K 110 22771-01K 110 22771A-01 (42RH only) 111 22771A-01 (46RH only) 111 22771A-01 111
92835-07 102
92835-03K, 101 92835-02K, 104 92835-03K, 101 92836-01K 105
MAZDA
G4A-EL GF4A-EL 71846-01K 121 74846-01K 121
MITSUBISHI
KM four speeds
JATCO
L4N71B 66942-01K 128 RL4F02A(various others) 93990 130 66942-01K 128
TOYOTA
A130 A131 A132(L) A540-E 89010-01 119 89010-01 119 89010-01 119 89031-01 119
OTHER
ZF4HP14
2
85991-01 131
2001 Sonnax Industries, Inc.
sonnax
800/843-2600 802/463-9722 fax: 802/463-4059 www.sonnax.com info@sonnax.com
SONNAX FAMILY VALVE CHART

REVERSE BOOST
75918-01K 8 84754-14K, 19K 42-43 84754-14K, 19K 42-43 84573-01K 13 84573-01K 13 35718-01K 13 34910-01K, 05K 11 K77898 & K77898A 18 77898E-K & 77898E-6K 32 77898E-3K & 77898E-4K 32 34200-01K, 03K 46 34105-01K 13 77999 13 77754-01K 13 35709-01K 10 77998-01K 34 77998-01K 34 34989-02K 45 75410-10, 37 84733-10 & 20 36 75410-10, 37 84733-10 & 20 36 77406-10 26 34500-Z 12 77406-10, 77409-15 26 77406-10, 77409-15 26 34500-Z 12
MANUAL VALVE
ACC. PIN KITS
ACC. SLEEVE KITS
SHIMS
36946 Series 53 56947-01 70 96201-01K, 08K, 12K,13K 87 96201-05 90 96201-01K, 08K, 12K,13K 87 96201-05 90 96201-01K, 08K, 12K,13K 87 96201-05 90 96511K, 12K, 13K 91 96511K, 12K, 13K 91
36428-Z & A-Z 52 36402-Z 64
73840-24, -LR & -FWD 97
86539-Z5 84 73251-01K 93
12780-Z 106 22700-Z 112 32539-Z5, 35539-Z5, 100 39539-Z5 100 92834-03K 104 39539-Z5, 100 92965-Z5 106
71400-15 122
41750-03 126
Buy Buy Genu Genu iine S ne So onna nnax x Par Parts ts

92834-03K 104 Part number Page number
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Valve and Bore Inspection

BY BOB WARNKE
very trade has developed special equipment to do a job quickly, accurately or with greater safety. The Electrician carries a circuit tester, a Lineman has rubber safety boots and gloves and the Transmission Rebuilder has his pocket screwdriver. Valve bodies are delicate. Inspection often begins with a pocket screwdriver, but ends with a ball peen hammer. After use of the hammer, it is heated, lubed, twisted and tossed while mumbling bosura. But scrapping the original valve body leads to high parts costs, down time and calibration concerns. Omitting the visual inspection can lead to bigger problems.
Visual Inspection: Some say All you have to do is look at aluminum valves or bodies, and they will stick. The point of this article is that outside inspection may not find an internal problem. We are familiar with picken and lookin at cast iron valve bodies, but on aluminum, getting anxious or pushing material causes it to get ornery and fight back. Using a round pick to stroke raw aluminum or anodized valves, often creates valve hang-up. Most of the new valves have an anodized hard coat, which penetrates into the aluminum by .001. The build up is very hard, yet brittle and sharp at the edge, which works as a wiper. Prying on that edge raises a Figure 1: Varied flat blade angles pry on spool face instead of sharp edge. slight burr, which causes Bores that have raised edges can be resized by the valve to seize in the bore. That burr may only extend .0015", but with aluminum valves and castings, inserting a drill shank, centering pins or a steel valve the minimum valve to bore clearance (diametrical) is and then lightly tapping on its side. Spinning a shank .0005" and maximum is .001". In comparison, the tol- with a low speed drill, and running abrasive cleaner erance with cast iron bodies and steel valves is twice over it, works to quickly polish a bore. Specific bore that of aluminum, due to steels expansion properties. sizing tools, which duplicate the OEM valve, work To prevent raising a burr, a set of valve stroking well for reforming material. Care must be taken if tools should be made from two flat blade pocket emery cloth is used to rework bores, as they easily
screwdrivers. Heat the tip and bend a 45 curve into one and a 90 curve into another (Figure 1). Start to move the valve from the face of a spool, as a circuit opens, continue with a 45 curve, follow using 90 curve, until the valve is fully stroked through its travel. Reverse the process slowly, allowing the valve to come back to rest. This identifies rough surfaces and bad springs. Valves normally spiral slightly during the compression of the spring, but should not catch or coil bind before full stroke. Long stem aluminum valves commonly bend after repeated bottoming. The AXOD-E forward control valve is an example. All valves should be rotated slowly while stroked to identify warpage. Some anodized valves flake at the edge or become sharp and rough. Rotate the valve against a fingernail and if the edge catches the nail, run a jewelers file over it.
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Figure 2: 4L60-E AFL limit valve bore wear.
become out-of-round. Valve and bore finish affects valve seal, stroke and oil loss. Bore surface finish is specified to be no rougher than 45 micro-inches. This number represents deviation from an average surface, where a low number is similar to a polish. The valve finish should be near 15. Surfaces rougher than this reduce valve action and increase leakage. These standards explain why reamers need a slow feed, cutting fluid and should not be loaded inward. The manual stroking of valves as mentioned in Figure 1, will not identify a worn bore. Remove and inspect valves and bores which are reacted on by duty cycled solenoids Which and Wear: The quick stroking of valves will not identify bore wear unless the area of focus is clear. To begin with, look at valves and end plugs, which are reacted on by duty cycled (pulsed) solenoids (Review the Complaint, Cause and Correction information in this catalog). Since the valve body is designed to control hydraulics, we can use oil diagrams to identify pulsed or active shift solenoid circuits. Find that circuit on paper and transfer it to the oil reacting on the valve, which indicates an area of concern. Visual Bore Inspection: The scrubbing action from contamination, high cycle rates and fluid loading on the valve etches away the
AFL
casting. This is comparable to a heavily traveled road or stair tread wear. When the valve is removed, look for worn pockets opposing the fluid entry side of the bore (Figure 2). A flashlight set over the casting with or without the valve installed can be a good visual indicator of wear. Examine bores closely when one spool separates a pressure from an exhaust circuit (Figure 3). Inspect short valves or plugs located between springs and oil circuits. Short valves and plugs want to tip into the bore or round off their edges. This movement and wear will jam the valve or allow oil to pass around it (Figure 4). Examples of this are found in 604 switch valves, 4R44E reverse engagement and AOD end plugs.
RIDGES Figure 4: Valves with high aspect ratio (length to height) are proned to toggle.
Measuring Bores: The actual valve to bore clearance can be measured with small dial bore gauges, telescoping gauges and pin gauges (Figure 5). The measuring equipment must be accurate to tenths of a thousandth or .0001". Measurements should include taper and concentricity to verify the total tolerance. Suggested valve to bore tolerance of aluminum valve bodies is .0005" minimum and .0012" maximum of total I.D. to O.D.
WEAR
EXHAUST Figure 5: Measurement Tools
Figure 3: Inspect bore which controls exhaust.
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(diametrical) clearance. To translate this for a wiggle test, .003" will slightly move or push oil from between the spool and bore. Beyond those figures leakage becomes excessive, and you can feel or wiggle the tolerance and see significant leakage during a Wet Air Test (WAT). The 4T60-E TCC apply valve (inside small spool) visibly moves with .005" clearance. The CD4E pressure Figure 6: Sag Test regulator bore (small spool) will WAT and leak severely with .004" and is often worn over .008". Wiggle Test: If the valve is assembled, prop the valve into the position that it regulates or cycles in, not the at-rest position. Place a pocket screwdriver on each side of the valve stem, then pry it into, and out of the loaded position, simulating the fluid forces. If it visibly moves, it is over the maximum tolerance specification. If it toggles easily from side to side of the bore, the body should be replaced or repaired.
Inverted Valve: This refers to inserting a valve backwards and positioning the mating spool where it lives in the bore. A close tolerance of the valve to bore will not allow the valve to sag off-center (Figure 6). This sag test can be visual, but is best defined with a Go-No-Go pin or drill bit. This procedure works on any valve, but is best defined with two spool diameters, as the 4T60-E and CD4E TCC valves. Knowing critical dimensions allows calculating a measurement or gauge pin. When possible, Sonnax will define measuring procedures or Go-No-Go gauges for excessive clearance. Wet Air Test (WAT) or Captive Air Test: This is a visual leakage test, similar to air checking a clutch. Sonnax identifies WAT locations whenever possible, because it educates visually, is a familiar practice and identifies excessive clearance (Figure 7). To isolate problems, the best results include using regulated air (30-40 psi); a controllable vacuum gun such as a rubber tipped Vacula, and a small amount
Figure 7: Wet Air Test
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of ATF fluid to identify the leak. A finger, shop rag or small plate is often used to enclose the circuit being pressurized. With a good fit between the spool and the bore, little to no leakage will pass through the surface area. Limitations of this test include the relatively higher viscosity of ATF used at room temperature and experience to know good vs. bad leakage. Air Gauges: This test requires the predetermined airflow and pressure values on a sealed working valve circuit. The airflow meter can either be pressure or flow sensitive. Generally these include a tube in which a ball is suspended by air held within the circuit. A pass-fail standard is set, and when leakage is excessive, the position of the ball lowers to indicate the leak. Remanufacturers use this test because of their high volume; it creates less mess, and once a standard is set, limited experience is needed. Drawbacks include each circuit must be isolated so plates must be developed, as well as instrument costs. Hydraulic Test Bench: Hydraulic control over a valve body in a simulator is accurate and closely duplicates the vehicle operation. As valves wear and new problems arise, the test procedure can be modified to pinpoint the problem. This material was compiled to explore different methods of testing and service work to valve bodies. Rebuilders have likely developed their own procedure, but I hope this material leads to improved results and success, together with a pocket screwdriver.
Technical Information/ Diagnostic Resources

Sonnax recognizes these groups as the leaders in transmission technical services and publications, providing rebuilders with the necessary information to keep up with the complex changes that hit our industry every day. The days of the 400 are far behind us. Transmissions cannot be fixed by just replacing the failed part any longer. Learn what it takes to repair today's transmissions, from understanding electronics, to using diagnostic tools, changes in component design and much more.
www.atra-gears.com 805-604-2000
www.atra-gears.com 805-604-2000
www.transbuilder.com 602-494-6233
www.transmissiondigest.com 602-494-6233
www.atsgmiami.com 800-245-7722
www.transonline.com 888-762-0229
www.iatn.net 714-257-1335
If you want to be a profitable shop and be able to keep up with the latest in transmission technology, become a member of these groups by joining now!
www.asashop.org 1-800-272-7466
www.sonnax.com 1-800-843-2600
sonnax
125-C
Complaint Delayed reverse engagement
Secondary Complaints: Poor line pressure Poor upshift quality Burned bands and clutches
Reverse Valve
Part No. 75918-01K
T V A N D R E V E R S E B O O S T VA LV E K I T
Sleeve
Cause
End Plug
Worn TV and reverse boost valve sleeve resulting in TV/Reverse oil cross leakage or exhausting
Valve Body
Retaining Ring
TV Valve
Correction
This replacement TV and reverse boost assembly eliminates these problems with four closely toleranced parts that restore hydraulic integrity of the circuits to prevent cross leaks and raise line pressure. Part No. 75918-01K
1985 and later models
SONNAX PART SUMMARY
ommon problems with a 125-C transmission are burned clutches or band, poor line rise response, or delayed reverse engagement. These problems can frequently be caused by a worn TV and reverse boost valve sleeve. The steel TV and reverse plungers continuously oscillate in the aluminum sleeve, which can cause wear resulting in oil cross leaking or exhausting. This oil loss can prevent the pressure regulator valve from reaching higher line pressure (maximum pump output) positions. The Sonnax replacement TV and reverse boost valve assembly 75918-01K eliminates these problems with four closely toleranced parts: a hardened steel TV boost valve, a hardened steel reverse boost valve, a high quality aluminum sleeve and an end plug. These parts will restore the hydraulic integrity of the circuits to prevent cross leaks and raise line pressure. This kit is designed for the late model (1985 and up) valve bodies.
1 Sleeve 1 TV Valve 1 Reverse Valve 1 End Plug 1 Retaining Ring
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200C
Poor line pressure
200-4R
Part Nos. 65754-01K, -02K & -03K
Complaint Soft 1-2 shift, poor detent and up-shift control

Secondary Complaints:
T H R O T T L E VA LV E S L E E V E K I T S
Valve Body
Poor upshift quality Burned bands and clutches
Throttle Valve Plunger

Spring Part Throttle Orifice
Cause
Plunger bore wear creates TV leaks that get worse as the unit heats up
Roll Pin Annular Grooves Shift Throttle Valve Orifice
Detent Orifice Identification Grooves (2 Grooves Shown)
Correction
These valve sleeve kits have annular cleaning/centering grooves added to the valve and an identification groove added to match OEM. Part No. 65754-01K Part No. 65754-02K Part No. 65754-03K
Each includes the following: 1 TV Plunger 1 TV Sleeve
Throttle Valve Sleeve
SONNAX PART SUMMARY
oor line rise, no detent downshifts, and soft 1-2 shifts are common complaints in vehicles with a 200 transmission. The steel throttle valve plunger continuously reciprocates within the steel throttle valve plunger sleeve, wearing the sleeve. This wear allows shift TV oil to leak past the plunger and exhaust, resulting in poor line rise. Also, detent feed oil leaks past the plunger and results in poor shift timing and/or soft shifts. This excessive leakage can be eliminated by installing one of three Sonnax replacement throttle valve plunger and sleeve kits: 65754-01K, 65754-02K, or 65754-03K. These three kits have different sized plunger diameters that must be matched to the vehicle's TV valve. Identification grooves have been added for ease in matching with the OEM TV valve (see chart below). Both the sleeve and plunger valve have been tightly toleranced to restore the hydraulic integrity of the circuit. Annular grooves have been added to the plunger valve for cleaning and to minimize side loading that creates friction leading to sticky and erratic operation.
Sonnax P/N
65754-01K 65754-02K 65754-03K
TV Valve Groove
no machined grooves 2 machined grooves 1 machined grooves
TV Plunger Dia.
.357" .390" .430"
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350 & C
Complaint Delayed engagement
No engine braking in manual 2nd Low line pressure in R, N, D Part No. 35709-01K
1 Piston, Servo 1 Sleeve 1 Teflon Seal
Spring
Part No. 35709-01K
Cause Correction
Case bore wear and oil loss at the intermediate servo This drop-in sleeve and piston salvages the case, and eliminate the complaints caused by oil loss.
I N T E R M E D I AT E S E R V O P I S T O N A N D S L E E V E K I T
Case
Spring Seat Pin
Washer
Repair Sleeve
Piston with Teflon seal installed
4L60-E
Complaint Stripped bell housing bolt heads
Cause
Part No. 77000-HBK
98 & Later with 2 Piece Case
Part No. 77700-HBK
Standard Torx bits often fit loose and damage the bell housing bolts during removal or installation of the bolts Use this Torx Plus bit for removing bell-housing screws.
Correction
1 Torx Plus Bit
T O R X P L U S B I T F O R B E L L H O U S I N G B O LT S
Torx Plus Bit
Bolt
10
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400
PR Valve: Delayed converter charge Poor reverse engagement Boost Valve: Soft 1-2 and 2-3 shifts Delayed reverse
Teflon Seal
Part Nos. 34910-01K, -03K & -05K
Complaint High line pressure, poor line rise

P R E S S U R E R E G U L AT O R A N D B O O S T VA LV E K I T S
PR Valve
End Plug
O-Ring
Cause
Wearing of the pump body casting or boost sleeve
Modulated Boost (Check for cross leaks with the pump halves assembled)
Pump Body
Reverse Orifice
Modulated TV Orifice
Correction
Use of these pressure regulator valve and reverse boost valve kits restores the hydraulic integrity of the pump. Part No. 34910-01K
1 Boost Valve 1 Boost Sleeve 2 O-Rings
O-Ring
Boost Valve Boost Sleeve "Factory style"
SONNAX PART SUMMARY

ehicles with a 400 transmission will often exhibit wear in the pressure regulator and reverse boost valve circuits. Wear in the pressure regulator area creates high and uncontrollable line pressure, delayed converter charge or poor reverse engagement. This may also result in high cooler pressure causing converter, crankshaft and/or friction element failure. Wear in the reverse boost sleeve results in poor line rise, soft 1-2 and 2-3 shifts and/or reverse engagement or shudder. The Sonnax replacement kits 34910-01K & 34910-05K reverse boost valve assemblies, and 34910-03K pressure regulator valve kit, restore the hydraulic integrity of the unit and salvage hard to find cores. The boost valve and sleeve kit is manufactured from high-quality heat-treated steel and the sleeve is available with or without (Factory style) o-rings. The pressure regulator valve incorporates a solid Teflon seal to prevent cross leakage between orificed line pressure and pump suction. The kit also includes an o-ringed end plug to assure proper back pressure to the pressure regulator valve.
Part No. 34910-05K

1 Boost Valve 1 Factory style Boost Sleeve
Part No. 34910-03K

1 Pressure Regulator Valve 2 Teflon Seals 1 End Plug 1 O-Ring
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11
4L80-E
Front/rear unit excessive endplay Premature seal ring failure Part No. 34500-Z
10 Shims (.010" Thick)
Application Note: Not for use in 97-up 4L80-E centerlube units. Use of shim in these units will restrict lube.
400
Part No. 34500-Z
Complaint Burned forward clutches

Cause Correction
Normal component wear allowing forward & direct drum travel, resulting in excessive unit endplay This unit endplay shim allows for proper setting of front unit endplay and supports the direct drum by supporting the sun gear.
U N I T E N D P L AY S H I M
Reaction Drum & Carrier Assembly Output Carrier Assembly
Rear Internal Gear Sun Gear
Sun Gear Thrust Bearing
Shim
4L80-E
Output shaft and case damage Metal contamination Part No. 34006-SP
1 Case Bushing
400
Part No. 34006-SP
Complaint Bushing walks out

Cause Correction
Lack of flange or stop surface on the case bushing This no walk-out case bushing is flanged to prevent movement in either direction.
NO WALK-OUT CASE BUSHING

Case Bushing case bushing has oil grooves
Thrust Washer
Transmission Case Selective Washer Lip prevents bushing from traveling toward front or back
12
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VARIOUS GM
Complaint Burned forward clutches/band
Secondary Complaint: 2nd & 4th clutch failure (84573-01K & -02K only) Part No. 77754-01K
4L60-E
O V E R S I Z E D A C C U M U L AT O R P I N S A N D R E A M E R S
Part No. 77999

4L60, 200-4R & 325-4L
4 Accumulator Pins
Note: For use with accumulators having an original pin diameter of 0.235".
4 Accumulator Pins
Note: For use with accumulators having an original pin diameter of 0.309".
Part No. 77754-02K

4L60-E
Part No. 77999-02K

4L60, 200-4R & 325-4L
10 Accumulator Pins 1 Reamer
Part No. 35718-01K

350
Part No. 34105-01K

400
4 Accumulator Pins 8 Retaining Rings (4sml, 4med)
4 Accumulator Pins 4 Retaining Rings
Part No. 35718-02K

350
Part No. 34105-02K

400
10 Accumulator Pins 20 Retaining Rings (10sml, 10med) 1 Reamer
10 Accumulator Pins 10 Retaining Rings 1 Reamer
Part No. 84573-01K

4T60 & E
4 Accumulator Pins
Part No. 84573-02K

4T60 & E
SONNAX PART SUMMARY
t is very common in GM units to find worn accumulator piston bores. This wear allows oil to cross leak into other circuits causing various complaints such as burned forward clutches, direct clutch/band failure and poor shift quality. Rather than replacing hard to find or expensive pistons, Sonnax offers oversized accumulator pins to restore hydraulic integrity of the piston. Each package contains four pins; a starter kit with 10 pins and 1 reamer is available on all applications.
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13
Improvements
NOT JUST REPLACEMENTS
SONNAX TRANSMISSION SPECIALTIES
Innovation:
Sonnax utilizes a unique professional network of design engineers, technical experts, and shop technicians to analyze mechanical problems in existing units. Each new Transmission Specialties product starts as a request to address a specific problem. Sonnax depends on input from professional rebuilders and our TASC Force Members. These problems are then turned into the highest quality, innovative, durable, cost-effective solutions.
Engineering:
A talented team of Sonnax engineers, whose combined experience totals over 200 years, diagnose the causes, specify the materials, and design our Transmission Specialties parts using the latest and most appropriate technologies available in the industry. Our Sonnax Technical Center works closely with our engineers in the design and proving of prototypes.
Testing:
Thorough and extensive testing is a critical part of our process. Before our parts are approved and offered for sale, careful testing is done at the Sonnax Technical Center and at TASC Force and associated transmission shops both on the bench and on the road. Proving of our Transmission Specialty parts is a joint effort between the Technical Center and the Sonnax-sponsored TASC Force (Technical Automotive Specialties Committee), a collaborative group of highly skilled and talented transmission experts.
For further information on Sonnax Transmission Specialty parts, please visit us at:
www.sonnax.com
Contact your Transmission Specialty distributor and ask for genuine Sonnax quality parts.
VARIOUS GM
Complaint Soft 1-2 upshifts
Part No. 6578-01
M
Part No. 6578-01
I N T E R M E D I AT E S E R V O P I S T O N B U S H I N G
200, 200-4R & 325-4L
A
CH
INI
5 Nylon Bushings
Note: This repair requires machining.
SONNAX PART SUMMARY
QUIRE
Intermediate Servo Piston Bushing
ommon complaints of vehicles with 200, 200-4R & 325-4L transmissions are soft 1-2 upshifts, a flare on 2-3 shifts, and premature band failure. The Sonnax intermediate servo piston bushing 6578-01 restores the OEM bore size, reducing oil leakage past the pin, and eliminating the replacement of the costly OEM servo piston.
Part No. 35410-T
Complaint
Part No. 35410-T
350, 400 & 4L60
Governor circuit oil loss, worn case bores, sticking shift valves
GOVERNOR CIRCUIT TEST TOOL
1 Governor Circuit Test Tool

Note: Diagnostic tool can be used at rebuild bench or in vehicle. Governor Circuit Test Tool
SONNAX PART SUMMARY
his Sonnax governor circuit test tool is specifically designed to test the governor circuit of 350, 400 & 4L60 transmissions for a worn bore, obstructions in the circuit, misalignment of the assembly, circuit leakage, or incorrect shift points due to oil loss or hanging valves.
Part No. 35012S
Complaint Bushing spin-out and case damage

Part No. 35012S
4L60 & E
M
A
OVERSIZED REAR CASE BUSHING

CH
INI
5 Rear Case Bushings

Note: This repair requires machining.
QUIRE
SONNAX PART SUMMARY
Rear Case Bushing steel-backed bronze lining
T
16
he OEM rear case bushing in the 4L60 & E transmissions spin out causing case damage. After the damage, it's impossible to reinstall a standard bushing. Bushing spin out may be due to lack of lubrication or too much load for the bearing area. Replace with Sonnax's oversized rear case bushing 35012S.
sonnax
4L60 & E
Complaint Poor 1-2 shift
Part No. 77911-01
M
Part No. 77911-01
2 N D A P P LY S E R V O S A V E R S L E E V E
A
5 Servo Saver Sleeves
CH
INI
Note: The Sonnax sleeve allows E Q E UIR the #554 inner sleeve to fit a #553 piston. With a minimal amount of machining the #554 piston can convert to a #553 piston.
R
SONNAX PART SUMMARY
Servo Saver Sleeve
n vehicles with a 4L60 & E transmission, servo apply areas often need to be increased to improve 1-2 shift. This is often done by replacing the 2nd servo piston assembly, typically with the #553 version. This practice has caused an overabundance of used #554 servo assemblies and poor availability of quality #553 assemblies.
Part No. 77911-02
Complaint Burnt 2-4 band

Part No. 77911-02
M
PISTON BORE SEAL

A
INI CH
5 Metal Clad Viton Seals
Note: Slight machining of servo piston is necessary to accommodate the seal.
QUIRE
SONNAX PART SUMMARY

omplaints of no 3rd gear, 2-4 band applying in 3rd gear, and burned clutches/bands can be caused by wear at 2nd apply servo piston. This metal clad Viton seal 77911-02 will restore the hydraulic integrity of piston/pin interface. This prevents 3rd accumulator oil from exhausting past a worn piston.
Metal Clad Viton Seal
Part Nos. 77731-01, 02K, -03, -04, -05, -08 & -RK
Complaint Planetary wear or failure

R E A R P L A N E TA RY R E B U I L D PA R T S
Part No. 77731-RK

Complete Planetary
Part No. 77731-02K

4 Pinion Pins
Note: Pinion endplay factory specification of between .008" to .024".
Part No. 77731-03

80 Needle Rollers
Part No. 77731-05

1 Batwing Washer
Part No. 77731-01

1 Pinion Gear
Part No. 77731-04

1 Round Washer
Part No. 77731-08

1 Oil Deflector (not shown)
sonnax
17
4L60 200-4R
Delayed reverse Soft slide shifts
Part Nos. K77898, K77898A & 77917-01K, -02K, -03K, -04K, -471, -500
Complaint Poor line rise, burnt clutches and band

R E V E R S E & T H R O T T L E B O O S T VA LV E S & S L E E V E S
Pump Body
Cause
Worn reverse boost valve sleeve or wear at pump body and worn TV boost sleeve
Pressure Regulator Valve
Spring
D2 test with oil here
Correction
These reverse & throttle boost valve kits, are made from hardened steel, with optional o-rings. Throttle Boost Valve
(O-ring Style)
Reverse Boost Valve & Sleeve TV Boost Valve & Sleeve Retaining Ring
Factory style Sleeves
Part No. 77917-01K

.423" diameter
SONNAX PART SUMMARY

common problem with the 4L60 and 200-4R transmissions is a burned band and/or clutches. This failure can be reduced by eliminating boost oil leakage. The Sonnax Factory style replacement assemblies 77917-02K, 77917-03K, and 77917-04K eliminate these problems with two closely toleranced, hardened steel parts: a throttle valve boost valve and a throttle valve boost sleeve. The three kit numbers are used for different applications. In addition, Sonnax offers the same replacement assemblies with o-rings on the throttle boost sleeve for extra protection: 77917-01K, 77917-471, and 77917-500. The o-rings on the sleeve separate the throttle pressure and reverse boost circuits, thus providing additional protection against cross leaks by preventing oil loss between the outside diameter of the throttle valve sleeve and the pump body. Complaints of poor reverse, delayed reverse or shudder in reverse can be traced to a worn reverse boost sleeve or pump bore. The Sonnax Factory style K77898A and o-ring style K77898 boost valve kits address this wear, while the o-ring style K77898 will also salvage pumps with a worn bore.
Part No. 77917-471

.471" diameter
Part No. 77917-500

.500" diameter
Part No. 77917-02K

.423" diameter Factory style
Part No. 77917-03K

Part No. 77917-04K

Each kit above and to the right includes the following: 1 Boost Valve 1 Boost Sleeve 2 O-Rings (O-ring style only)
Part No. K77898 Reverse Boost Valve

(O-ring Style)
Part No. K77898A

(Factory style)
18
sonnax
4L60
Complaint Poor line rise
Secondary Complaint:
3-4 clutch and band failure
Part Nos. 77968 & -RM
O V E R S I Z E D T H R O T T L E VA LV E
Cause
A low throttle boost oil condition
Valve Body
Correction
Oversized Throttle Valve
Reamer
Stop the excessive leakage by installing this oversized replacement throttle valve that has slightly larger spool diameters. The valve body bore can be made larger with the special reamer. The oversized valve will fit the newly reamed bore. Part No. 77968
1 Oversized Throttle Valve
R
O TO L
SONNAX PART SUMMARY

low throttle boost condition is a common complaint in vehicles with a 4L60 transmission. This loss of throttle boost oil creates poor line rise and accelerates 3-4 clutch and band failure. In late model transmissions, the hardened steel throttle valve continuously oscillates in the cast iron valve body bore and eventually wears the three bore diameters. This wear allows throttle valve feed oil to leak past the valve spool and exhaust, resulting in a low throttle boost condition. This excessive leakage can be eliminated by installing the oversized Sonnax replacement throttle valve 77968. The three spool diameters on this valve are slightly larger than the late model OEM valve, allowing the valve body bore to be modified to restore the hydraulic integrity of the assembly. The valve body bore can be made large enough to accept this replacement valve by reaming it with the specially designed reamer 77968-RM. This hand reamer has three tightly-toleranced cutting diameters that will slightly enlarge the valve body bore in the area of the throttle valve. The reamer is piloted by the bore of the throttle valve plunger sleeve. This is much less expensive than replacing the worn valve body. It eliminates mis-calibration or similar wear when exchanging with another used valve body.
QUIRE
Part No. 77968-RM

1 Reamer
Note: It is necessary to use Sonnax Reamer 77968-RM to re-size the worn valve body bore.
sonnax
19
4L60
No detent downshift Poor throttle control Part No. 77966-93K Part No. 77966-94K
Part No. 77966-94MK
Each kit contains the following: 1 Plunger 1 Sleeve
Notes: 1. 77966-93K (OEM 93) 77966-94K (OEM 94) 77966-94MK (High Performance) 2. The 77966-94MK is a high performance sleeve that allows full throttle upshifts from 3rd gear to overdrive.
Valve Body
Part Nos. 77966-93K, -94K & -94MK
Cause Correction
The steel TV plunger wears the TV plunger sleeve, allowing TV feed oil to leak past the plunger and exhaust These sleeves are made with high quality aircraft aluminum; the sleeve and plunger have been tightly toleranced to restore hydraulic integrity.
T H R O T T L E VA LV E S L E E V E A N D P L U N G E R
OEM identification numbers 93 or 94 located here
Throttle Valve Plunger
Throttle Valve Plunger Sleeve
Roll Pin
4L60
Complaint 3-4 clutch/band failure
Poor line rise Soft shifts Part No. 77872-01
5 TV Links
TV Link
Part No. 77872-01
Cause Correction
Insufficient TV linkage travel This shorter TV link insures re-adjustment of the throttle cable and was designed with the carry-out unit in mind.
SHORTENED TV LINK
Valve Body
20
sonnax
4L60 & E
Complaint Delayed reverse, code 1870
No 3rd gear 3-4 clutch failure Converter overheat Part No. 77918S-K
1 Stator Support Shaft 3 Bushings
Note: Bushings are provided to allow use with 4L60 units and late PWM 4L60-E units (except w/ 300 mm converter).
Set Screw To Mechanically Lock In Sleeve Universal Bolt Slot Indexing
Part No. 77918S-K
Cause Correction
Overheating and manufacturing flaws cause sleeve rotation and block oil flow which leads to transmission failure Replace the shaft with this support shaft. The sleeve in the shaft is secured with Loctite and a set screw to prevent rotating in use.
U N I V E R S A L S TAT O R S U P P O R T S H A F T K I T
100% Leak Tested Stator Support Shaft
Bushing 77002B Bushing 35007A
Bushing 35007B
4L60 & E
Complaint Reduced 3-4 clutch life
Poor 2-3 shift feel
Part No. 77701-076
Cause Correction
Inadequate metering of the 2nd band servo release oil This solution meters servo release oil for a shorter 2-3 shift while providing proper exhaust for a smooth 3-2 down shift.
Part No. 77701-076

1 Check Valve
Notes: 1. Sonnax P/N 77701-076 has U.S. patent number 5,536,221. Patent infringement will not be tolerated 2. Installs over and together with 3rd accumulator check-ball capsule. Can be used with either OEM capsule or field fix of cup plug.
S E R V O R E L E A S E C H E C K VA LV E
Transmission Case
Check Valve allows 3-4 clutch feed orifice calibration without creating 2-3, 3-2 concerns
sonnax
21
Innovation
IDEAS, METHODS & PRODUCTS
Reaming to repair bores & specialized tools to match repair market needs
Wear-resistant hard-coated aluminum and hardened steel valves

O-ringed valve sleeves: for added protection against cross leakage
Designs made specifically for use with remanufactured parts Annular grooves & built-in reliefs to prevent sticking Factory style valve sleeves: for ease of installation E4OD pump gears with improved drive surfaces Diagnostic procedure: Wet Air Test (WAT) SonnaFlow : unique diagnostic tool Longer servo-pins with o-ring seals Sleeving of the accumulator bores
TM
Case and valve body savers
www.sonnax.com
4L60 & E 200-4R

Shortened band life
Valve Body
Part Nos. 77777M-K, L-K & K-K
Complaint 1-2 bang (light throttle) or slide bump shift

A C C U M U L A T O R V A LV E T R A I N A S S E M B LY
Cause
Accumulator control incorrect for vehicle application
Accumulator Valve Spring
Accumulator Plug
Correction
Using one of these three assemblies will maintain holding power and proper shift feel. The sleeve is made from high quality aluminum and each kit contains three springs of varying spring rates. Part No. 77777M-K
(.341")
Accumulator Sleeve
Accumulator Valve
SONNAX PART SUMMARY

ehicles with 200-4R or 4L60 & E transmissions can experience 1-2 light throttle abrupt or bang shifts, or a slide-bump on the 1-2 shift, based on a mismatch of accumulator control valve for the application. This valve train has 7 different OEM size variations: B, A, N, M, L, K, and F. They range from the largest valve diameter giving the firmest shift (B) to the smallest valve diameter giving the softest shift (F), respectively. The size variations are clearly stamped with the letter on the aluminum sleeve. Most vehicles, depending upon the transmission/engine combination, can use either the M, L, or K version. However, these are not available unless scavenged from other valve bodies. Sonnax has designed a replacement accumulator valve train assembly for the M (.341" valve diameter) 77777M-K, L (.330" valve diameter) 77777L-K and K (.315" valve diameter) 77777K-K versions. Using one of these three assemblies will maintain proper shift feel. The sleeve is manufactured from high quality aluminum that is designed to prevent excessive wear due to the reciprocating motion of the steel valve. Each accumulator valve kit contains three springs of varying spring rates to choose from.
Vehicle Type Valve Assembly
Heavy Cars & Trucks Medium Weight Cars Lighter Weight Cars
Part No. 77777L-K

(.330")
Part No. 77777K-K

(.315")
Each includes the following: 1 Accumulator Valve 1 Accumulator Sleeve 1 Accumulator Plug 3 Accumulator Springs
Note: The Sonnax sleeves are not stamped with the letter I.D. The diameter listed with the part numbers above is of the smallest land on the valve.
Accumulator
M Version L Version K Version
Yellow 3 lb.
Light Shift Light Shift Light Shift
White 5 lb.
Medium Shift Medium Shift Medium Shift
Pink 7 lb.
Firm Shift Firm Shift Firm Shift
with High Axle Ratio (3.08-3.23-3.42) (such as Camaro & Firebird) with Mid Axle Ratio (3.42-3.55-3.73) (under 3,200 lbs) with Mid to Low Axle Ratio (3.73-4.11-4.33)
24
sonnax
4L60 & E
Complaint
Part No. 65797
5 Pivot Pins
200-4R
Part No. 65797
High line pressure at an idle

Cause Correction
A worn pump slide pivot pin This hardened pump slide pivot pin is a direct replacement and helps restore hydraulic integrity.
PUMP SLIDE PIVOT PIN
Pivot Pin
Pump
4L60 & E
Complaint 1-2 slide bump shift
Soft 1-2 shift
Part Nos. 77704S & 74926
Cause Correction
The OEM spring is broken or a stronger spring is needed for high performance applications Use the purple accumulator spring for stock and the enhanced for performance and firmer 1-2 shifts.
Part No. 77704S

Enhanced Performance
1 - 2 A C C U M U L AT O R S P R I N G
Purple Spring
5 Springs
Part No. 74926

Purple 1-2 Accumulator Spring 5 Springs
Enhanced Performance Spring
1-2 Accumulator Housing
Piston
sonnax
25
4L60 & E
Complaint Soft 3-4 shift
Part No. 77767K
1 Dual Piston Assembly 1 Steel Washer
Note: Sonnax Part 77767K has U. S. Patent Number 5,944,627. Patent infringement will not be tolerated.
Part Nos. 77767K & -SK
Cause Correction
Insufficient holding power of the 4th gear servo piston The apply surface of the new piston has been increased by 40% to increase holding power on heavy-duty and performance applications.
4 T H G E A R " S U P E R - H O L D " S E R V O P I S T O N TM
Part No. 77767K-SK

4 Replacement Seals (see below)
Blue PTFE Coated, Viton O-Ring Scarf Cut PTFE Seal
Steel Washer Scarf Cut PTFE Seal
Viton O-Ring
Case Section
Dual Piston Assembly offers 40% more holding power due to greater apply area
4L60 & E
Drivetrain noise
350/C
Part Nos. 77406-10 & 77409-15
Complaint Excessive unit endplay

Cause Correction
Part No. 77406-10
10 Rear Unit Endplay Shims
Input Drum
Normal wear of drivetrain components These endplay shims allow for proper adjustment of front and rear unit endplay.
R E A R & F R O N T U N I T E N D P L AY S H I M S
Output Shaft Assembly
Part No. 77409-15

10 Front Unit Endplay Shims
Shim
Shim Shim place against drum pocket

26
sonnax
4L60-E
2nd starts Soft shifts 3-4 clutch failure No 4th gear 1870, slip-ratio codes
Sleeve with retaining ring installed
Part Nos. 77754-09K & -TL
Complaint Wrong gear starts, solenoid codes, clutch/band failure

A C T U AT O R F E E D L I M I T VA LV E K I T
Cause
Actuator feed limit bore wear results in low pressure at shift and EPC solenoids
Valve
End Plug
Correction
Spring
This kit salvages 4L60-E valve bodies. The kit includes a re-designed, anodized AFL valve that regulates pressure and a wear resistant sleeve to reestablish hydraulic integrity. Part No. 77754-09K
1 Valve Sleeve Assembly 1 Spring 1 Retaining Ring
O TO L
SONNAX PART SUMMARY
T
D
he OEM actuator feed limit (AFL) valve design has a large reaction area and is highly affected by side loading, which wears the valve body bore. The EPC solenoid oscillates the torque signal and AFL oil which increases valve action. As the bore wear increases, oil pressure is reduced to the shift solenoids which causes solenoid and ratio codes. The same AFL oil loss results in lower line pressure. The improved Sonnax kit 77754-09K (4L60-E) includes an anodized valve and wear resistant sleeve. The valve has annular grooves to prevent side loading and has 54% more support by operating in the full contact sleeve. Due to the valve diameter and sleeve, this repair requires a reamer and reamer guide tool kit, Sonnax part number 77754-TL, which services both the 4L60-E and 4L80-E (see page 47 or information on the 4L80-E).
QUIRE
Part No. 77754-TL

1 Twist Drill 1 Reamer 3 Guides 1 Collar
sonnax
27
4L60 & E
Falling out of lock-up when hot Fluid blowing out the fill tube Lock-up immediately after 2nd gear (no power complaint) Blued/overheated converters
No leakage here during WAT
Part Nos. 77805-K & 77805E-K
Complaint No lock-up condition, code 1870

T C C A P P LY V A LV E S
Pump
TCC Apply Valve 77805E-K
Cause
Excessive pump bore to valve clearance
TCC Apply Valve 77805-K
Retaining Clip
Valve Stop
Correction
These TCC apply valves will eliminate bore cross leakage with a Teflon seal. Part No. 77805-K
4L60 & 4L60-E Non-PWM
Teflon Seal
SONNAX PART SUMMARY

ehicles with a 4L60 or 4L60-E transmission have numerous converter overheat and lock-up complaints related to TCC apply valve bore wear. These include no lock-up or lock-up immediately after 2nd gear when fluid warms up. Frequently the solenoid will have no control over the valves position. These complaints are usually created by excessive pump bore to valve clearance. Often converter feed oil will leak past the spool, which added together with orificed signal oil, will be more than the solenoid can exhaust. This may completely stroke the valve into the lock-up position and create a no power or no brake cancel condition. Oil cross leaks may float the valve into a midway position and restrict cooler flow, which burns up the converter. Sonnax has developed a hardened steel TCC apply valve 77805-K for the 4L60 and 4L60-E non-PWM units and an anodized aluminum valve 77805E-K for the 4L60-E PWM units, that will eliminate the bore cross leakage. These precision valves have a Teflon seal to prevent the cross leaking of converter signal oil and converter feed oil.
Part No. 77805E-K

4L60-E PWM only
Each includes the following: 1 Valve 1 Teflon Seal
28
sonnax
4L60-E PWM & NON-PWM

Complaint Code 1870, harsh 1-2
Overheated or blued converters
Part Nos. 77754-03K, -04K & -R2
T C C R E G U L AT O R VA LV E K I T S
Isolator Valve
Cause
Severe wear of the TCC regulator valve bore allows regulated converter apply pressure to exhaust
Retaining Clip Valve Body
Spring
Regulator Valve
Correction
These kits have a longer spool diameter to prevent leakage. A wear resistant sleeve restores hydraulic integrity of the apply circuit and gives full support to the valve to prevent side loading. Part No. 77754-03K
Offers an increased TCC apply rate
O TO L
Reamer
Sleeve
SONNAX PART SUMMARY
onnax now offers two kits for this assembly: 77754-03K and 77754-04K. The isolator valve is the same in both kits and has a .560" longer spool diameter to ride in the unworn portions of the valve body bore and prevent leakage. Annular grooves have also been added for better valve centering. A wear resistant sleeve has been added to the regulator apply valve to restore the hydraulic integrity of the apply circuit and to give full support to the valve to prevent side loading. Part number 77754-04K offers the same converter apply pressure as the OEM design and can be used with all model years (including non-PWM versions). Part number 77754-03K offers an increase in TCC apply pressure, where additional converter clutch holding capabilities are needed. An annular groove on the regulator apply valve spool gives added insurance against side loading. Reaming of the valve body bore is necessary for the installation of both sleeves. The OEM retaining clip is re-used. The kit includes a spring for use in PWM units. Since the valve body castings for PWM and non-PWM units are identical, kit 77754-03K can be used in converting non-PWM valve bodies for use in PWM units and converting PWM valve bodies for use in non-PWM units.
QUIRE
Part No. 77754-04K

Offers OEM TCC apply rate Recommended for EC3 units.
R
O TO L
Each includes the following: 1 Isolator Valve 1 Sleeve 1 Regulator Valve 1 Spring
QUIRE
R R
Note: EC3 is short for electronically controlled capacity clutch.
Part No. 77754-R2

1 Reamer (required for use with above part #s)
sonnax
29
Engineering
MEETING OR EXCEEDING OEM PERFORMANCE
Diagnosis of root cause
Proper geometry-exacting tolerances
Optimum selection of materials based on application
Quality assured with instrumentation & manufacturing technology
Designed with rebuilder needs in mind
Process & manufacturing engineering
Uncompromising standards
www.sonnax.com
4L60-E
Poor shift quality
Part Nos. 77898E-K, 77898E-3K, 77898E-4K & 77898E-6K
Complaint Insufficient line rise, 3-4 clutch failure

R E V E R S E B O O S T VA LV E & S L E E V E K I T S
Cause
A worn boost sleeve can allow torque signal and reverse oil cross leakage or leakage to sump
Valve Body
Boost Valve Boost Sleeve
Correction
The closely toleranced valve and sleeve kits restore hydraulic integrity and prevent leakage. Kits are available in the .470" stock replacement or .490" increased boost ratio sizes, with or without o-rings. Part No. 77898E-K
Oversized .490" EPC Spool Diameter O-Rings
Factory style
identification groove on .470" ratio
SONNAX PART SUMMARY

ehicles with a 4L60-E transmission frequently have poor line rise, which can result in 3-4 clutch, 2-4 band failure or poor shift quality. The duty cycle of the EPC solenoid causes the boost sleeve to wear quickly. Oil enters the torque signal orifice, leaks past the boost valve, and exhausts through the reverse orifice, resulting in poor line rise. Reverse oil can exhaust both to the sump and back through the torque signal orifice. The outside diameter of the boost sleeve also allows some leakage through the pump body, which decreases pressure rise. Sonnax offers two replacement boost valve kits that will prevent the problems mentioned above by matching a closely toleranced valve and sleeve. OEM boost ratio (.470" EPC spool diameter) kits are offered 77898E-4K and 77898E-6K as well as increased spool diameter kits (.490" EPC spool diameter) 77898E-K, and 77898E-3K which will result in a higher boost ratio to raise line pressure and provide firmer shifts. The boost valves have been specially hard coated to eliminate excessive wear from occurring on the inside diameter of the sleeves. These boost sleeves have been manufactured from Deltalloy 4032 high quality aluminum specifically designed to resist wear. On o-ring type sleeves, the two o-rings provide additional protection against leakage through the pump body and assist in maintaining pressure in the circuits that supply the boost valve.
Part No. 77898E-4K

OEM Ratio .470" EPC Spool Diameter
Each includes the following: 1 Boost Valve 1 Boost Sleeve 2 O-Rings
Part No. 77898E-3K

Factory style .490" EPC Spool Dia.
Part No. 77898E-6K

Factory style .470" EPC Spool Dia.
Each includes the following: 1 Boost Valve 1 Boost Sleeve

32
sonnax
4L60 & E
Limited maximum pressure Reverse chatter
Pump Body
Part Nos. 77917-06, -07 & -TL
Complaint Insufficient line rise, 3-4 clutch failure

P R E S S U R E R E G U L AT O R VA LV E K I T S
Pressure Regulator Valve 4L60-E Boost Assembly valve Boost Assembly sleeve Pressure Regulator Valve 4L60
Spring
Cause
Pressure regulator valve bore wear allowing leakage and contributing to erratic pump slide movement
Spring
Correction
Repair the valve bore and restore pressure control to the system with these oversized pressure regulator valve and reamer kits. Part No. 77917-06
4L60
R R
O TO L
Reverse Boost Valve & Sleeve TV Boost Valve & Sleeve Retaining Ring
Drill Jig
Reamer
SONNAX PART SUMMARY
QUIRE
Part No. 77917-07

4L60-E
R
onnax offers an oversized pressure regulator valve for the 4L60, 77917-06 and the 4L60-E, 77917-07. The Sonnax valve permits pump covers to be restored to OEM specifications despite wear and leakage at the pressure regulator valve. The pump cover is reworked using the Sonnax Reamer and Guide Kit 77917-TL which refinishes and prepares the valve bore to accept the oversized PR valve. Wear usually occurs at 3 locations. The most common wear areas are on either side of the decrease circuit where the double spool constantly oscillates. With these areas worn there is leakage of line pressure in boost conditions and leakage of decrease pressure during non-boost conditions. The result is twofold. First, line pressure is too low when high line holding power is needed during boost conditions (pressure can be 50-100 psi low in reverse). Second, the decrease circuit fails to effectively adjust pump output. The pump slide movement is erratic causing excess pump noise and wear. Also, line pressure is too high and uncontrollable during non-boost conditions. The last wear area is at the balance end of the pressure regulator. The result is balance oil leakage which locates the valve in a high line position. The Sonnax PR valve helps restore control over the pressure regulating circuit by eliminating leakage.
O TO L
QUIRE
Each includes the following: 1 Pressure Regulator Valve
Part No. 77917-TL

1 Reamer & Drill Jig
Note: Reamer and drill jig are the same for both the 4L60 & 4L60-E. Wiggle Test
sonnax
33
4L60 & E
Damaged cases
Part No. 77998-01K
Complaint Worn or scored accumulator bores

Cause Correction
Part No. 77998-01K
1 Repair Sleeve 1 Piston with O-Ring 1 Accumulator Pin Repeated oscillation of the accumulator piston scores the 3-4 accumulator bore during normal operation This simple drop-in solution saves cases with an aluminum sleeve, a replacement piston with an o-ring seal, and a new accumulator pin.
3 - 4 A C C U M U L AT O R S L E E V E K I T
Accumulator Pin Repair Sleeve
Piston with O-Ring made of high quality fluorocarbon material
4T60-E
Part No. K84956-SP
16 Springs
Note: Not compatible with 1996-up black plastic roller clutch update.
Part No. K84956-SP
Complaint No movement, rattle noise in park

Cause Correction
1-2 roller failure or insufficient spring loading on 1-2 rollers These heavy duty roller clutch springs outperform OEM springs and insure rebuild durability.
1-2 ROLLER CLUTCH SPRING KIT

Roller Clutch
Springs
34
sonnax
4T60 & E
Complaint 1-2 shuttle shift
2nd gear start with light throttle bump back to 1st Failure to shift to 2nd Part No. 84754-23K
1 (1-2) Shift Valve
Spring
Part No. 84754-23K
Cause Correction
A worn OEM valve This drop-in replacement valve is hard anodized with annular grooves to reduce sticking and does not require a reamer.
1 - 2 S H I F T VA LV E
1-2 Shift Valve
Valve Body
Annular Grooves
4T60 & E
Complaint Low or high line pressure
Low or high line pressure due to pivot pin mismatch High pressure caused by a worn out pin Part No. 84881
Solid Version
Part Nos. 84881 & 84881A
Cause Correction
Normal wear of the pin due to continuous motion of the pump slide These direct replacement thru-hardened steel pins come in both solid and grooved designs.
PUMP SLIDE PIVOT PINS

Pump Body
Part No. 84881A

Grooved Version
Pivot Pin 84881A
Each includes the following: 5 Pump Slide Pins
sonnax
35
4T60 & E
Complaint
Loss of lube oil control Reduced bearing life Part No. 84733-10
10 Shims (.010")
Part Nos. 84733-10 & -20
Rapid sealing ring wear, drive line engagement clunk

Cause Correction
Excessive input clutch endplay and drum travel These shims are designed for precise and accurate reduction of input clutch endplay and to adjust for component wear.
INPUT CLUTCH HUB SHIMS

Input Clutch Hub
Part No. 84733-20

10 Shims (.020")
Shim
Bearing Shim
4T60 & E
Complaint
Part No. 84995-01
1 Leak Repair Plate
Note: For use with stamped steel side cover.
Part No. 84995-01
Leakage of oil at side cover to channel plate inner gasket

Cause Correction
4th clutch heat, side cover corrosion, crushing or splitting of the gasket when the side cover pan nuts are torqued Fix the leak without removing the side cover or replacing the failed gasket with this leak repair plate.
A X L E / S I D E C O V E R L E A K R E PA I R P L AT E
Side Cover
Axle/Side Cover Repair Plate

36
sonnax
4T60 & E
Washers not serviced separately Excess differential/axle backlash Part No. 75890-30
4 Thrust Washers
Part No. 75890-30
Complaint Differential side gear thrust washer failure

Cause Correction
Worn side gear thrust washers allow the gears to move away from pinions causing backlash and clunk Hardened thrust washers allow differential salvage and correct set-up.
THRUST WASHER
Differential
Thrust Washer
Side Gears
4T60 & E
Complaint Driveline noise, backlash
Reduced differential bearing life Part No. 75410-10
10 Shims (.010")
Part No. 75410-10
Cause Correction
Excessive endplay This differential carrier to case shim is used with OEM shims to accurately adjust endplay and improve planetary life.
DIFFERENTIAL CARRIER TO CASE SHIM
Shim
Thrust Bearing
Differential Carrier Assembly Thrust Washer
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37
Testing

100% TESTED PRIOR TO RELEASE
Dyno-tested & road-tested at Sonnax Technical Center Tested for compatibility with different model years Tested for complete and explicit instructions Tested in various conditions & climates
Tested in shops by TASC Force members
TASC Force Approved
www.sonnax.com
4T60-E
Converter overheat Low converter apply pressure Falling out of lock-up hot
(PWM ONLY)
Part Nos. 84754-01K, -08K & -RM
Complaint Code 39 / 740 / 1870, converter shudder

T C C R E G U L AT O R VA LV E & I S O L AT O R VA LV E
Valve Body
Spring Reamer
Cause
Low converter apply pressure, a worn regulator valve bore, and insufficient isolator boost/PWM oil
Isolator Valve
Isolator Valve TCC Regulator Valve
TCC Regulator Sleeve 91 & 92 Applications
Correction
Restore the hydraulic integrity of the TCC regulator circuit by replacing with these TCC regulator kits. Part No. 84754-01K
93 & Up PWM Units
TCC Regulator Valve
93 & Up Applications TCC Regulator Sleeve
SONNAX PART SUMMARY
1 Isolator Valve 1 TCC Regulator Valve 1 TCC Regulator Sleeve

Note: No Reaming Required.
ommon complaints of PWM 4T60-E transmissions are codes 39, 740, 1870, converter shudder, converter overheat and excessive converter clutch slippage. These complaints are typically caused by a worn valve body bore or sleeve at the TCC regulator valve and/or isolator valve area. In '91 and '92 designs, the steel TCC regulator and isolator valve operates in the valve body bore. This motion eventually wears the bore and allows converter clutch apply oil (regulated line pressure) to exhaust to the sump. Wear at the isolator valve bore allows leakage of converter charge oil and PWM boost oil. In 1993 and up units, GM changed the design of the TCC regulator to oscillate in an aluminum sleeve. This sleeve also wears, allowing critical TCC apply to exhaust to the sump.
Part No. 84754-08K

91 & 92 PWM Units
O TO L
1 TCC Regulator Valve 1 TCC Regulator Sleeve 1 Spring 1 Isolator Valve
QUIRE
Part No. 84754-RM

1 Reamer
To overcome these complaints, Sonnax has developed two TCC regulator valve kits. 84754-08K and required reamer 84754-RM are used with '91 and '92 units, while 84754-01K is used with all '93 and up PWM units. The two kits restore the hydraulic integrity of the circuit. The regulator valves are made with anodized aluminum and the sleeves are made of wear resistant ALCOA Deltalloy aluminum. The isolator valves are made from hardened steel and feature additional length and annular grooves for better valve centering and stability. The 84754-01K for '93 and up units does not require a reamer.
Note: See page 41 for additional information on this subject.
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4T60 & E
No lock-up
A B
Part Nos. 84754-16K, -22K, -TL, -97K, -98K & -DJ2
Complaint Code 1870, falling out of lock-up hot

T C C A P P LY V A LV E K I T S
Cause
Wear of TCC apply valve bore allows leakage of TCC signal oil to exhaust and apply valve to move into TCC release position
Valve Body
OEM Stock Size 84754-22K
Valve Teflon Seal A B
Spring
Correction
Replace with these TCC apply valves to restore circuit integrity. Part No. 84754-16K
Up to '96 (oversized diameter)
E
O TO L
Valve Body Bore wear here, requires Reamer and Oversized Valve 84754-16K
Reamer required for 84754-16K Drill Jig
SONNAX PART SUMMARY
Part No. 84754-22K

Up to '96 (standard diameter)
QUIRE
Part No. 84754-97K

'97 and up (oversized diameter)
E
R
solating converter codes which are valve related is difficult. The TCC apply valve should be considered as the switch for converter apply and release oil, where the regulator valve 84754-01K controls the apply pressure and TCC piston slippage. The apply valve and its bore wear (indicated above) can be isolated with either the SonnaFlow or a scanner. On the Sonnaflow, the TCC valve stroke will be evident as a .2 gpm increase in flow as the valve strokes. If the valve strokes off or releases hydraulically, the flowmeter will indicate the same reduction. When the bore is worn, the solenoid has no control over the valve as heat rises and the oil thins. Electronically, look for TCC slip RPM to be 10% of engine RPM. The scanner will indicate the TCC is enabled, indicating the TCC has not locked up as the valve has stroked to the un-apply position. There are two wear points in the TCC apply valve bore. The most common is at the largest end spool closest to the solenoid (see ref. B above). TCC Signal oil is allowed to leak past the spool to exhaust. The second is at the small end of the valve where line pressure enters (see ref. A above).
O TO L
QUIRE
Part No. 84754-98K

'97 and up (standard diameter)
Each includes the following: 1 Apply Valve 1 Teflon Seal 1 Spring
Part No. 84754-TL

for 84754-16K & 84754-97K
Reamer and Drill Jig
Part No. 84754-DJ2

Drill Jig for 84754-98K only
For units with wear at the large (B) spool only, use 84754-22K (4T60 and up to '96 4T60-E) or 84754-98K for '97 and up units. For units with wear at both diameters (A & B) use 84754-16K (4T60 and up to '96 4T60-E) or 84754-97K for '97 and up units. For 84754-16K only the 84754-TL is required. For 84754-97K, both the 84754-TL and 84754-DJ2 are required.
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41
4T60 & E
Complaint Soft shifts, poor line rise
Poor reverse boost 2nd and /or 3rd clutch distress
MODULATED LINE BOOST VALVE & REVERSE BOOST VALVE KITS
Valve Body
Cause
Worn and leaking boost sleeves
OEM Spring
Spring Identifier (See A in Charts Below) Spring
Correction
These four replacement boost valve kits provide more sealing area with sleeves and valves made from high quality, hardened steel to prevent exessive wear. Part No. 84754-12K
Mod. Line Boost Valve Kit (Low Ratio)
Reverse Boost Valve & Sleeve w/OEM spring and retaining clip
Modulated Boost Valve & Sleeve
SONNAX PART SUMMARY

ehicles with 4T60 or 4T60-E transmissions often have complaints of poor line rise, soft shifts, poor reverse boost, and/or 2nd & 3rd clutch distress which can be caused by worn/leaking boost sleeves. The OEM boost valve spools have very narrow contact surfaces which contribute to the leakage. Sonnax has developed four replacement valve kits: 84754-12K (low ratio) & 84754-17K (high ratio) for the mod. line boost valve and sleeve, and 84754-14K (low ratio) & 84754-19K (high ratio) for the reverse boost valve & sleeve. The sleeves and valves are made from high quality, hardened steel to prevent premature wear and the valve spools have been lengthened to provide more sealing area within the sleeves. Both kits include a replacement spring to provide proper calibrations for the lengthened valve spools.
MTV BOOST VALVE
OEM DESIGN
Part No. 84754-17K

Mod. Line Boost Valve Kit (High Ratio)
Each includes the following: 1 Mod. Line Boost Valve 1 Mod. Line Boost Sleeve 1 Mod. Line Boost Spring
Note: See Figure to the right for use.
REVERSE BOOST VALVE

OEM DESIGN
Part No. 84754-14K

Reverse Boost Valve Kit (Low Ratio)
Part No. 84754-19K

Reverse Boost Valve Kit (High Ratio)
Each includes the following: 1 Reverse Boost Valve 1 Reverse Boost Sleeve 1 Reverse Boost Spring
Note: See Figure to the right for use.
Low Boost Ratio

A B C D .276" .567" .273" .328" Sonnax Kit No. 84754-14K Sonnax Kit No. 84754-12K
High Boost Ratio

A B C D .199" .567" .293" .348" Sonnax Kit No. 84754-19K Sonnax Kit No. 84754-17K
Note: MTV & reverse boost assemblies can be swapped to achieve varied boost rates.
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Part Nos. 84754-12K, -14K, -17K, -19K, -24K & -25K
REVERSE BOOST WET AIR TEST INFORMATION
Part No. 84754-24K

Line (PRN) Low/1st No Leakage Reverse & Mod. Line Boost Valve Kit (Low Ratio)
Each includes the following: Part No. 84754-12K Part No. 84754-14K
Mod TV
Part No. 84754-25K

Reverse & Mod. Line Boost Valve Kit (High Ratio) End of Sleeve/No Leakage
Each includes the following: Part No. 84754-17K Part No. 84754-19K
Identifier (See A in Charts Below)
Perform a Wet Air Test on the reverse boost valve assembly for leakage by placing a small amount of oil into the line (PRN) circuit. Follow with low air pressure. There should be little or no air/oil leakage through the low-1st orifice or exhaust at spring.
#307 Original OEM Spring, inner clipped to valve Modulated TV Circuit No Leakage Here Low 1st Orifice No Leakage Here #312 New Sonnax Spring, stout inner
Line (PRN) Circuit
Diameter of spool B identifies application (See chart at left)
Modulated Boost Valve & Sleeve
#305 New Sonnax Spring, outer
Reverse Boost Valve & Sleeve Exhaust
#311 Original OEM Spring, Outer
Note: The #311 spring can be changed to set idle pressure, which will not affect the Sonnax parts.
Sonnax No.
84754-12K 84754-14K 84754-17K 84754-19K
Stem
A= .276" C= .273" A= .199" C= .293"
Description
Mod. Line Boost (Low Ratio) Reverse Boost (Low Ratio) Mod. Line Boost (High Ratio) Reverse Boost (High Ratio)
Application
Common in 3.1, 3.4, 4.1, 4.5 L Engines Paired with -12K Common to 2.3 Quad., 3.8 Paired with -17K
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4T65-E
Complaint Harsh reverse engagement
Soft up-shifts (especially 1-2) Low line rise, forward or reverse
Part No. 84754-30K
B O O S T VA LV E & S L E E V E K I T
Springs
Cause
Bore wear near the small valve causes harsh or delayed reverse depending on the location and severity of the leak, and the temperature; wear near the end plug causes soft shift quality and low line rise
Boost Sleeve Assembly
SONNAX PART SUMMARY

ehicles with a 4T65-E transmission often have complaints of soft up-shifts (especially 1-2), delayed reverse and low line rise. This can be traced to the OEM boost sleeve assembly wearing. The OEM boost sleeve assembly consists of 2 steel valves and a steel plug that reside in the boost sleeve. The steel valves wear the aluminum sleeve and allow leakage of boost pressure. The OEM boost assembly is not serviceable separately from OEM, which forces the purchase of a new and expensive valve body. Sonnax now offers an upgraded OEM Valve Assembly boost sleeve assembly 84754-30K to replace the worn OEM parts, allow the OEM valve body to be used, and restore the hydraulic integrity of the circuit. The Sonnax valves are made of hard-anodized aluminum and have Sonnax Valve Assembly been designed to increase oil lubricity, center the valves and increase longevity. The line boost valve is also longer than the OEM valve to increase wear surface area. The sleeve is made of aircraft quality aluminum and has been designed with oil channels to evenly distribute boost valve oil. The Sonnax kit 84754-30K is a drop-in replacement and requires no machining.
Correction
The replacement boost sleeve delivers oil 360 around the valve, reducing side load. Also the surface contact of the spools is greater which improves durability and reduces oil loss. Part No. 84754-30K
1 Boost Sleeve Assembly
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4L80-E
Case replacement due to 2-1 servo bore wear Low line pressure in all ranges but manual 2nd No engine braking in manual 2nd Part No. 34989-02K
1 Sleeve 1 Piston 1 Spring 1 Teflon Seal 2 Retaining Rings (Lrg & Sml)
OEM piston seal can be tested here for leakage (WAT)
Part No. 34989-02K
Complaint Delayed engagement, low line pressure

Cause Correction
The piston seal wears away aluminum at the 2-1 servo bore; clearance and oil loss reduces pressure in all ranges except 2nd Drop-in steel sleeve with o-rings, eliminates the oil loss at I.D. and O.D. case can be salvaged even with severe bore wear.
FRONT SERVO PISTON AND SLEEVE
Sleeve with o-rings
Retaining Ring Piston goes onto pin, and the retainer follows (only 1 retainer used).
Spring
Servo Piston with Teflon seal
4L80-E
Excess front endplay Reduced bearing, thrust washer, and sealing ring life Part No. 34301-078
.078" Thick
400
Part Nos. 34301-078 & 34301-094
Complaint Forward clutch & sealing ring failure

Cause Correction
Worn components, machined hard parts, excess ring travel This pump washer takes up play between the forward clutch hub and direct clutch housing, reducing wear and salvaging valuable hard parts.
FORWARD CLUTCH DRUM WASHERS
Washer
Part No. 34301-094

.094" Thick
Each includes the following: 5 Washers
Drum
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4L80-E
Buzzing noise
Part Nos. 34200-01K & 34200-03K
Complaint High line pressure, broken parts

Pump Body
Cause
Worn boost valve/sleeve allows reverse oil leakage and imbalance of the pressure regulator valve
O-rings Reverse Boost Valve
Correction
Insure proper regulator valve control with the oringed balanced oil plug that comes along with the boost valve and sleeve kit. Part No. 34200-01K
1 Boost valve 1 Boost sleeve 2 O-rings (sleeve) 1 Balance plug & O-ring
Balance Oil Plug w/O-Ring
Reverse Boost Sleeve
"Factory style"
SONNAX PART SUMMARY
ommon problems in vehicles with a 4L80-E transmission are uncontrollable line rise (upwards of 500 600 psi), high line pressure in reverse, buzzing noise, broken direct clutch drums and/or broken cases. These problems are usually caused due to a cross leak at the sleeve. High line pressure and buzz is created by oil leakage past the aluminum balance plug. The Sonnax replacement assemblies 34200-01K & 34200-03K eliminate these problems with two closely toleranced, hardened steel parts: a reverse boost valve and a reverse boost sleeve. The kit also includes a replacement aluminum balance oil plug with an o-ring to insure proper sealing and adequate back-pressure on the pressure regulator valve. Although the sleeve and valve are sold separately by OEM dealers, we recommend replacing both parts as a kit due to potential wear of the sleeve and valve. This kit includes instructions to retrofit parts dating back to 89. In addition, the Sonnax replacement assembly 34200-01K has o-rings on the sleeve to separate the torque signal and reverse boost circuits, providing additional protection against cross leaks and the salvage of pumps with worn bores.
Part No. 34200-03K

Factory style
1 Boost valve 1 Boost sleeve 1 Balance plug & O-ring
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4L80-E
3-neutral condition No 4th gear 2nd gear start Ratio codes 85,86,68
Sleeve with retaining ring installed
Part No. 34200-16K
Complaint Wrong gear starts, solenoid codes, clutch/band failure

A C T U AT O R F E E D L I M I T VA LV E
Cause
Actuator feed limit bore wear results in low pressure at shift and EPC solenoids
AFL Valve
End Plug
Correction
This kit salvages 4L80-E valve bodies. It includes a re-designed, anodized AFL valve that regulates pressure and a wear resistant sleeve to re-establish hydraulic integrity. Part No. 34200-16K
1 AFL Valve/Sleeve Assembly 2 Springs (Long & Short) 1 Retaining Ring
O TO L
Spring
SONNAX PART SUMMARY
he OEM actuator feed limit (AFL) valve design has a large reaction area and is highly affected by side loading, which wears the valve body bore. The EPC solenoid oscillates the torque signal and AFL oil which increases valve action. As the bore wear increases, oil pressure is reduced to the shift solenoids which causes solenoid and ratio codes. The same AFL oil loss results in lower line pressure. The improved Sonnax kit 34200-16K (4L80-E) includes an anodized valve and wear resistant sleeve. The valve has annular grooves to prevent side loading and has 54% more support by operating in the full contact sleeve. Due to the valve diameter and sleeve, this repair requires a reamer and reamer guide tool kit, Sonnax part number 77754-TL, which services both the 4L60-E and 4L80-E (see page 27 also).
QUIRE
Part No. 77754-TL

1 Twist Drill 1 Reamer 3 Guides 1 Collar
Note: Tool also services 4L60-E AFL kit 77754-09K.
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4L80-E
Complaint 2nd gear starts
Shifts 1-2-3-neutral No 3rd or 4th gear Part No. 34994-02K
1 Spring
Part No. 34994-02K
Cause Correction
Low signal pressure to shift solenoids A and B
1-2 and 2-3 shift valve spring recalibration.
1 - 2 S H I F T VA LV E S P R I N G
Valve Body
Spring
4L80-E
Complaint No lock-up, code 68
No Overdrive Overheated fluid Part No. 34016-W
4 Bushings
Installation Tip: For best performance, install bushing and hone I.D. to .001" overall clearance with input shaft.
Stator Support
Part No. 34016-W
Cause Correction
TCC apply oil leaks past the front stator support bushing This wide front stator support bushing fills the entire stator support shaft bore.
W I D E F R O N T S TAT O R S U P P O R T B U S H I N G
Bushing wider, fills entire stator groove
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4L80-E
Complaint Converter shudder, code 68
TCC apply/release problems Burned converters Part No. 34994-01K
1 TCC Regulator Valve 1 Scarf Cut Seal 2 Springs
Part No. 34994-01K
Cause Correction
TCC regulator apply valve wearing the aluminum bore, and causing a loss of converter apply pressure oil This TCC regulator apply valve kit restores converter apply pressure and includes a spring for increasing apply pressure.
T C C R E G U L AT O R VA LV E K I T
Springs
Solenoid
TCC Regulator Valve
Scarf Cut Seal
Roll Pin
SATURN -TAAT
Complaint Erratic line pressure
Cause
Part No. 95200-01
1 Cushion Spring
Note: The PR cushion spring is not available from OEM as a separate part.
Part No. 95200-01
Broken line pressure regulator valve cushion spring This improved spring eliminates the need to replace the upper valve body; simply replace the broken spring.
Correction
L P R VA LV E C U S H I O N S P R I N G - O R A N G E
Line Control Plunger
Pressure Regulator Boost Sleeve
Line Pressure Regulator Valve
Washer not in all applications
Cushion Spring Orange
Line Pressure Regulator Spring

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GM Friction Material & Applications

BY BOB WARNKE
ncreased fuel economy has led to systems that apply the converter clutch during a wider range of driving conditions, including low speeds and while decelerating. To avoid driveability concerns, engineers have had to develop materials that could be slipped during low speeds and deceleration. There are two main factors an engineer needs to consider: the coefficient of friction and heat tolerance. Materials with a high coefficient of friction apply more aggressively than those with a lower coefficient. The materials heat tolerance is determined in part by whether it is a thermal insulator or conductor. Conductive materials transfer heat better than insulators. The chart in Figure 1 shows four common friction materials used for converter clutches and their properties. These materials offer a wide range of properties. The paper material, for example, has a high friction coefficient, but has a low tolerance to heat. Kevlar
Figure 1
verters, as they may fail prematurely. For example, a paper lining will quickly overheat in an EC3 system, and should never be used in these applications. Identifying Friction Materials in Use: Can you tell what type of lining is inside a converter? Converter ID Tag: There may be a tag on the cover identifying the friction material (Figure 3), but it often burns off. Conductor vs Insulator: IF the lining has no metal contamination, and IF the parts are centered properly, a resistance check between the cover and turbine will identify a conductive (carbon) or non-conductive lining. To do this, lift the turbine off the cover with snap ring pliers, place an ohmmeter lead on pliers, cover and measure resistance. Determining EC 3 or Not: The practical method of identifying the control system is to install a scanner during an initial road test. On the PWM system, the TCC enable will indicate "Yes" after a 2-3 shift, as the WOVEN CARBON KEVLAR TCC duty % brings Moderate Low TCC slip near -0-. Very High High With EC3 some Conductor-High Insulator applications enable Cores Only/ Yes Patented Material after the shift to 2nd (reprogrammed and later versions often 3rd), as the duty % lingers at the 30-40%. The EC3 system maintains a converter clutch slip until highway speeds, where duty % brings slip to -0-. TCC enable will remain yes during the shifts and deceleration. Generally, EC3 applications should use woven carbon, PWM should use composition carbon or Kevlar, and On/Off systems should use paper or Kevlar. Controlling TCC Slip: Effects of Altering Hydraulic Controls: Blocking the converter regulator valve increases the apply pressure to match line pressure. In most applications, this will result in a
CONVERTER CLUTCH FRICTION MATERIAL COMPARISON:

CELLULOSE/PAPER COMPOSITION CARBON
Coefficient Temp. Rate Conduct Heat Availability
High Low Insulator Yes
Moderate-High Very High Conductor-Moderate Yes
has a low coefficient of friction but a high tolerance to heat. Generally a mix or composition of materials is used for Pulse Width Modulated (PWM) designs, and woven carbon (Figure 2) is used in Electronically Controlled Capacity Clutch (EC3) designs. Carbon conducts heat or carries it away from the surface, where other materials do not. Dissipating heat is critical to a clutch which is allowed to slip. Because of variations in friction material, many durability and drive-ability concerns exist. Friction materials with properties different than that designed for a given application should not be Figure 2: The material on the left is woven carbon. used when rebuilding torque con- The material on the right is composition carbon.
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Figure 3
OBSERVED FRICTION APPLICATION AND CONTROL:

TRANS. CONTROL FRICTION MATERIAL CONVERTER TAG,3RD DIgit
rapid or slight bump on apply, but does eliminate most TCC slippage. Blocking the valve will place higher loads on the converter. Depending on the type of converter regulator modification, the leakage of AFL and PWM solenoid oil may not be fixed. These leaks can reduce line rise and shift solenoid oil. The EC3 system is not as forgiving to hydraulic control alterations. The OEM woven carbon friction material is not designed for an agressive application. Because the computer brings on the converter earlier, a bumpy premature lock-up and trailer-hitching can occur. Road Test and Diagnostics: Determining which valve or component is causing a slip code is not as difficult as it may seem. The tool to use is a scanner that can identify the type of system, amount of converter slip and calculated gear ratio. When the TCC is not applied, there will be a 10% higher engine rpm than turbine and output rpm. In 3rd gear, with TCC fully applied, engine, turbine and output rpm will be the same. Example: 3rd gear -TCC enable: no (off) -Engine rpm 1850 -Output rpm 1665 = 10% 3rd gear -TCC enable: yes (applied) Engine rpm 1850 Output rpm 1850 = 0 slip
4L30-E All years 4L60 82-89 90-92 4L60-E 93-94 95-96 97 W cars 3.4 97 (298 trucks) 98 all 98-00 (300mm) 4L80-E 91-98 99-00 4T40-E 245mm 4T60 86-89 90 4T60-E 91-95 96 3.4 DOHC 96 others 96-98 4 cyl 97 3.8L 97 others 98-00 4T65-E 96- 3.4DOHC 97 & later w/258mm 4T80-E 95 & later
PWM on-off on-off on-off PWM EC3 PWM EC3 EC3 PWM PWM EC3 on-off on-off PWM EC3 PWM EC3 EC3 EC3 EC3 EC3 EC3
Composition paper paper with low carbon paper with carbon composition carbon woven carbon composition carbon woven carbon woven carbon paper with carbon composition carbon composition carbon paper paper with carbon paper with carbon woven carbon composition carbon composition carbon woven carbon composition carbon woven carbon composition carbon woven carbon
9,H
G,H,L N,P G,H,L N,P B,A
tag# 0829 G,L
F,P,H G,Q G,Q F,P,H G,Q F,P,H G,Q,H F
PWM
composition carbon
Note: Early carbon formulations included a small percentage of carbon with the cellulose /paper.
Slip of 4 to 60 rpm is normal for PWM control under load and deceleration. Slip of 4 to 250 rpm+ is normal for EC3 under slip mode, reducing to 0 at cruise. Slip of 10%, with TCC enable yes (applied), indi-
cates the control valve has not stroked. Slip of 140-180 on a PWM or EC3 system during full apply/high duty %, equates to low apply pressure from a worn regulator valve or spun stator sleeve. Slip of 250+ with engine rpm of 1850 would indicate an output gear ratio problem. This can be created by outside signal interference with DRAC, turbine sensors, mismatched controller/PROM, or computer not recognizing the inputs. The Sonnaflow also can be used to indicate control valve action, pump output, filter aeration, and cooler flow which all can influence TCC apply.
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51
C6
Complaint
Part No. 36414-01K
5 Shims (.044")
Part No. 36414-01K
Driveline slack and engagement noise

Cause Correction
Severely worn sunshells at the sungear contact area The shim prevents contact between the forward planet and sunshell by raising the sun gear to its original position.
SUNSHELL SAVER SHIM

Sunshell
Sunshell Saver Shims place between the inner snap ring and sunshell ledge
C6
Complaint
Reduced seal ring life Part No. 36428-Z
10 Shims (6-slots - .010" thick)
Part No. 36428-Z & 36428A-Z
Rear component drive line wear, clunk

Cause Correction
Excessive total unit endplay This shim allows for proper setting of unit endplay. The shim fits between the OEM washer and planet.
U N I T E N D P L AY S H I M S
Part No. 36428A-Z

10 Shims (4-slots - .010" thick)
Input Shell with Sun Gear Assembly
Ring Gear
Reverse Planetary 3 or 4 pinion
Thrust Washer 3 tanged
Thrust Washer 4 tanged
Shim 4 slots Shim 6 slots

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C6
Complaint
Poor line rise Reverse shudder
Valve Body
Part Nos. 36946-01K, -02K, -03K & -04K
Direct clutch failure

Cause
Boost valve wearing the inside diameter of the boost sleeve causes oil to leak past boost valve and exhaust through reverse orifice
Boost Valve
Springs
Factory style
Correction
These wear resistant replacement assemblies eliminate the problems with closely toleranced boost valves and sleeves.
Gas ratio:
O-Rings Kits -01K & -02K only. Kits -03K & -04K do not have o-rings Boost Sleeve LP Coasting Regulator Orifice Reverse Boost Orifice Modulated Line Pressure Orifice
SONNAX PART SUMMARY

ehicles with a C6 transmission often have poor line rise, which results in erratic shift timing, reverse shudder, or direct clutch failure. This can be caused by the reciprocating boost valve wearing the inside diameter of the boost sleeve. When this occurs, oil that enters the modulated line pressure orifice leaks past the boost valve and exhausts through the reverse orifice, resulting in poor or no line rise. The outside diameter of the boost sleeve may allow some leakage through the valve body, which can result in insufficient line rise. The Sonnax replacement assemblies 36946-01K and 36946-02K eliminate the above problems with closely toleranced boost valves and o-ringed sleeves. The four o-rings provide additional protection against both cross-leakage and oil exhausting through the valve body bore. Factory style replacement assemblies 36946-03K and 36946-04K eliminate the above problems, but do not have o-rings. The sleeve is manufactured from Alcoa Deltalloy 4032 aluminum, which is specially designed to resist wear. The boost valve is manufactured from high quality anodized aluminum to prevent excessive wear on the inside diameter of the boost sleeve. The 36946-01K and -04K provide normal line pressure boost (gas ratio), while the 36946-02K and -03K provide increased line pressure boost (diesel ratio).
Part No. 36946-01K

O-rings
Part No. 36946-04K

Factory style
Diesel ratio:
Part No. 36946-02K

O-rings
Part No. 36946-03K

Factory style Each includes the following:
1 Boost Valve 1 Boost Sleeve 4 O-Rings (In kits -01K & -02K only)
Note: This does not recalibrate shift timing, or allow gas and diesel valve body interchange!
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C6
Poor line rise, no kickdown Part No. 36833-01K
1 Modulator Valve 2 Springs
O TO L
Part Nos. 36833-01K & 36833-TL
Complaint Direct clutch failure, stacked upshifts

Cause Correction
Severe wear of the transmission case at the modulator valve bore due to continuous valve oscillation This slightly oversized modulator valve restores the hydraulic integrity of the circuit.
O V E R S I Z E D M O D U L A T O R V A LV E & R E A M E R S Y S T E M
D
QUIRE
Part No. 36833-TL

1 Reamer 1 Drill Jig
Modulator Valve Springs
Reamer
Drill Jig
E4OD
Part No. 36440-01
1 Repair Sleeve 1 Spring Pin
M
A
C6
Part No. 36440-01
Complaint Damaged or excessively worn pilot journal

Cause
CH
INI
Insufficient lubrication, poor alignment, or excessive loading This forward planetary repair sleeve allows worn carriers to be repaired with a minimal amount of machining.
QUIRE
Correction
F O R W A R D P L A N E TA RY R E PA I R S L E E V E
Planetary Oil Groove
Pin
Forward Planetary Repair Sleeve pin added to prevent rotation
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E4OD
Bushing failure
C6
Part Nos. 36008A, B, C & D, T36605-03, -04 & T36008A
Complaint Spun-out bushings and case damage

OVERSIZED & STANDARD REAR CASE BUSHING INSTALLATION SYSTEM
Reamer Fixture Flange
Cause
Lack of lubrication, excessive journal clearance, or too much load for the bearing area
Reamer Fixture
Correction
This one piece, oversized rear case bushing installation system can replace a spun-out bushing and save expensive cases from being replaced. Part No. 36008A
4 Oversized Bushings
Note: 3 Grooves to front
R
O TO L
1-5/8" Reamer
One-Piece Bushing hardened, steel-backed
QUIRE
Part No. 36008B

4 Bushings (Standard O.D.)
Note: 3 Grooves to front
Part No. 36008C

4 Oversized Bushings
Note: 3 Grooves to front, 1 to back late model design
E
R
Bushing Installation Tool

O TO L
QUIRE
Part No. 36008D

4 Bushings (Standard O.D.)
Note: 3 Grooves to front, 1 to back late model design
SONNAX PART SUMMARY
he OEM rear case bushings in the Ford C6/E4OD transmissions tend to wear out prematurely or spin out causing damage to the case. After the case is damaged, it is impractical to reinstall a standard bushing. Bushing spin out may be due to lack of lubrication or too much load for a given bearing area.
Part No. T36008A

1 Bushing Installation Tool
Part No. T36605-03

1 Reamer
Part No. T36605-04

1 Reamer Fixture
Sonnax has developed a Standard and Oversize One-Piece Bushing Installation system specifically designed for this application. This system includes a custom designed 1-5/8" reamer, T36605-03; a reamer fixture, T36605-04; installation tool, T36008A; and two bushing options: 36008A 3 groove early model and 36008C 4 groove late model. Our replacement bushings 36008B & 36008D are improvements over the OEM, providing increased bearing surface area and lubrication flow on non-damaged cases.
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55
E4OD
Delayed reverse
4R100
Part Nos. 36424-01K & 36424-03K
Complaint Poor line rise, soft shifts

B O O S T VA LV E & S L E E V E K I T S
Pump Body
Cause
Severe wear of the boost sleeve and loss of EPC & reverse boost oil
Boost Valve
Correction
These replacement assemblies eliminate these problems with an anodized and closely toleranced pressure regulator boost valve and "Factory style" or o-ringed sleeve.
O-Rings improve EPC circuit feed
Factory style
Boost Sleeve
Part No. 36424-01K

SONNAX PART SUMMARY

ehicles with an E4OD transmission frequently have problems with poor line rise and/or soft shifts. These complaints are often caused by severe wear of the pressure regulator sleeve, allowing EPC and reverse boost oil leakage. The replacement assemblies 36424-01K and 36424-03K (Factory style) eliminate these problems with a closely toleranced pressure regulator boost valve and sleeve. Our aluminum valve has been anodized to eliminate excessive wear. Wet Air Test leakage discovered after correctly installing the Sonnax boost valve may indicate pump cross circuit leaks. In addition, the Sonnax replacement assembly 3642401K comes with two o-rings to provide additional protection against leakage at the sleeve bore. A Wet Air Test must be performed on re-machined pumps for verification of flatness.
Reverse Feed Hole EPC Boost Feed Hole
Part No. 36424-03K

1 Boost Valve 1 Boost Sleeve Factory style
56
sonnax
E4OD
Complaint
Soft shifts Premature clutch failure OEM valve gets stuck closed
4R100
Part Nos. 36948-09K & 36948-12
Loss of 2nd, 3rd or 4th gear

A C C U M U L AT O R C O N T R O L VA LV E K I T
Spring Accumulator
Cause
Accumulator control valves stick or shut off flow to clutches too quickly and at too low of a pressure
Valve
Spring
Retaining Clip
Spring End Plug
Correction
Valve is now redesigned to be a regulator which will not cut off oil flow to the clutch. Improved clip to prevent valve from over-travel.
Fits all 3 locations; 2nd, 3rd and 4th accumulator valve locations
Clip
SONNAX PART SUMMARY
Part No. 36948-09K*

1 Valve 1 Retaining Clip 4 Spring Shims
O TO L
QUIRE
he OEM E4OD & 4R100 accumulator control valves can stick, shutting off flow to the clutches. This causes soft shifts and premature clutch failure. This sticking is caused by the valves wearing a step in the bore. The new Sonnax control valve has an increased length to prevent getting hung up. The Sonnax kit 36948-09K also has a stiffer retaining clip to keep the valve from over stroking. An annular groove keeps the valve centered within its bore and reduces uneven bore wear. Spring shims supplied with each kit allows the rebuilder to selectively increase the apply pressure and shift feel. The new valve also has a reduction at the spool diameter, acting as an orifice to keep fluid flow to the clutches at all times and eliminating premature clutch failure. The 36948-12 bore sizing tool will repair worn bores, allowing smooth valve travel, and is required to establish a clean bore.
*The tool is not required unless the bore is damaged.
Part No. 36948-12

1 Bore Sizing Tool
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57
E4OD
Low EPC pressure Poor line rise
4R100
Part Nos. 36948-03K, -05K & 96948-01K
Complaint Soft 1-2, 2-3 shifts, intermittent harsh shifts

L I N E P R E S S U R E M O D U L AT O R VA LV E & S L E E V E
Spring Accumulator Valve Body
Cause
Retaining clip
Severe wear of line pressure modulator sleeve allowing EPC oil leakage and /or plunger valve hang up
Spring & Spring Seat
Line Pressure Modulator Valve
O-Ring
Correction
There are three variations of this line pressure modulator sleeve and valve kit. Each has o-ringed sleeves to prevent excessive EPC oil loss and annular grooved valves to properly center the valve in the sleeve and eliminate side loading. Part No. 36948-03K
(E4OD 94 and up - .331")
Line Pressure Modulator Plunger Valve annular grooves to prevent side loading
Sleeve
SONNAX PART SUMMARY
Part No. 36948-05K

(E4OD 89-95 - .372")
ome E4OD & 4R100 transmissions have soft 1-2 or 2-3 shifts, intermittent harsh shifts or poor line rise complaints. This can be either ECU (electronic control unit) related or accumulator pressure related. These complaints are caused by severe wear of the line pressure modulator sleeve allowing EPC (electronic pressure control) oil to leak past the valve, resulting in soft shifts. Severe wear will also make the valve intermittently stick causing harsh shifts. Sonnax now offers 3 size variations of the line pressure modulator sleeve and valve kit: 36948-03K, 36948-05K, and 96948-01K that eliminate this oil loss problem with closely-held tolerances. The sleeves have an o-ring added, similar to the AX4N style, to help prevent excessive EPC oil loss. The valves incorporate annular grooves to properly center the valve in the sleeve and eliminate side loading, which can lead to excessive wear. For heavy duty street or high performance trucks, use the AX4N valve kit 96948-01K for quicker and firmer 1-2 and 2-3 shifts.
Part No. 96948-01K

(Heavy Duty/High Performance - .427")
Each includes the following: 1 Valve 1 Sleeve 1 O-Ring
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sonnax
E4OD
Complaint
Damaged pump gears or torque converter impeller hub Repeated converter failure and code 62 caused by low pump volume
Part Nos. 36438A-01K & 36438AX-01K
Low line pressure, excessive pump noise

PUMP GEARS
Cause
Wear on the pump gears and with the mating impeller hub reduces pump capacity and increases pump noise
Inner Pump Gear
Correction
These direct replacement and oversized gears are specially designed to improve the fit and durability of the pump to torque converter interface. Part No. 36438A-01K
Direct Replacement
Pump
Outer Pump Gear
SONNAX PART SUMMARY
Part No. 36438AX-01K

M
Oversized
CH
INI
onnax now offers high quality replacement gear sets for F5 and later E4OD pumps. Two designs are offered: a direct replacement gear set 36438A-01K and an oversize gear set 36438AX-01K. Both Sonnax gear sets are designed to meet or exceed OEM pump gear performance. The Sonnax gears are specially designed to improve the fit and durability of the pump to torque converter interface. The direct replacement gears are designed to fit existing F5 and later pump housings with no machining required. The oversize gears are designed for F5 and later pump housings with excessive wear. The oversize gears allow worn pump housings to be refurbished by machining the pump cavity. Note: In 1995 the E4OD pump was redesigned to utilize pump gears with 10 lobes on the outer gear. Prior to 1995 the outer pump gear had 11 lobes. The pump casting was also revised. Prior to 1995 the pump casting was designated as E9 or F1. Beginning in 1995 the casting designation was changed to F5 and currently F8. The Sonnax pump gears will work with any F5 or later pumps. The E9 and F1 E4OD pumps suffered from low pump output and should be replaced with an F5 or later model pump.
QUIRE
Each includes the following: 1 Inner Pump Gear 1 Outer Pump Gear
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59
Transmission Gerotor Pumps

BY BOB WARNKE
uel economy, space limitations and production costs influence pump design. Therefore, most gear pumps are designed with minimal requirements for the clutch, accumulator, converter and cooler. As a pumps components wear, its output becomes less. At the same time this is happening, bushings and seals wear, creating leaks, so a marginal pump cannot supply enough volume to keep the system pressure up. During a rebuild, many of the leaks are fixed, so a marginal pump gets by until oil loss returns.
Figure 1: Variable Displacement, Rotary Vane Pump To verify pump condition: (In vehicle or on Dyno) Reverse 1200 RPM Extend TV or raise Boost to max. Good pressure rises to 230-270 and does not drop off more than 20 psi. Worn pump pressure rises, then shortly drops off by 50-75 psi. Pressure often surges.
and may be used for additional lube feed. Gear Pumps: The Gerotor pump (Figure 3, Gerotor) has slightly more displacement per revolution than a Crescent pump (Figure 4, Crescent) of the same size, but not by much. Each tip to tip contact isolates a chamber, which increases in area as it passes the inlet. The expanding of this area results in low pressure, drawing sump fluid into it by atmospheric pressure. Those chambers then decrease in area as they approach the outlet port. The pressure regulator valve in the outlet cir- Figure 3: Gerotor pump gears cuit varies the amount of fluid exhausted to the sump, converting output volume into pressure.
Slide in Low output position; equalized inlet and outlet chambers reduces output.
Pump Basics: Gear pumps have a consistent output per revolution (fixed displacement) which increases with higher rotational speed. Because of hydraulic and frictional drag, gear pumps draw engine power in relation to input speed. By contrast, a rotary vane pump (variable displacement, as in Figure 1) repositions the slide under low demand to reduce output and drag. Dual stage scavenger pumps (Figure 2) allow a low volume gear set to be used during high rpm, low demand conditions. A dual stage pump can also Scavenger assist inlet prime gear
inlets; rotors pull from bottom pan and fill side pan sump
Figure 2: 4T80-E Pumps
Gerotor Design, Porting and Cavitation: In a Gerotor pump, the design elements include the number of lobes, thickness, and the shape and position of the inlet and outSecondary Pump inlet: Suction from upper sump filter. Output let ports (Figure 5, E4OD pumps). Note the charges line pressure and boosts size, sweep, inlet port and outlet slot variaprimary inlet. tions. The size of the lobe and the speed of each tip passing the inlet determines the flow. High Upper sump filter inlet rotor tooth counts, with high rpm, limit the fill available to each inlet chamber and can contribute to cavitation. For example, cavitation of a boat motor leaves a low-pressure area, on which the propeller blades cannot push. Similar to the propeller, high tip speed
Primary pump inlet: Suction from upper sump filter. Inlet pressurized by regulator valve's exhaust. Output charges line pressure
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sonnax
will not allow atmos- another gear on the pump and measuring onto the pheric pressure to fill face of the OE gear works well (Figure 6). Plasti-Gauge used for for engine bearings also the inlet chambers. The resulting cavi- works well to measure pocket depth. Insert the tation produces Plasti-Gauge at the most critical wear point gear rattle, which between the inlet and outlet ports. The gears must can cause pump Chamber Tip damage. If cavitation Inlet/suction Outlet/pressure continues, air half side bubbles become trapped in the ATF and affect the regulator valve balance. A restrictive filter Note the rotor tip position and area of each chamFigure 4: ber. Excessive tip to tip, face and outer diameter aggravates the problem because Crescent pump/41TE clearance, reduce output. the inlet will not fill properly. Fluid becomes aerated from low oil level or suction Figure 5a: leakage. Air will be pulled into the inlet easier than Left: 9 Lobe inner, 10 outer Gerotor F-5 & later cover casting # fluid, which reduces the charge. To minimize these Displacement of 1.7 cu.in. per revolution. conditions, the filter must be clean and able to flow Right: 10 Lobe inner, 11 outer Gerotor fluid at sufficient volume, the fluid level must be cor- E-9 to F-2 cover casting # Displacement of 1.5 cu.in. per revolution rect, and the ATF should contain anti-foaming addiExcessive tolerance reduces output. tives. Clearance: Pump output is least at low rpm during hot idle. Internal clearance, together with thermal expansion, further reduces output. This explains why a worn pump contributes to delayed engagement, low pressure and TCC engine stall. The centerline of the inner rotor is controlled by hub-to-gear and hub-to-pump bushing clearance. When the inner gear is allowed to move off center, each chambers seal and efficiency is reduced. Pressure build up at the outlet forces the rotors apart, which loads the outer rotor into the wall/bearing surface, reducing the oil film. As wear increases, pump output further decreases, and the pocket or gear becomes scored. Gear face to pump clearance (gear vs. pocket depth) is critical in controlling output and drainback. Remanufactured clearances cannot be held overly tight or the oil film on the surfaces will be wiped off resulting in scoring. Measurement and Leakage: The Gerotor figure references indicate specific measurements. There are a few tricks that will improve Gerotor inspection. Some pumps have curved surfaces, which make it difficult to use a straight edge when measuring face to pocket clearance. Setting
Gerotor standards below: 1) Converter hub to inner gear max. radial .004" 2) Face to pocket; min. .001" max. .002" 3) Tip to tip; .0025" per side, total radial .005" 4) Outer Gerotor to pocket: total radial. 004" 5) Pump housing flatness: .001".
Slot depth and length is critical. Must be matched to gear design and replaced.
Higher capacity pump; note the reinforced outlet pressure port.
Figure 5b: E4OD pump variations
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61
Fill to flush, drain-down timed to recess.
then be assembled and reset by pressing a plate over the Figure 6: Measuring gear pocket. pump to duplicate The inner Gerotor should be held firmly as illustrated. Pocket depth can assembly . then be measured with feeler gauge Timing the leak- or Plastigauge. This is an depth down of the outlet micrometer.alternative to using point Most critical wear chambers can be is separation between inlet and outlet. Clearance not to exceed .002" used as a quick GoNo-Go test (Figure 7). The output of the pump is directly related to the internal tolerances. Knowing this, a Go-No-Go leakdown test can be used with an assembled pump. In this test, the converter or a hub must be installed to position the gears. Place the filter port at 12:00. Fill the pump inlet circuit with solvent (mineral spirits) until level with the outer casting as shown in Figure 7. A good pump will not drain below the recess for over forty-five seconds. Pumps that cause the condition of engine stall, low cooler flow or various TCC related concerns, drain down rapidly. Experiment with this on the next new pump that is purchased. The nice part of this test is that it provides insight before dis-assembly. Stator Support: On some pump stators, a bushing isolates the oil circuit (see 4L80-E bushing 34016-W). On the E4OD, release oil must flow though the six slots around the front stator bushing (Figure 8, E4OD stator). Confirm this by using a paper clip (of .036 wire) to see if the wire will pass through each slot. Restricted ports can cause engine stall, poor converter fill and a Fig.8 E4OD stator glazed TCC lining. ports Turbine shaft sealing rings require If ports are stability and 100% surface contact. restricted, remove bushing An example of a problem area is the and enlarge.
Figure 7: E4OD leakdown test
47RE turbine shaft seal. When this seal leaks (Figure 9, 47RE pump), oil pressure builds at converter release, causing slip and overheating of the lining. When stator tubes are replaced, the press procedure often moves material, allowing oil loss at the feed ports. Before pressing another tube in place, deburr the radius of the holes and apply Loctite to the surfaces. Air Tests for Warpage and Cross Leaks: Air testing an assembled pump should be a rebuild procedure on 41TE/ 42LE, 42/47 RE, E4OD, 4L80E, 4L60/-E, CD4E, G/F4EAT units. Any pump that has been overheated or resurfaced should be checked for warpage, poor machining, or worn boost valves. Finding these problems before installing the pump can eliminate high pressure in reverse, engine stall and clutch bind up from cross leaks. Refer to E4OD boost valve 36424-01K WAT test on page 56. Inspection and Rework: Experience is success, and this saying relates to a pump as well. An untouched, mated and experienced pump, is often the best replacement. Using mixed halves, resurfacing or sometimes just taking a pump apart seems to create problems. The slightest repositioning of the halves relocates high-low spots and increases cross leaks (Note: Importance of align-
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sonnax
Converter apply /charge oil
Release psi. Forward clutch oil
Inspect stator support closely for scoring at this ring area. Scoring is caused from turbine shaft runout at converter cover bushing or pilot. Dowel pins, flex plate and crankshaft affect this also. Cross leaks during lockup, will overun the ability to exhaust. This creates a build up of release pressure causing TCC piston slip, heat and failure.
Figure 9: 47RE turbine shaft
ment pins on CD4E and the E4OD, Figure 10). Look for surface patterns near the bolt holes and passages, which indicate cross leaks and warpage. Designs using gaskets or plates should have well defined witness rear marks or gasket 2-727 well band anchor pins work for alignment. This crush patterns. method aligns the O.D. and Use care during the hole index, without using a band. handling to prevent surface dents, which raise material and cause cross leaks. Before assembly, use a surface block or very fine polishing stone to re-work irregular surfaces. Flush threads should be countersunk slightly to avoid pullup on retorque. Gauge and SonnaflowTM Diagnostic Procedures (refer to pages 78 &79): The inspection and rebuild procedures mentioned above apply to the
bench, but verifying the pump on a Dyno or the vehicle is most beneficial. The pump has one job, and that is to produce enough volume to maintain regulated pressure in all circuits. A weak pump at low RPM will not maintain line pressure, unless the RPM is raised to increase output. The Sonnaflow indicates a weak pump; as the regulator strives to maintain line pressure, the cooler feed is reduced. Some pumps become so bad that even higher RPM will not produce enough volume. In this condition both a pressure gauge and the Sonnaflow will dip dramatically during a shift and engagements. The CD4E, G4A-EL, and 41TE pumps can be diagnosed easily with this method. Another pump test procedure is to tax the pump at mid-range RPM and call for the highest pressure with full EPC or throttle boost. A weak pump will often struggle to get to specifications for maximum or peak and then taper off. Aeration and low fluid level can be found as erratic line pressure readings, or by using the Sonnaflow tied into a digital graphing meter, which would indicate erratic frequency readings. Filter restriction can also be found using the Sonnaflow, indicated as lower than normal cooler flow and a large dip in flow seen during shifts. If a filter is suspected, pressurize the fill tube and watch flow and line pressure for significant increase. Pressurizing the case forces the fluid through the filter and raises the pump inlet pressure. A case vent that is plugged will not allow Figure 10: E4OD pump alignment and atmospheric pressure to WAT test. force fluid into the pump inlet, which results in no flow or pressure. If you have any pump rebuild concerns or tips, please contact us via the Sonnax website.
Wet Air Test each of these ports. There should not be cross leakage between them or from the orange painted areas. If leaks occur, clamp outer edge and install o-ringed boost valve. Continued leakage requires resurfacing or replacement.
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63
E4OD
Complaint Rear component drive line wear
Driveline clunk Reduced seal ring life Part No. 36402-Z
10 Shims (4 slots - .010" thick)
Part No. 36402-Z
Cause Correction
Excessive total unit endplay This shim allows for proper setting of unit endplay. The shim fits between the OEM washer and planet.
U N I T E N D P L AY S H I M
Reverse Planetary
Ring Gear
Input Shell with Sun Gear Assembly Thrust Washer, 4 Tanged Thrust Washer, 4 Tanged
Shim, 4 slots
E4OD
Part No. 36743G
5 Gaskets
Part No. 36743G
Complaint Forward clutch failure and poor lube flow

Cause Correction
Leakage between the center support and hub This center support gasket eliminates leakage between the center support and the hub.
CENTER SUPPORT GASKET

Center Support Hub
Also Available:
Part No. 36743H

1 Center Support Hub-Bearing type
Part No. R16

M
1 Bearing for 36743H

Note: Center support shaft must be machined to accomodate bearing.
CH
INI
Center Support
N
QUIRE
Silicone Printed Gasket Note: Sonnax Part No. 36743G is U.S. Patent pending. Patent infringement will not be tolerated.
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sonnax
A4LD
Case needing replacement
C3, 4R44E & 5R55E
Part No. 56532-01K
Forward clutch and reverse band failure Complaint ??

R E V E R S E S E R? ?O S L E E V E K I T V
Cause
Sleeve
Heavy scoring at the inner piston bore causes drive oil loss; when severe enough, this oil loss can reduce forward clutch or reverse band life
Correction
This reverse servo sleeve kit restores the function of the reverse piston and salvages the case.
Servo
Back-up Ring
O-ring
SONNAX PART SUMMARY
Part No. 56532-01K

1 Servo Sleeve 1 Back-up Ring 1 O-ring
M
A
CH
INI
QUIRE
Note: Machining of original servo is required.
he reverse servo bore on the A4LD case can become scored. Scoring is caused by repeated oscillation of the reverse servo piston within the bore during normal operation. Once this bore is damaged the case must be scrapped. Install the Sonnax A4LD Reverse Servo Sleeve Kit 56532-01K. This kit contains a steel sleeve, an o-ring and a back-up ring.
Note: The kit also contains instructions to save the servo piston assembly by simply turning the piston O.D. 1/16" smaller. No machining of the transmission case is required.
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65
A4LD
Complaint
Poor modulator control Low line in forward or reverse
Part Nos. 56947-02K & -04K, 56947-03K & -05K
Delayed reverse and soft upshifts

H I G H & L O W R AT I O B O O S T VA LV E K I T S
Valve Body
Cause
A worn boost sleeve, which allows reverse and/or TV pressure to cross leak or exhaust
Boost Sleeve Factory style Boost Valve
Correction
These replacement boost valve kits are consistent with the OEM sizes, have a sleeve made from aircraft quality aluminum and a hard anodized valve to resist wear; they are held to tight tolerances to restore hydraulic integrity. Part No. 56947-02K
(High-ratio with O-rings) O-Rings
Diameter I.D.
Spring Seat
Boost Sleeve O-ring style
SONNAX PART SUMMARY
Part No. 56947-04K

(Low-ratio with O-rings) Each contains the following:
ome typical complaints of vehicles with an A4LD transmission are low line pressure in forward or reverse, soft upshifts, delayed reverse, and poor modulator control. These complaints can often be caused by a worn boost sleeve, which allows reverse and/or TV pressure to cross leak or exhaust.
1 Sleeve 1 Valve 2 O-Rings
Sonnax now has replacement boost valve kits consistent with the two OEM sizes. These kits are available with o-rings 56947-02K & -04K and also Factory style 56947-03K & -05K. The sleeve has been manufactured from aircraft quality aluminum designed to resist wear. The aluminum valve has been hard anodized to also prevent excessive wear. These parts are held to very tight tolerances to restore the hydraulic integrity of the assembly. High ratio - .388" diameter I.D. Low ratio - .323" diameter I.D. 2.3L 2.8, 2.9, 3.0, and 4.0L
Part No. 56947-03K

(High-ratio Factory style)
Note: The High-ratio valve offers higher line rise than the Low-ratio valve.
Part No. 56947-05K

(Low-ratio Factory style) Each contains the following:
1 Sleeve 1 Valve
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sonnax
A4LD
Complaint
Converter fill problems
Part No. 56947-06K
Soft shifts, low line pressure

PRE P R E S S S SR E ER R E GU L A TTO RRV A L VL VK I T K I T U UR EG UL A O VA E E
Valve Body
Cause
A worn valve body bore allowing line to leak to exhaust
Spring Seat
Spring
OEM Washer Spring Seat
Correction
This oversized valve and reamer kit re-sizes the valve bore and restores the hydraulic integrity of the circuit.
O-rings Spring
Boost Sleeve
Boost Valve
SONNAX PART SUMMARY
Part No. 56947-06K

1 Pressure Regulator Valve 2 Springs 1 Boost Valve & Sleeve Assembly 2 O-rings
R
O TO L
S
D
QUIRE
ome typical complaints of vehicles with an A4LD transmission are soft shifts, low line pressure, and/or converter apply problems. A worn valve body bore at the pressure regulator valve can often cause these complaints. Line pressure is allowed to leak to exhaust, preventing the valve from stroking properly and feeding the converter apply circuit
Part No. 56947-TL

1 Reamer 1 Drill Jig
Sonnax now has a replacement pressure regulator valve kit 56947-06K. The oversized pressure regulator valve restores the hydraulic integrity of the circuits. Sonnax reamer kit 56947-TL must be used to re-size the valve body bore to accept this valve. The reamer kit works for both the early and late A4LD valve bodies. The replacement valve has been anodized to prevent excessive wear. The converter apply spool land has been lengthened to increase spring force against the oversized valves. Two stiffer springs have been included in the kit, to be used only for the late valve bodies (2nd and 3rd designs). A high ratio boost valve kit is included to counteract the increased balance diameter on the pressure regulator valve.
Note: See the instruction sheet for complete WAT instructions.
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67
A4LD
Worn converter hub Worn pump bushing Part No. 56001X
M
4R55E & 5R55E
Part No. 56001X
Complaint Repeated front seal leakage

Cause Correction
Excessive hub to bushing clearance and soft babbitt bushing material This finish-in-place bushing replicates the OEM bell housing bushing assembly and has a steel backed bronze lining.
FINISH-IN-PLACE BELL HOUSING BUSHING

A
5 Bushings
CH
INI
Note: Finish-in-place style E QUIRE bushing requires advanced machining skills to insure proper I.D. & location after installation.
R
Bushing steel backed bronze lining

Bell Housing
A4LD
Part No. 56521-K
10 Oversized Pins 1 Reamer
Part No. 56521-K
Complaint 1-2 bind up, costly replacement of cases

Cause Correction
A dragging band due to a deformed bore and loosened pin This rear band anchor pin kit insures correct pin depth set-up and salvages A4LD cases with early uncapped rear band anchors.
REAR BAND ANCHOR PIN KIT
Reamer use to ream out existing hole

Case
Anchor Pin
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sonnax
A4LD
Complaint
Sprag thrust washer failure
Part Nos. 56600B-01K, 56600B, 56250-01K, 56600 & 56600-DJ
Sticking governor, bronze in the pan

A E MODE L A TLE TM O D E L L LL OW S P RR A G P DP D E T E O W S P A G U U AT A
Thrust Washer Hardened Steel End Cap
Reverse Drum
Cause
The steel wave thrust washer and bronze scoop washers flex and contaminate unit
Rear Sprag Inner Race Thru-hardened
Correction
This kit salvages cases, allows for 2.8, 2.9, & 3.0 cases to be converted to a 4.0 case, prevents metal contamination of worn washers, has an upgraded inner race, and the components are available separately as well. Part No. 56600B-01K
2 End Caps 1 Rear Sprag Inner Race 1 Thrust Washer
O TO L
Drill Jig (suggested)
Part No. 56600B 56600
Application 4.0 Liter Engine 2.8, 2.9 & 3.0 Liter Engines
Race Dia. 2.70 2.50
End Cap
SONNAX PART SUMMARY

sticking governor after rear sprag service or sprag thrust washer failure is a common complaint in late model A4LD 4.0 units. This is caused by the steel wave thrust washer (located behind the rear sprag inner race) and the bronze scoop washers flexing and contaminating the unit with metal. During fabrication of the bronze washer, small cracks are formed between the bronze and steel layer of the washer. Once in service, these cracks allow bronze particles to flake off from the washer, and the problem is compounded by the flimsy steel thrust washer that it is running against. Sonnax now offers an A4LD Late Model Low Sprag Update Kit 56600B-01K. This allows A4LD 4.0 cases with worn or loose sprag races to be salvaged. The kit contains a new inner race which is thru-hardened AISI 52100 steel with longer, deeper cutting serrations (to insure a tight fit after reinstallation), a sturdy hardened steel thrust washer and two high quality solid bearing bronze end caps. Sonnax kit 56600B-01K also allows 2.8, 2.9 & 3.0 cases to be converted to 4.0 liter cases. The steel thrust washer and two solid bearing bronze end caps 56250-01K are also sold separately for use with 4.0 cases. Also available is Sonnax 56600 which is a replacement race for the 2.8, 2.9 and 3.0 roller clutch units. This race is also thru-hardened AISI 52100 steel with longer, deeper cutting serrations. The Sonnax drill jig 56600-DJ allows for easy removal and installation of the inner race and eliminates the risk of damaging the case.
QUIRE
Part No. 56600B

1 Rear Sprag Inner Race
(see chart for applications)
R R
O TO L
QUIRE
Part No. 56250-01K

2 End Caps 1 Thrust Washer
Part No. 56600

1 Rear Roller Clutch Inner Race
R
O TO L
(see chart for applications)
QUIRE
Part No. 56600-DJ

1 Drill Jig 1 Dowel Pin
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69
A4LD
Complaint Burned forward clutches
Binding condition in park Valve related delayed reverse Part No. 56947-01
1 Manual Valve Index
Part No. 56947-01
Cause Correction
Manual valve indexed out of position This index will overcome loose linkage tolerance and prevent the manual valve from opening up the forward clutch circuit in park.
M A N U A L VA LV E I N D E X
Valve Body
Manual Valve
Manual Valve Index
A4LD
Complaint Early lock-up
Engine chuggle when coasting to a stop Part No. 56995A
2 Springs
Note: This is a shudder related to the converter clutch shift valve, not the shuttle valve.
TCC Pressure Modulator Valve
Part No. 56995A
Cause Correction
A weak converter clutch shift valve spring This spring is stronger than the OEM version and offers lock-up apply (and release) at a higher vehicle speed.
ANTI-SHUDDER SPRING
Valve Body Converter Clutch Shift Valve
TCC Solenoid and Shuttle Valve Bore
Anti-Shudder Spring
70
sonnax
4R44E
Low line pressure Poor modulator control
4R55E
B O S T VA LV I B O O O S T V A L V EE K KTI T
Part No. 37947-01K
Complaint Soft shifts, delayed reverse
Valve Body
Cause
Worn boost sleeve and boost oil loss
Correction
Restore hydraulic integrity with a hard anodized, aircraft-quality aluminum, replacement boost valve kit.
Boost Valve OEM ratio Boost Sleeve
Part No. 37947-01K

1 Boost Valve 1 Boost Sleeve
SONNAX PART SUMMARY
ome typical complaints of vehicles with an 4R44E & 4R55E transmission are soft shifts, delayed reverse, poor modulator control, and/or low line pressure in forward and reverse. A worn boost sleeve contributes to these complaints. Reverse and/or TV pressure will be allowed to cross leak or exhaust. Sonnax now has a replacement boost valve kit 37947-01K for these transmissions. The sleeve has been manufactured from aircraft quality aluminum, and is designed to resist wear. The aluminum valve has been hard anodized to also prevent excessive wear. These parts are held to very tight tolerances to restore the hydraulic integrity of the assembly. This kit will improve engagement related to loss of boost oil and increase line rise in forward and reverse.
sonnax
71
AOD
Complaint Insufficient line rise
Uncontrollable shift timing Imbalance of TV pressure Clutch or band failure
No leakage from casting (bottom) side of the valve body.
Part Nos. 76989K & 76989K-03K
T H R O T T L E VA LV E P L U G & S L E E V E K I T S
Valve Body
Cause
Throttle Valve Plug
Spring
The throttle valve plug wears the sleeve, allowing throttle valve feed oil to leak past the plug and exhaust
Throttle Valve Sleeve
Correction
The replacement kit includes a tightly toleranced sleeve that has been manufactured from Deltalloy 4032 to resist excessive wear. Part No. 76989K
1 Throttle Valve Plug 1 Throttle Valve Sleeve 2 O-Rings
Retaining Clip
Throttle Valve Sleeve Factory style O-Rings
SONNAX PART SUMMARY
ncontrollable throttle pressure due to oil loss is a common complaint in vehicles with an AOD transmission. This results in low line pressure and poor throttle and shift timing adjustments. The hardened steel throttle valve plug continuously reciprocates within the aluminum throttle valve sleeve, thus wearing the inside diameter of the sleeve. This wear allows throttle valve feed oil to leak past the plug and exhaust, resulting in poor line rise. This excessive leakage can be eliminated by installing Sonnax throttle valve plug and sleeve kits 76989K or 76989-03K. The replacement throttle valve sleeve has been manufactured out of a special aluminum designed to prevent wear. The sleeve is available without or with o-rings added to the sleeve to prevent feed oil from escaping past the valve body bore. The steel plug has been tightly toleranced to allow minimum clearance with the inside diameter of the sleeve, thus restoring the hydraulic integrity of the assembly.
Part No. 76989-03K

1 Throttle Valve Plug 1 Factory style Throttle Valve Sleeve
72
sonnax
AOD
Complaint Direct clutch failure
Insufficient line rise Soft slide shifts, delayed reverse
Part Nos. 76990K & 76990-03K
B O O S T VA LV E & S L E E V E K I T S
Valve Body
Cause
Leaks at the boost valve prevent proper line rise
Boost Sleeve made from ALCOA Deltalloy 4032 aluminum to prevent wear Boost Valve
Correction
Replace the boost valve and sleeve to restore hydraulic integrity. Part No. 76990K
O-Rings added for additional leakage protection from boost oil loss
Factory style
Part No. 76990-03K

1 Boost Valve 1 Factory styleBoost Sleeve
SONNAX PART SUMMARY

ehicles with an AOD transmission frequently have problems with poor line rise which results in direct clutch failures and soft shift slides. These complaints are often caused by severe wear of the pressure regulator boost sleeve, allowing oil leakage. The hardened steel boost valve continuously reciprocates within the aluminum boost sleeve, and wears the inside diameter of the sleeve. This excessive leakage can be eliminated by installing the Sonnax pressure regulator boost valve and sleeve kits 76990K and 76990-03K. The replacement boost sleeves have been manufactured out of a special aluminum designed to prevent wear and are available with or without o-rings. The orings are added to the outside diameter of the 76990K sleeve to prevent feed oil from escaping past the valve body bore. The steel valves has been tightly toleranced to allow minimum clearance with the inside diameter of the sleeves, thus restoring the hydraulic integrity of the assembly.
Note: The WAT procedure is clearly shown in the instructions included with the parts.
sonnax
73
AOD
Cause
Leaking valve end plugs
Small (SML)
Part Nos. 76999-04K, -05K, -SML, -MED & -LRG
Complaint Erratic shift timing

O - R I N G E D VA LV E E N D P L U G K I T S
Medium (MED)
Large (LRG)
Correction
These plugs have been manufactured of high quality aluminum to resist wear. The o-ring on the outside diameter prevents leakage between the plug and the valve body. The medium 3-4 plug is replaced by the 3-4 shift valve assembly after mid-83.
2-3 Shift (MED)
1-2 Capacity Modulator (SML)
1-2 Accumulator (LRG) 3-4 Shuttle (SML) 1-2 Shift (MED) 3-4 Shift Valve (Late: Post Mid-83)
3-4 Shift (MED)
Part No. 76999-04K

(Early: Pre Mid-83)
Note: All plugs have been redesigned with a single o-ring and tapped holes to ease the installation & removal of the plugs 2-3 Back-out (SML)
End Plug (MED) (Early: Pre Mid-83) Orifice Control (SML)
3 Medium Plugs 1 Small Plug 8 Small O-rings
SONNAX PART SUMMARY

ehicles with an AOD transmission often have shift timing complaints due to governor or accumulator oil circuit leakage caused by leaking valve end plugs in the valve body. Most AOD valve assemblies are designed with an end plug to help retain the line-up and seal the circuitry. As these end plugs wear, circuit oil is lost and affects shift timing. Installing Sonnax o-ringed valve end plugs can eliminate this excessive leakage. These include replacement plugs for the following valve applications: 1-2 accumulator, 1-2 shift, 2-3 shift, 1-2 capacity modulator, orifice control, O.D. servo regulator, 3-4 shift (plug or sleeve), and either the 3-4 shuttle or 2-3 backout. These plugs have been manufactured out of high quality aluminum designed to resist wear. The o-ring on the outside diameter prevents leakage between the plug and the valve body. The plugs have a standard 8-32 UNC threaded hole for assistance in installation and removal. These o-ringed plugs are more durable than knurling the O.D. of the original plug and will not leak after time. For your convenience, bags of 3 of each of the small, medium and large plugs are also available separately.
Part No. 76999-05K

(Late: Post Mid-83)
1 Small Plug 8 Small O-rings 2 Medium Plugs 1 3-4 Shift Valve Sleeve Assembly
Part No. 76999-SML

3 Small Plugs
Part No. 76999-MED

3 Medium Plugs
Part No. 76999-LRG

3 Large Plugs
74
sonnax
AOD
Part Nos. 76970 & -RM
Complaint Poor line rise, sticking TV plunger

O V E R S I Z E D T H R O T T L E V? ?L V E P L U N G E R & R E A M E R A
Uncontrollable throttle pressure
Cause
Valve Body
Valve body wear allows throttle valve feed oil to leak past the plunger and exhaust, resulting in poor line rise
Oversized Throttle Valve Plunger annular grooves to prevent side loading
Correction
The reamer resizes the valve body bore to accept the oversized TV plunger and restore hydraulic integrity.
No Excessive Leakage Valve Body with Separator Plate
Reamer
Note: The leakage you're checking for during the WAT is from under the valve body.
Plunger Here TV Plug & Sleeve Here
Part No. 76970

1 TV Plunger
R
O TO L
SONNAX PART SUMMARY
QUIRE
Part No. 76970-RM

1 Bore Reamer Tool
oor line rise, uncontrollable throttle pressure, and sticking plungers due to worn bores are common complaints in vehicles with an AOD transmission. The hardened steel throttle valve plunger continuously reciprocates within the aluminum valve body, wearing the valve body bore. This wear allows throttle valve feed oil to leak past the plunger and exhaust, resulting in poor line rise. This excessive leakage can be eliminated by installing an oversized throttle valve plunger 76970 which has a slightly oversized diameter. The replacement valve is made with annular grooves to center the valve and prevent wear due to side loading. By utilizing Sonnax reamer tool 76970-RM material can be removed from the valve body bore in order to accept this oversized TV plunger and restore the hydraulic integrity of the circuit. In addition, to insure full circuit integrity, use Sonnax 76989K TV plug and o-ringed sleeve kit (see page 72).
sonnax
75
AOD
Complaint Slide shift into 2nd gear
Cause Correction
Intermediate clutch failure

Part No. 76991-01K
1 Valve 3 Springs 2 O-Rings 1 End Plug
O TO L
A worn 1-2 capacity modulator bore causes second clutch oil leaks and insufficient clutch pressure This oversized modulator valve is made of anodized aluminum to prevent wear, restoring the hydraulic integrity of the circuit.
O V E R S I Z E D 1 - 2 C A PA C I T Y M O D U L AT O R V A LV E K I T
QUIRE
Springs
Valve Body
Valve
Part No. 76991-TL

1 Reamer & Drill Jig Tool
Reamer O-Rings
End Plug
Reamer Guide Springs allow adjustment of 1-2 shift.
AOD
Complaint Overdrive band failure
Part No. 76833
Cause Correction
3-4, 4-3 shift concerns Forward clutch failure

Part No. 76833
1 Servo Pin 1 O-Ring 1 Retaining Ring
Excessive clearance of servo-pin to case-bore and leakage of release oil This overdrive servo pin has an o-ring to positively seal against the case bore.
OVERDRIVE SERVO PIN
Servo Piston Spring
Overdrive Servo Pin Retaining Ring O-Ring

76
sonnax
AOD-E
Part No. 76948-06
5 Springs
4R70W
Part No. 76948-06
Complaint Forward clutch failure

Cause Correction
Low line pressure Replace the spring with this stronger PR spring.
E L E VAT E D P R E S S U R E R E G U L AT O R S P R I N G
Pressure Regulator Spring
SONNAX PART SUMMARY
ow line pressure on heavy-duty applications of Ford AOD-E and 4R70W transmissions results in forward clutch failure due to slippage. A stronger regulator spring is required to bring base idle line pressure up to 68 psi. The Sonnax regulator spring 76948-06 will insure the proper clutch engagement. Typical applications for this PR spring are squad cars and vehicles requiring frequent and hard acceleration.
AOD & E
Complaint Restricted lube flow
Cause
Part No. 76811-01K
M
Part No. 76811-01K
Spline wear causes the direct drum shaft to contact the output shaft and shut off lube flow This retaining ring fit prevents the direct drum shaft from contacting the output shaft and shutting off lube flow.
Correction
A
5 Retaining Rings
CH
INI
Late model shafts require no modifications, early style shafts will require machining a ring groove.
D I R E C T D R U M S H A F T R E TA I N I N G R I N G
QUIRE
Retaining Ring
Direct Drum Direct Drum Shaft
sonnax
77
Sonnaflow: Cooler Flow Sensor

BOB WARNKE AND DENNIS MADDEN
Q A
Using the tool to prevent repeat planet failure . . . an Insurance Policy! Why cant I rely on a bucket and the typical 1 qt. in 20 second shop test to verify if my radiator is plugged? Using a bucket and testing the flow on the lift does not duplicate the driving conditions of TCC apply, aerated fluid, failsafe or radiators that plug as their heat increases (The Chrysler units 41TE, 46RH are a good example). When restricted, they often flow less with higher operating temperature. Besides the greater accuracy of a road test, there is less mess. A pressure gauge by itself cannot measure flow. Using two gauges and measuring the difference or the pressure drop across cooler circuit can be used to calculate the flow rate. This procedure is be very time consuming and not as accurate in regards to viscosity changes.
GPM/Hz 2.6/361
Part No.: FM-01K Sonnaflow Part No.: FM-03K Diagnostic lead
The Sonnaflow installs easily in the return cooler line. You can then monitor cooler return (lube) oil during any driving condition. For an even more accurate test you can monitor the Sonnaflow system with an oscilloscope or Graphing DMM, like Snap-On's Vantage.
GPM/Hz 2.6/361
42-47RE
41TE/42LE
2.5/333 Condition: Repeated planetary failure, TCC lining failure 2.2/305 Correction: Replace cooler lines and/or radiator. Converter failure plugs lines and 2.0/278 then overheats planets. 1.8/250 1.6/222 1.4/194 1.2/167 1.0/139 0.8/111 0.6/83 0.4/56
PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL Notes: Flow is less due to 5/16" vs. 3/8" cooler line on 42RE & 47RE units. Good cooler flow circuits have sharp increase/decrease of lock-up control. Updated valves allow fluid in park to charge converter.
2.5/333 Condition: Good vs. bad flow 2.2/305 Correction: Repair cooler flow, replace bypass valve, replace pump. 2.0/278 Good Flow Pressure Regulator Buzz Idle Restricted Cooler 1.8/250 1.6/222 1.4/194 1.2/167 1.0/139 0.8/111 0.6/83 0.4/56 0.0/0 Bad Good
0.0/0
PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL HOT IDLE DRIVE Notes: #46 and later plate # increase cooler flow. #33 plates decrease flow in TCC. Pump output very crucial, flow drops hot, during shifts and return to idle.
GPM/Hz 2.6/361
E4OD
GPM/Hz 2.6/361 2.5/333 2.2/305 2.0/278 1.8/250 1.6/222 1.4/194 Good 1.2/167 1.0/139 0.8/111 0.6/83 Bad 0.4/56 0.0/0
RE4RO1A
2.5/333 Condition: Repeat code 62, TCC failure leading to lube failure 2.2/305 Correction: Replace radiator to increase cooler flow. Install high volume pump. 2.0/278 1.8/250 1.6/222 1.4/194 1.2/167 1.0/139 0.8/111 0.6/83 0.4/56 0.0/0
PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED
Good
Bad
TCC CANCEL REVS ENGAGEMENT
PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL Notes: RE4RO1A critical to flow coolant to prevent lube failure. All restricted radiators affect/reduce TCC apply spike.
78
sonnax
Q A
A restricted cooler is a sure way to wipe out the geartrain. The Sonnaflow will quickly alert you to a restricted cooler.
Sonnaflow as a diagnostic tool. I have seen in the advertising that the Sonnaflow has a diagnostic lead (FM-03K). What advantage is it for me to purchase this lead? What can it tell me, to justify its purchase? The optional diagnostic lead has Banana Jacks that attach to most DVOM or graphing multimeter, such as the SnapOn Vantage. These leads transfer a Hz (cycles per second) output, which is read on the scope as a frequency. In short, more flow generates more cycles per second and a constant flow outputs a steady frequency. The slightest decrease or erratic increase in cooler flow is observed on the scope when set on the correct frequency scale. By monitoring this signal you can: Identify a low oil level or filter sucking air Identify poor pump capacity or low output Identify valve action Isolate hydraulic versus electronic complaint
Effects of cooler restriction on TCC; Snap-On Vantage; stored screen memory of E4OD
200 GOOD: E4OD Cooler flow with OE restriction. Shows applied, release and re-apply flow 200 BAD: E4OD Cooler flow, with flow restricted to .9 GPM BAD: E4OD Cooler 200 flow, with maximum flow restricted to .5 GPM. Shows applied TCC, release and re-apply. 100
100
100
GOOD 0 0 0
GPM/Hz 2.6/361 2.5/333 2.2/305 2.0/278 1.8/250 1.6/222 1.4/194 1.2/167 1.0/139 0.8/111 0.6/83 0.4/56 0.0/0
AX4S
GPM/Hz 2.6/361
4L80-E
2.5/333 Condition: Purple Line: Normal Green Line: Poor - TCC valves not completely stroking Red Line: 2.2/305 Poor - Idle engaged engine surge Drop out 3rd 2.0/278 Correction: To eliminate TCC 1.8/250 apply valve cycle-seal off TCC regulator and 1.6/222 TCC shift valves. Idle 1.4/194 engine surge requires higher pump output 1.2/167 and more release oil 1.0/139 pressure: VCM recalibrate. 0.8/111 0.6/83 0.4/56 Failsafe
PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL
Normal Poor TCC Valve Control Restricted Radiator
Mis-wired EPC to shift Bad Bypass Sleeve
0.0/0
D-R Low Idle Surge

PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL
GPM/Hz 2.6/361 2.5/333 2.2/305 2.0/278 1.8/250 1.6/222 1.4/194 1.2/167 1.0/139 0.8/111 0.6/83 0.4/56 0.0/0
PARK
General Diagnostics
Drain-Back = No flow on initial start (above 50F) Restricted Filter = Low flow, large dips in flow, sluggish shift reaction and increase. Aerated Fluid = Low oil level, filter inlet leak, mis-matched pump halves Aerated Fluid Weak Pump Bad Filter, Pump, Cooler
DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL
GPM/Hz 2.6/361 2.5/333 2.2/305 2.0/278 1.8/250 1.6/222 1.4/194 1.2/167 1.0/139 0.8/111 0.6/83 0.4/56 0.0/0
PARK
General Diagnostics
No Control Over TCC Valve
1-2 Shift Engagements
2-3 Shift
Drain-back Delayed Engage Stuck Lock-up Valve

DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL
sonnax
79
AOD-E
Delayed or no lock-up Uncontrollable TCC
4R70W
Part No. 76948-04K
Complaint Code 628, shudder condition

B Y PA S S C L U T C H C O N T R O L S L E E V E & P L U N G E R VA LV E
Cause
The complaints are symptoms of too much oil to the bypass control valve plunger, or wear at the control sleeve
Look for leakage from exhaust port on casting (bottom) side of valve body.
Valve Body
Correction
Restore the hydraulic integrity at the bypass control sleeve, and regulate converter charge oil flow to the plunger.
Plunger Valve
Bypass Sleeve with control orifice
Part No. 76948-04K

1 Bypass Sleeve 1 Plunger Valve
SONNAX PART SUMMARY
ome common complaints with AOD-E & 4R70W transmissions include delayed lock-up, shudder, no lock-up, or converter codes. When too much oil is routed to this plunger valve, the bypass valve has slow reaction from MCC/TCC solenoid oil. If there is excessive wear at the plunger valve, regulated converter charge oil can leak to exhaust. Because this regulated converter charge oil is always present, either as release or apply pressure, severe leakage at the sleeve can result in a no TCC apply situation.
Sonnax now offers a replacement bypass clutch control sleeve and plunger valve 76948-04K with a restricted oil flow orifice. The single .030" orifice, much smaller than the OEM size, allows the bypass clutch control valve to properly stroke to the TCC apply position. This eliminates the need for modifying the plunger feed hole in the separator plate, which is a common industry adjustment.
80
sonnax
AOD-E
Poor soft shift quality Insufficient line rise Erratic, buzz, or uncontrollable pressure in reverse Broken cases
4R70W
Part Nos. 76948-01, -02K & -09
Complaint Premature clutch/band failure, poor reverse boost

P R E S S U R E R E G U L A T O R V? ? E & B O O S T S L E E V E K I T A LV
Retaining Clip Identification recess here on '96 and later valve
Spring Valve Body
Cause
Worn main regulator valve and worn reverse boost sleeve
Main Pressure Regulator Valve annular grooves to prevent valve side loading Pressure Regulator Boost Valve (correct assembly shown, may not have a spring over boost valve stem)
Exhaust to Pump Suction Converter Line Charge Balance Oil Line, from Pump EPC Boost Oil
Pressure Regulator Boost Sleeve
Reverse Boost Oil
Correction
These direct replacement main regulator valves are closely toleranced, made from high quality aluminum, specially coated to resist wear, and have annular grooves to center them in the bore and prevent premature wear.
Valve wear at this point will allow EPC boost oil to leak off into exhaust. This lowers line rise ability. If wear and cross leaks are severe enough, reverse oil will react on the full diameter of the regulator valve and create Exhaust to extremely high pressure in reverse (i.e. case & parts breakage). Minimal wear causes poor reverse line rise. Pump Suction
SONNAX PART SUMMARY

common complaint in vehicles with an AOD-E/4R70W transmissions is low line pressure or throttle sensitive buzz, especially when hot. This is often caused by a worn main regulator valve. This wear allows EPC (electronic pressure control) oil to leak to exhaust, resulting in poor line rise. When the oil temperature increases, the oil becomes less viscous and more leakage occurs. The Sonnax replacement valves 76948-01 & 76948-09 eliminate the above problems with close tolerances and they are made from high quality hard coated aluminum to eliminate excessive wear. Annular grooves have also been added to the pressure regulator valve. These grooves allow oil to surround the valve, thus centering it in the bore to prevent side loading which causes premature wear. Another common complaint with these transmissions is poor reverse boost, often the result of a worn pressure regulator boost sleeve. The sleeve should be checked while replacing the main pressure regulator valve. Sonnax offers a replacement pressure regulator boost valve and sleeve kit 76948-02K.
Part No. 76948-01

1 Main PR Valve
'91-95 version
Part No. 76948-09

1 Main PR Valve
'96 and up version
Part No. 76948-02K

1 PR Boost Valve 1 PR Boost Sleeve
Note: 76948-01 is for valve bodies identified by having 13mm socket heads on the alignment bolts. 76948-09 applies to valve bodies having .173" alignment pins with 10mm heads.
sonnax
81
AOD-E
Complaint
Part No. 76833E
1 Servo Pin 2 O-Rings 1 Washer
Note: Comes with an optional washer to pre-load the spring for a firmer 3-4 shift.
4R70W
Part No. 76833E
Overdrive band or forward clutch failure

Cause Correction
The O.D. servo pin wears the case bore, causing forward clutch circuit leaks This Overdrive servo pin has two o-rings to positively seal against the piston I.D. and the case bore.
OVERDRIVE SERVO PIN

Spring Retainer
Washer
Servo Piston Piston Sleeve
O-Rings Overdrive Servo Pin
AOD-E
4R70W
Part No. 76204-01
Complaint TCC apply & release problems

Cause Correction Cross leakage of forward clutch and converter release pressure Lube and converter release oil
A worn stator support I.D. at the input shaft Teflon ring area allows oil leakage This hardened steel sleeve is pressed into a machined stator support to provide a new seal surface and restore oil circuit integrity.
S TAT O R S U P P O R T S L E E V E
Inspect here for wear
Stator Support Sleeve
Part No. 76204-01

M
1 Sleeve
CH
INI
QUIRE
Stator Support Converter Release Orifice
82
sonnax
ATX
Very Complaint ?? late or no upshift
Hydraulic bind on accelerator linkage Poor throttle pressure control
Part Nos. 86940-01 & -03
T H R O T T L E C O N T R O L V A LV E & T H R O T T L E P L U N G E R S L E E V E S
Valve Body
Cause
Wear on the throttle control valve sleeve and/or throttle plunger sleeves from the steel valves can allow TV oil to exhaust
Throttle Control Valve Sleeve
Throttle Control Valve
Throttle Plunger Sleeve
Correction
The replacement throttle control valve sleeve is made from high quality aluminum to eliminate excessive wear. The throttle plunger sleeve of anodized aluminum resists wear from the throttle plunger. Part No. 86940-01
1 Throttle Plunger Sleeve
Washer
Throttle Plunger
SONNAX PART SUMMARY

ehicles with an ATX transmission frequently experience poor throttle pressure control, very late or no upshift and a hydraulic bind on accelerator linkage. These complaints can be the result of a worn throttle control valve sleeve. The hardened steel throttle control valve continuously strokes in the aluminum sleeve. This wears the inside diameter of the sleeve and allows oil cross leakage. Regulated TV oil can become open to exhaust, resulting in throttle pressure and shift problems. If TV balance oil leaks, the result can be very late or no upshift. The replacement throttle control valve sleeve 86940-03 eliminates these problems. The direct replacement sleeve is manufactured from high quality aluminum to eliminate excessive wear from occurring on the inside diameter of the spool. Vehicles with ATXs also experience problems with sensitive shift timing, unadjustable TV response, low line pressure and/or no kickdown. These complaints are often caused by wear in the throttle plunger sleeve caused by the throttle plunger. Sonnax offers a replacement throttle plunger sleeve 86940-01. This sleeve is made from anodized aluminum to resist wear.
Part No. 86940-03

1 Throttle Control Valve Sleeve
sonnax
83
ATX
Complaint Erratic or no 1-2 & 2-3 shift
Pin and weight hang-up Part No. 86412-01
4 Governor Pins
Part Nos. 86412-01 & -T
Cause Correction
Wear of the governor body and pins This oversized governor pin allows weights to move freely after pin holes are drilled to accept the oversized pins.
OVERSIZED GOVERNOR PIN & TEST TOOL
Part No. 86412-T

1 Test Tool
Test Tool Features: Allows easy testing of ATX governor oil circuit Tests for these conditions: -Worn transmission governor bore -Obstructions in the governor circuit -Incorrect shift points Governor Pin Governor Circuit Test Tool
Governor
ATX
Complaint
Part No. 86539-Z5
10 Shims (.005" thick)
Part No. 86539-Z5
Difficulty obtaining correct preload of idler gear

Cause Correction
Idler Shaft
Normal wear These shims, used in conjunction with the selective spacer, allow the proper preload of .001"-.003" to be acquired.
SELECTIVE IDLER GEAR SHIM

Tapered Bearing Cone Idler Gear
Selective Cone Spacer
Tapered Bearing Cone
Shim used between the bearing cone and selective cone spacer
84
sonnax
AXOD-E
Part Nos. 96201-16K & 96201-BST
Complaint No forward or reverse, slips forward and reverse

F O R W A R D C O N T R O L VA LV E & B O R E S I Z I N G T O O L
Shifts 1-2-3-2 Burnt forward clutch
Cause
The forward clutch control valve is stuck
Forward Clutch Control Valve
Spring Retainer 96201-09
Correction
Resize the bore with this sizing tool and replace the forward clutch control valve.
SONNAX PART SUMMARY
Bore Sizing Tool
T
D
Part No. 96201-16K

1 Forward Control Valve 1 Replacement Spring
Note: This valve does not require a reamer. The bore sizing tool restores the original bore.
O TO L
QUIRE
he forward clutch control valve strokes to turn the forward clutch on and off. Each time it strokes to the on position it bangs against the steel retainer. This constant banging can eventually break the retainer. The broken retainer forces the valve off center, often bends the valve, or the valve pushes right through the retainer. The complaint depends on where the valve sticks, and whether the valve has broken through the plate. Sonnax has developed a replacement valve 96201-16K with a longer and sturdier spool, eliminating the OEM stem. This allows a larger contact area with the retainer, preventing the valve from bending or breaking the retainer. This design is sturdier than the original valve and will not break through the plate. This valve kit also includes a replacement spring. If the original valve is bent, repair the bore with the Sonnax resizing tool 96201-BST.
Part No. 96201-BST

1 Bore Sizing Tool
R R
sonnax
85
AXOD
Reduced cooler and lube pressure Part No. 96201-06K
1 Bypass Sleeve 1 Bypass Plunger Valve
Part No. 96201-06K
Complaint TCC apply and release problems, code 628

Cause Correction
Severe wear of the bypass clutch control plunger valve sleeve These tightly toleranced items restore hydraulic integrity and are designed to prevent wear.
B Y PA S S C L U T C H C O N T R O L S L E E V E & P L U N G E R VA LV E
Bypass Plunger Valve
Valve Body Clip
Bypass Sleeve
Place ATF into the retaining clip passage with sleeve installed in valve body. Pressurize this cavity. Leakage at plunger end of sleeve is line pressure.
AXOD & E
Downshift clunk 2-3 shift flare Part No. 96728
1 Servo Piston
Part Nos. 96945S, 96728, 96995A & 96945R
Complaint Delayed forward engagement

Cause Correction
Servo pin-bore leakage, incorrect spring calibration & retainer breakage The upgraded servo piston and spring correct delayed engagements. The servo rod is longer & the retainer is upgraded & resists breaking.
UPGRADED LOW/INTERMEDIATE SERVO, SPRING, ROD & R E TA I N E R C L I P

Servo Piston Servo travel is just as important as oil integrity. Set up servo travel to a maximum of .120".
Servo Piston Cover
Part No. 96995A

1 Servo Spring
Servo Spring
Part No. 96945R

5 Spring Retainer Clips
Spring Retainer Clip
Part No. 96945S

1 Servo Pin
Servo Pin
86
sonnax
AXOD & E AX4N & AX4S

2-1 downshift clunk Non-adjustable throttle pressure, high pressure Harsh reverse, & clutch or band failure
Part Nos. 96201-01K, -08K, -12K & -13K
Valve Body
Cause
Boost Valve
O-Rings insures boost oil
The boost valve wears the inside diameter of the boost sleeve and causes oil to leak & exhaust through the reverse orifice, resulting in poor line rise
Boost Sleeve highest quality aluminum Factory style
Correction
This replacement assembly eliminates these problems with a closely toleranced boost valve & sleeve, and the hard aluminum valve eliminates excessive wear. Part No. 96201-01K
(3.8 Liter)
SONNAX PART SUMMARY

ehicles with an AXOD, AXOD-E, AX4N, or AX4S transmission frequently have the following problems: flare 1-2 or 2-3 upshifts, 2-1 downshift clunk, non-adjustable throttle pressure, High pressure, harsh reverse (300 PSI) and clutch or band failure from poor line rise. This can be caused by the reciprocating boost valve wearing the inside diameter of the boost sleeve. When this occurs oil that enters the TV orifice leaks past the boost valve and exhausts through the reverse orifice, resulting in poor line rise. The outside diameter of the boost sleeve also allows some leakage through the valve body, which can result in poor reverse boost. The Sonnax replacement assemblies 96201-01K, 96201-08K, 96201-12K, & 96201-13K eliminate the above problems with a closely toleranced boost valve and sleeve. The boost sleeve is manufactured from Alcoa Deltalloy 4032. This high quality aluminum has a special composition that eliminates the need for hard anodization, while remaining equally wear resistant. The boost valve is made from aircraft quality aluminum with a special hard coat. This will eliminate excessive wear from occurring on the inside diameter of the sleeve. Two o-rings on the 96201-01K & 96201-12K provide additional protection against leakage through the valve body and assist in retaining pressure in the areas that supply the boost valve. Hydraulic tests conducted on these replacement parts, simulating actual application usage, show zero to minimal leakage. Each of these Sonnax kits are leak tested before leaving the factory.
Part No. 96201-12K

(3.0 Liter) 1 O-ring Boost Sleeve 1 Boost Valve 2 O-Rings
Part No. 96201-08K

(3.8 Liter)
Part No. 96201-13K

(3.0 Liter) 1 Factory style Boost Sleeve 1 Boost Valve
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87
AXOD & E
Retaining ring becomes loose and pops out Part No. 96730-RR
1 Retaining Ring
AX4S
Part No. 96730-RR
Complaint No movement
Cause Correction
OEM retaining ring does not fill groove This retaining ring is thicker and fits more securely in the groove, eliminating excess clearance that leads to the ring popping out.
R I N G G E A R R E TA I N I N G R I N G
Retaining Ring is thicker than OEM and fills entire ring gear groove
Drum
Ring Gear
AXOD & E
Complaint No forward or no 3rd gear
Part No. 96806
1 Servo Tube Bracket
Part No. 96806
Cause Correction
Insufficient factory press fit between the tubes and case, resulting in tube blow-off This bolt-on bracket positively retains the servo tubes, eliminating the chance of blow-off.
SERVO TUBE BRACKET
Servo Tube Bracket

Servo Apply Tubes
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sonnax
AXOD-E
TCC apply unnoticeable, slippage occurs or TCC stays applied during coast Lube system failure
AX4S
Part No. 96206-01K
No Complaint ?? TCC apply or code 628

B Y PA S S C L U T C H C O N T R O L S L E E V E & P L U N G E R V A LV E
Valve Body
Cause
Excess wear allows regulated converter charge and cooler oil leakage
Bypass Plunger Valve
Lube/Coverter oil
Spring located between the valve and sleeve
Retaining Clip
Correction
Restore hydraulic control and prevent cooler/lube oil loss by replacing the valve and sleeve. Part No. 96206-01K
1 Bypass Plunger Valve 1 Bypass Clutch Control Sleeve
Smaller feed ports result in responsive TCC control.
Bypass Clutch Control Sleeve
SONNAX PART SUMMARY

ehicles with an AXOD-E or AX4S transmission frequently have lube system failures, TCC apply and release problems and code 628. These complaints can be aggravated by severe wear of the bypass clutch control plunger sleeve. Excess wear allows regulated converter charge and cooler oil leakage. This oil is fed to the lube circuits, cooler, TCC and into the sleeve to help maintain the TCC in the release position. If the sleeve is worn, oil will exhaust past the plunger sleeve through the manual valve. Because this regulated converter charge oil is always present, either as release or apply pressure, severe leakage at the sleeve can result in a no TCC apply situation. Sonnax has a tightly toleranced bypass clutch control sleeve and plunger valve 96206-01K which restores hydraulic integrity and eliminates the above problems. To minimize wear of the precision sleeve, it is manufactured from 4032 Deltalloy aluminum and the aluminum plunger valve has been anodized. The sleeve has also been lengthened to prevent oil loss at the valve. The regulated converter feed holes in the sleeve have been made smaller than the OEM size to restrict flow and allow for a quicker stroke/apply of the TCC bypass valve.
Note: The orifice size in the sleeve has been reduced which increases TCC control. The orifice may be opened to restore OEM size and control.
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AXOD & E
Burned forward clutch Low converter charge Part No. 96201-05
1 Manual Valve
AX4N/AX4S
Part No. 96201-05
Complaint Delayed forward engagement

Cause Correction
Worn valve body and oil loss at the valve bore This manual valve restores the intended fit with the bore. Its special hard coat finish prevents wear.
M A N U A L VA LV E
Valve Body
Manual Valve wide spools supported by unworn valve body to seal circuits
AXOD & E AX4N/AX4S

Complaint Low cooler flow, slips in all ranges
Excessive converter clutch slip Part No. 96803
M
Part No. 96803
Cause Correction
Turbine seal ring wear on the soft aluminum channel casting surface This hardened and ground steel sleeve salvages worn channel plates and retains original OEM alignment.
C H A N N E L P L AT E R E PA I R S L E E V E
A
5 Repair Sleeves
Note: This repair sleeve requires machining.
CH
INI
QUIRE
Channel Plate Repair Sleeve hardened & ground - restores to better than new condition
Channel Plate
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sonnax
AXOD & E
Harsh shifts
AX4S
Part Nos. 96511K, -12K, -13K & -123K
Delayed engagement, flare shifts Complaint ??

A C C U M U L AT O R B O R E S L E E V E K I T S
Cause
Scored accumulator bores create loss of clutch pressure or cross leaks
Piston Sleeve No machining required
Correction
This drop-in accumulator kit has an aluminum sleeve and new steel piston with a Viton o-ring. The length of the piston-to-pin contact area has been increased to reduce piston cocking and increase sealing surface area.
SONNAX PART SUMMARY
Viton O-Ring
Part No. 96511K (N-D) Part No. 96512K (3-4) Part No. 96513K (1-2)
Each includes the following: 1 Sleeve 1 Piston 1 Viton O-Ring
he accumulator bores on AXOD & E/AX4S channel castings can become scored, which creates loss of clutch pressure or cross leaks. The continuous oscillation of the piston within the bore causes excessive wear. Also a broken accumulator spring can get caught between the piston and the bore causing a deep groove.
Part No. 965123K

1 Each of the kits above
Sonnax now offers accumulator bore sleeve kits. These drop-in kits contain an aluminum sleeve and a new steel accumulator piston with a Viton o-ring. The piston is compatible with all OEM springs as well as the OEM piston pins. The length of the piston-to-pin contact area has been increased to reduce piston cocking and increase sealing surface area. Sonnax offers 3 different kits: the ND accumulator kit 96511K, the 3-4 accumulator kit 96512K and the 1-2 accumulator kit 96513K. Sonnax also offers a master kit 965123K, consisting of all three items. These kits require no machining and easily press into the bore.
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AX4N
Complaint No TCC apply & code 628
Poor TCC apply and release Lube system failure Excessive cooler circuit oil loss Part No. 96206-03K
1 Plunger Valve 1 Bypass Clutch Control Sleeve
Note: Inspect for worn bore.
Retaining Clip
Part No. 96206-03K
Cause Correction
A worn bypass clutch control sleeve allowing regulated converter charge and cooler oil leakage Restore the hydraulic integrity and prevent cooler oil leakage at the bypass clutch control sleeve.
B Y PA S S C L U T C H C O N T R O L S L E E V E & P L U N G E R K I T
Plunger Valve Bypass Clutch Control Sleeve
Valve Body
Spring located between valve and sleeve
AX4N
Complaint Soft 1-2 or 2-3 shifts
Intermittent harsh shifts Poor line rise
Part No. 96948-01K
Cause Correction
Severe wear of the line pressure modulator sleeve Restore EPC circuit integrity by replacing the sleeve and valve.
L I N E P R E S S U R E M O D U L A T O R P L U N G E R V A LV E & S L E E V E
Part No. 96948-01K

1 Valve 1 Sleeve 1 O-Ring
Accumulator Valve Body
Spring
Spring & Spring Seat
O-Ring
Line Pressure Modulator Valve
Line Pressure Modulator Plunger Valve annular grooves to prevent side loading
Sleeve
Retaining clip
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sonnax
AXOD-E
Part No. 96201-15K
5 Valve Saver Caps 5 Retainer Clips
AX4S
Part No. 96201-15K
Neutrals on the 3-2 downshift, harsh 3-2 kickdown Complaint ???

Cause Correction
The valve constantly bangs the retainer, resulting in broken retainers that get lodged and sometimes damage the end of the valve This valve saver cap and retainer allow re-use of the 3-2 shift timing valve.
VA LV E S A V E R C A P
Also Available
Part No. 96201-09

1 Retainer
3-2 Shift Timing Valve Spring
Part No. 96201-10

1 Retainer
Note: These retainers are used in numerous Ford valve body locations. Valve Saver Cap 96201-15K
Spring
Pull-in Valve
Plug
Retainer 96201-09 Retainer 96201-10
Mangled valve
Broken retainer
CD4E
Complaint Excessive endplay
Cause
Part No. 73251-01K
2 Shims ea. (.008" & .015" thick) for #9 Bearing 2 Shims ea. (.005" & .010" thick) for #13 Bearing
Part No. 73251-01K
OEM shims have too great a difference between shim selections This shim kit adjusts the planet, drum, and differential endplays and offer a more precise adjustment.
Correction
S H I M K I T F O R S E T T I N G E N D P L AY
Driven Sprocket
Shim
Shim
#9 Bearing Drive Sprocket to Overdrive/Reverse Carrier
#13 Bearing Differential to Driven Sprocket
Differential
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93
CD4E
Complaint ??Codes 628 / 1744 / 1740, high line pressure
Lube oil loss Reduced converter clutch life Bushing or planet failure
Converter Regulator Valve
P R E S S U R E R E G U L AT O R & B Y PA S S C L U T C H C O N T R O L K I T S
Bypass Clutch Valve Land for sag test Plunger Valve
Bypass Clutch Control Sleeve

End plug
Cause
Worn bores in the converter bypass and pressure regulator line-up
Valve Body Spring
OS Pressure Regulator Valve includes built-in pressure relief Spring End Plug
Spring
Retainer Clip
Correction
This pressure regulator and bypass clutch control kit restores hydraulic integrity of the valve circuits. Part No. 73840-BK
1 OS Bypass Clutch Valve 1 Plunger Valve 1 Bypass Clutch Control Sleeve 4 Lubrication Plugs (1 extra)
O TO L
SONNAX PART SUMMARY

ehicles with CD4E transmissions often have complaints of runaway high line, broken hard parts and Code 628/1744/1740. High pressure concerns are caused by wear in the pressure regulator valve bore and converter concerns are caused by wear at the bypass clutch control valve bore. Sonnax now offer the 73840-RK for pressure regulation concerns and 73840-BK for converter concerns. These two kits are also available together in a master kit 73840-MK. All valve kits require the associated reamer tool listed on this page.
SAG TEST
D
Part No. 73840-RK

1 Converter Regulator Valve 1 OS Pressure Regulator Valve 1 End Plug 4 Lubrication Plugs (1 extra) 1 O-Ring 1 Spring
O TO L
QUIRE
Part No. 73840-MK

Master Kit: Includes Converter Bypass & Pressure Regulator Kits above
94
O TO L
QUIRE
QUIRE
To test for a worn bypass clutch control valve bore, install OEM valve backwards, with large spool in position. With .070" or less clearance between bottom of the valve and the bore means the bore is worn out. A good tool to use for a gauge is a .070" drill bit.
Part No. 73840-BTL

Services the 73840-BK only
Part No. 73840-MTL

Master Tool Kit Services the 73840-MK, -BK or -RK
Part No. 73840-RTL

Services the 73840-RK only
sonnax
Part Nos. 73840-BK, -RK, -MK, -BTL, -RTL & -MTL
BYPASS CLUTCH CONTROL & LUBE IMPROVEMENTS

OEM VALVES SONNAX IMPROVED VALVES
SONNAX PLUG KIT Increases Converter & Rear Lube PSI Feed to Lube is Now from Line PSI
FIG. 1
The OEM control sleeve & bypass bore wear, causing: Low converter pressure Converter slip codes 628/1744/1740 Low lube pressure (front lube) Bushing and planetary failure Converter crowding, engine stall in D-R No TCC apply when hot Slip converter codes 628/1744/1740
Front Lube Differential Lube
Sonnax Plug OEM Converter PSI Feed Lengthened Spool with Exhaust Slots Provides Continuous Bore Support
Lengthened Spool Provides Better Support & Prevents Leakage
Annular Grooves Prevent Side Loading
Oversized Valve Re-Establishes Valve/Bore Fit
Annular Grooves Prevent Side Loading
NOTE: Reparing this sleeve or bore alone wont address: High Line pressure run-away Harsh engagements Failsafe lube shutdown All lube concerns Complete fix includes pressure regulators in Fig. 3. Both valve assemblies in kit 73840-MK.
OEM PRESSURE REGULATOR CONCERNS

FAILSAFE POSITION OF OEM LINE PRESSURE REGULATOR VALVE, NO FLOW TO COOLER
No Converter or Lube Feed High Pressure EPC/TV Pump Line In Sump Balance Circuits Worn Exhaust Bore Here Causes Valve to Stay in High Line/No Exhaust
FIG. 2
OEM HIGH LINE PRESSURE POSITION
OEM Spring Regulates at Approx. 100PSI, Which means Any Converter Feed Over 100PSI Shuts Valve Down To No Flow. The Valve Is Not an Exhaust Control Design, But Flow Control. .060 OEM Converter Feed Bypass. If Opened Further High Line Feeds to TCC/Lube High PSI Line Pump In
OEM Bore Wears Here, Lowers Converter Pressure
OEM Very Low Flow or No flow High PSI Out
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95
Part Nos. 73840-BK, -RK, -MK, -BTL, -RTL & -MTL
IMPROVED SONNAX LINE PRESSURE & CONVERTER REGULATOR VALVES

SONNAX VALVE IN START UP POSITION, OR FAILSAFE, ALLOWS FLOW TO COOLER
1 4
FIG. 3
SONNAX VALVE IN HIGH PRESSURE POSITION REGULATING MAXIMUM CONVERTER PRESSURE

BENEFITS: LOCATION 1: No oil loss at worn bore, stabilized OD LOCATION 2: High flow cooler/converter circuit LOCATION 3: Valves will not shut off flow, but regulate at full line pressure 1 2 3
2 BENEFITS:
5
OEM .060 Lube Feed To Lube Converter
Cooler/Lube Balance
LOCATION 1: Full time converter/cooler feed at start and low pump output LOCATION 2: Controls line and cooler in advent of EPC/TV failsafe LOCATION 3: Regulates flow to converter regulator through high or low line pressure LOCATION 4: Converter feed-to-line timed with line-to-exhaust LOCATION 5: Oversized valve/reamed bore restores balance circuits NOTE: Installing these two valves will improve the source of lube/converter feed, but will not overcome a worn bypass sleeve and bypass valve. Complete fix includes bypass valves in Fig. 1. Both valve assemblies in kit 73840-MK.
CD4E PRESSURE TESTING
FIG. 4
Poor Pressures: Listed below, result from worn valve bodies and loose bushings. Less than 2 psi when Hot Less than 10 psi when Cold Less than 20 psi at an idle, while hot, and a pressure spike above 110 psi during TCC engagement.
All pressure tests are taken in drive range.
Front Lube
- CT Converter Turbine psi
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sonnax
CD4E
Complaint ??Soft 1-2, flare 2-3
Burned band Drum overheat
Part Nos. 73840-24, -LR & -FWD
O - R I N G E D A C C U M U L AT O R P I S T O N & S P R I N G K I T S
Cause
Accumulator bore wear and/or piston sticking
Accumulator Piston Viton o-rings installed
Springs
Valve Body
Correction
Prevent leakage of worn valve body castings with this o-ringed accumulator piston and spring kit.
Retaining Clip
Part No. 73840-24

(2-4 Clutch), 1 Spring
Part No. 73840-LR

(Low/Reverse Piston), 3 Springs
Part No. 73840-FWD

(Forward Piston), 2 Springs
SONNAX PART SUMMARY

ehicles with a CD4E transmission may have complaints of harsh engagement, soft or harsh shifting particularly from 1st to 2nd gear. These complaints can be due to worn or out-of-round accumulator bores and/or pistons sticking in the bore. Sonnax now offers an accumulator piston kit 73840-24 for the 2-4 piston, 73840-LR for low/reverse, and 73840-FWD for forward. This anodized aluminum replacement piston has two o-rings that will prevent blow-by leakage. The piston has been dimensionally modified to stop in different axial locations than OEM to prevent it from hanging-up or sticking on the previously worn bore ridges. Modified replacement springs are included for each application to fit in the smaller piston pocket.
Each includes the following: 1 Accumulator Piston 2 Viton O-Rings Modified Springs (see above) 1 Rivet (used in installation)
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97
Bushings Take a Beating

By MAURA STAFFORD of Sonnax and MIKE STEEN of Certified Transmissions
ushings are designed to be wear items, and ing why the bushing failed. Dirt often reach the full extent of their expected embedment (Figure 2) is one of lives. But during a rebuild, we often see signs the most common causes of bushof premature wear or failure. While at first glance ing failure. While a bushing is Figure 1: NEW BUSHING bushings seem like insignificant low-tech items, fail- designed to accommodate some No sign of wear. ing to pay close attention to them can cause some dirt, embedded dirt, abrasives, or high-tech problems. For example, converter hub metal fragments will lodge and displace the surroundbushings are subject to high loads due to hydraulic ing bushing material. This creates high spots that conunbalance, flex of the converter mounting plate and tact the journal and create a halo around the debris. If the bushing I.D. (inside diameter) has slight misalignments that might exist. a polished or finely scratched appearance, Too much clearance in this area can this is a sign of abrasive wear (Figure 3). cause front seal blow out, converter This is commonly caused by particulate drainback, poor converter charge, and Figure 2: in the oil, direct contact with the journal, cooler pressure and flow problems. EMBEDMENT These can lead into potential geartrain Debris embedded in bush- or a rough journal finish. Scoring is more displacing material and extreme than abrasive wear, and is typicalfailure due to poor lubrication, converter ingcausing wear halos ly caused by severe contamination. shudder and converter slip. This article A bushing that has a smeared or wiped surface most is intended to provide a basic understanding of bushings, causes of distress, design considerations, and likely has suffered from oil starvation (Figure 4). This which rebuild procedures prevent bushing failure allows the journal to contact the bushing and smear material. This can be caused by blocked lube holes, and improve transmission performance. The basic function of an automatic transmission pump volume or pressure bushing is to align and provide load support for shafts, problems, cold weather gears and clutch drums. During normal operation and starts, too tight clearances, when properly aligned, the clearance between a bush- or overheated and diluted Figure 3: ing and journal diameter fills with oil, allowing the oil. A hot short condition RADIAL ABRASION AND AXIAL SCORING shaft to float on the oil film. The housing into which looks severely wiped, black Debris caused slight radial a bushing is pressed often functions as a heat sink, from heat, and actually has scratches. Debris and axial part drawing heat away from the bushing and journal. patches of alloy torn away movement created severe scoring. This reduction of friction and heat increases the over- from the steel backing. This can be caused by prolonged wiping, overloading, bushing overheat, or oil all efficiency of a transmission. Bushings also act as restrictors to prevent oil flow starvation. Localized spots of wear on the bushing I.D. may be between components. The front stator support bushing in many units prevents release oil from blowing caused by debris trapped between the housing bore past the turbine shaft to the apply side of the con- and bushing O.D. (outside diameter). This debris verter. In other instances, bushings are used to inten- will cause the bushing I.D. to have high spots that tionally direct oil flow to components. Virtually all contact the journal. Axial or radial grooves and rear extension housing bushings have oil grooves to scratches on the O.D. can indicate a bushing that is provide a pumping action that sends lubrication to spinning or walking out of the bore (Figure 5). This is usually due to an undersized bushing or a housing the rear seal of the transmission. Generally, during a rebuild, bushing wear or failure that has lost its size and shape from repeated service is obvious. Much can be learned about the overall or extreme pounding. Wear patterns can indicate if the journal or housing health and function of the transmission by determin-
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sonnax
is non-cylindrical or ings works well. Clearances should be checked with misaligned. Wear at feeler gauges. If not available, a standard sheet of the edges of a bushing paper is . 002 thick and is an excellent gauge. When replacing bushings, the real challenge might indicates a barrel Figure 4: WIPING AND OVERHEATING shaped bore or hour- be maintaining these proper clearances. There are Oil Starvation caused bushing to overheat and wiping to occur. glassed shaped jour- generally two types of replacement bushings availnal. The reverse is true for wear at the middle of a able: finish-in-place or precision manufactured. bushing. Wear towards only one edge of the bushing Most original equipment bushings have been finindicates a tapered journal or housing. A skewed or ished in place, which provides closer control of alignangled wear pattern typically represents parts out of ment and running clearances. Precision bushings are carefully sized to have a specific press-fit into the alignment. housing bore, which then crushes There are some design and Figure 5: SPIN OUT Radial scoring on bushing O.D. indicates the bushing inside diameter to a preassembly specifications that should bushing spun out of the housing bore. determined size and clearance with be considered during a rebuild that the journal. Due to housing bore tolconcerns bushings. The surface finerances, loss of bore size and shape ish on bushings, housings, and jourfrom multiple bushing replacements, nals greatly affect performance and journal wear, and bushing manufacturing methlongevity. A surface that is too rough will supply the contamination to hang valves, plug solenoids and ods, precision bushing to journal clearances will usuwipe a bushing out in no time. To aid in retention, ally be greater than that of finish-in-place bushings. the housing bore for a steel-backed bushing should be If the original bushing is worn and must be replaced, 60-125rms and between 40 to 70rms for solid bronze an oversized bushing that may be finished in place is bushings. A bushing I.D. should be a 30rms finish or recommended. If they are not available or impractibetter. Journals should have a finish between 8 to cal, a precision type aftermarket bushing should be 12rms, although up to 20rms is acceptable. The jour- used, and a close check for excessive clearance would nal should be polished while rotating against the pol- be advised. Bushings should be removed and installed with the ishing paper in the same direction it will rotate in assembly. This prevents the microscopic journal correct tools to prevent housing, journal, and/or scales from kicking up during actual rotation and bushing damage. There are generic sets of bushing prematurely wearing the bushing or journal. For chisels designed to cut a bushing out of a bore. For journal touch-ups, a 280 to 320 grit paper may be extra small bushings, thread taps can be used successfully. The best way to install a bushing is with an used. There are many factors that influence the appro- arbor press and an adapter specific to the bushing. priate bushing clearance, such as bushing and hous- The adapter should press flatly and firmly on the ing materials, type of journal material and hardness, bushing edge and have a mechanical stop for proper operating temperatures, quality of machining, and axial location. Avoid manual pounding of a bushing lubrication methods. Bushing manufacturers recom- into place. The bore should be free from debris. mend a clearance of 0.0005 in./in. of shaft diameter, Pressing in new bushings shaves small pieces of with a 0.0005 inch minimum for babbits, and material off the O.D. or housing bore, and can be a 0.00075 in./in. of shaft diameter, with a 0.0005 inch source of unwanted contamination. Lubricant on the minimum for copper-lead and bronze bushings. It is bore or bushing O.D. can be used to prevent galling usually necessary to increase these amounts in appli- and ease assembly. Proper unit endplay specificacations with heavy loads, or high speeds or tempera- tions should be maintained to prevent shafts ending tures. From experience weve found that .001 of within bushings and oil holes being misaligned. clearance for every inch of journal diameter is rec- Hopefully this will provide some food for thought ommended for most transmission applications, and during rebuilds. .003 to .004 total clearance for converter hub bush-
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99
A404
Part No. 32710-01
1 Reverse Band Strut
A413, A470 & A670
Part No. 32710-01
Complaint No reverse, rear band strut breakage

Cause Correction
Thin struts cannot withstand the force of servo piston lever as it applies the reverse band This reverse band strut has a thicker cross section and is made of higher yield strength alloy steel.
REVERSE BAND STRUT

Lever Adjusting Screw
Reverse Band Strut
Reverse Band
A404 A413, A470, A670

Complaint
Part No. 32539-Z5
10 Shims (.005" thick) Transfer Shaft Shim
Part Nos. 32539-Z5, 35539-Z5, 39539-Z5
Excessive endplay, left-over unpopular spacers

Cause Correction
Some spacers provided in spacer kits are commonly unused because of the unpopular size These shims allow for accurate setting of endplay & preload and the use of leftover, unpopular washers.
Part No. 35539-Z5

10 Shims (.005" thick) Output Shaft Shim
P R E L O A D & E N D P L AY S H I M S
Part No. 39539-Z5

10 Shims (.005" thick) Differential Preload Shim Also fits 41TE & 42LE
Output Shaft Gear Transfer Shaft Gear
Shim 32539-Z5 Transfer Shaft
Shim 35539-Z5 Output Shaft
Shim 39539-Z5 Differential

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sonnax
800/843-2600 802/463-9722 fax: 802/463-4059 www. sonnax. com info@sonnax. com
41TE
Converter shudder Clogged filter or radiator
42LE
Part No. 92835-03K
Complaint
Repeat planetary meltdown, no cooler flow

C O N V E R T E R R E G U L AT O R VA LV E K I T
Valve Body
TCC lining failure
Bias Valve with internal apply pressure control

Bias Valve Sleeve
Cause
High converter apply pressure and insufficient control of apply and release oil circuits
Switch Valve
Bias Valve Spring
Correction
This converter apply pressure regulator valve kit will reduce comebacks, planet failures, and converter claims.
SONNAX PART SUMMARY
igh converter apply pressures in the 41TE & 42LE transmissions cause deflection of the TCC. This in turn causes a chain reaction of failures. The TCC "balloons", the lining disintegrates, clogs the filter and radiator cutting off lube and the planets or the unit itself burns up. This high apply pressure occurs because of insufficient control of the apply and release oil circuits. Sonnax now offers a redesigned converter regulator valve kit, that is compatible with all controllers and will regulate TCC apply and release oil (see chart below). This improved design includes a new switch valve to control the flow entering the converter, a regulator bias valve to prevent the apply pressure spike and as cost savings re-uses the OEM bias spring and sleeve.
Part No. 92835-03K

1 Switch Valve 1 Regulating Bias Valve
Converter Apply Pressure Comparison

Increasing Apply Pressure
OD, Idle
Increase Pump RPM/TCC Off
TCC Application
TCC Off/ Canceled
Stages of Converter Application with EMCC Body

OEM with the Sonnax valve
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41TE
Various switch codes Reduced cooler flow Lower pump volume Part No. 12502-01
5 Front Pump Bushings
42LE, A670 & A904
Part No. 12502-01
Complaint Pump seal leakage, codes 35 & 38

Cause Correction
Excess hub to bushing clearance causes lower pump output and front seal leakage This pump bushing will restore the clearance required for proper operation and this close tolerance bushing can reduce oil loss.
IMPROVED FRONT PUMP BUSHING
Pump Body
Bushing
41TE
Complaint
Poor lube control Harsh shifting Part No. 92835-07
1 Pressure Regulator Sleeve
42LE
Part No. 92835-07
High line pressure, erratic converter apply pressure

Cause Correction
A worn pressure regulator reducing sleeve allowing oil leakage This replacement pressure regulator sleeve prevents excessive wear, restores hydraulic integrity, and reduces oil loss.
P R E S S U R E R E G U L AT O R R E D U C I N G S L E E V E
Note: The '89-'91, #33 separator plate design had a steel sleeve and plugs. The Sonnax hard anodized sleeve has increased durability and compatibility when used with OEM steel plugs.
Spring Valve Body Pressure Regulator Valve
Low/Reverse Boost Valve
Inner Sleeve
Pressure Regulator Sleeve milled slot eliminates circuit cut off by end plug
Low/Reverse Orifice Line Balance Plug
End Plug
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sonnax
41TE
Part No. 92003-01K
1 Bushing
R
42LE
Complaint Premature underdrive clutch failure

Cause
O TO L
Leaks in the Underdrive circuit caused by excessive input clutch hub bushing to support clearance Replace the input clutch hub bushing with this tighter-fitting bushing.
Correction
D
QUIRE
INPUT CLUTCH HUB BUSHING & TOOL

Input Clutch Hub
Part No. 92003-TL

1 Bushing Tool 3 3 1/2 Hex Bolts
Bushing
Stator Support
41TE
Part No. 92004-L
42LE
Part Nos. 92004-L & -SP
Complaint
5 Bushings - late design, .937Dia.
Planetary failure, shaft breakage

Cause Correction
Poor tolerancing of the OEM bushings allows critical lube to exhaust These unique one-piece bushings restore the desired fit with the Underdrive shaft to prevent excessive radial movement.
Part No. 92004-SP

5 Bushings - early design, .959Dia.
Note: Bushing 92004-SP is for the early design (1995 & earlier), 41TE and 41TE; Bushing 92004-L is for the later design (1996 & up), 41TE and 42LE.
OVERDRIVE CLUTCH HUB BUSHING

Steel Backed Bushing
Early Design: OD 1.142" Later Design: OD 1.162"
Underdrive Clutch Hub
Overdrive Clutch Hub
sonnax 103
41TE
Low reverse switch code
42LE
Part No. 92835-02K
Complaint Erratic or no TCC, 2nd gear starts

Cause Correction
Solenoid switch valve plugs cocking in the bore This replacement switch valve plug kit has a thru-hole that guides the stem on the mating plug.
Part No. 92835-02K

2 Replacement Plugs
S O L E N O I D S W I T C H VA LV E P L U G S
Replacement Plugs
Plug
Solenoid Switch Valve
41TE
High CVIs due to worn bores Slide shifts
Part No. 92834-03K
1 Sleeve 1 Piston 2 O-rings 2 Teflon Seals
42LE
Part No. 92834-03K
Complaint 1-2 shudder, coastdown clunk

Cause Correction
Scuffed and worn accumulator bores resulting in a poor seal This accumulator piston and sleeve kit restores hydraulic integrity, refurbishes worn bores, and saves valuable cases.
A C C U M U L AT O R P I S T O N & S L E E V E K I T
Sleeve o-rings installed
Piston Teflon seals installed
Valve Body
Note: Also works on all 3 accumulator case bores.

Springs
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41TE
Complaint
Solenoid Repair Kit 3 Diaphragms 3 Brass Contacts
42LE
Part Nos. 92836-03K, -02 & -03
Intermittent pressure switch codes (21, 22, 23 & 24)

Cause Correction
Worn switch contacts and leaking switch seals or replacement seals that are too thick Replace worn diaphragm and switch contact with properly dimensioned parts.
Part No. 92836-03K
SOLENOID PACK RUBBER DIAPHRAGM &/OR BRASS CONTACT REPAIR
Part No. 92836-02

9 Diaphragms
Cover
Part No. 92836-03

9 Brass Contacts
Diaphragm
Solenoid Pack
Switch Contact (Brass)
41TE
42LE(94-97 w/internal bypass valve)
Part No. 92836-01K
Complaint
Erratic switch codes Soft, long 1-2 shift Erratic coast down bumps Converter clutch slippage, and code 38 Converter pressure drop due to excess fluid bypass Part No. 92836-01K
2 Bypass Plugs
Lock-up shudder
Cause Correction
The cooler bypass valve may be stuck open, reducing converter apply pressure This bypass plug disables the OEM bypass valve and directs all fluid through the cooler.
B Y PA S S P L U G
Case On the 41TE case which has a bypass, there is a casting bulge above the right fitting. Case Fitting re-installs over plug
OEM Bypass Valve
Note: This Bypass plug prevents having to remove the unit when the OEM design is stuck open.
Bypass Plug installs into case
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41TE
Part No. 92965-Z5
10 Shims .005 thick
Part Nos. 92965-Z5, -30, -37, & -45
Complaint Bearing failure, gear train noise

Cause Correction
Setting the preload and endplay of transaxle output shaft and transfer shaft bearings, rebuilders may exhaust popular spacer sizes These spacer and shim kits allow more accurate setting of preload and endplay, and may be used with leftover OEM selective spacers.
Part No. 92965-30

10 Spacers .030 thick
T R A N S F E R / O U T P U T S H A F T G E A R S PA C E R S & S H I M S
Transfer Shaft Gear
Part No. 92965-37

Part No. 92965-45

Spacer 92965-45
Output Shaft Gear
Spacer 92965-37 Spacer 92965-30 Shim Kit 92965-Z5
A904
Part No. 12780-Z
10 Shims .010 thick
42RE
Part No. 12780-Z
Complaint Excessive total transmission endplay

Cause Correction
Worn gear, snap ring, and/or spline This shim allows for adjustment of the total and rear unit endplay and works with both 3 and 4 tanged thrust washers.
R E A R P L A N E T E N D P L AY S H I M
Ring Gear
Driving Shell with Sun Gear Assembly
Rear Planet Assembly
Shim for 3 or 4 tanged thrust washers
Thrust Washers, 3 or 4 tangs

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42RE
Loss of lube oil to the gear train High replacement cost of the reverse drum
42RE
Part Nos. 12962N-01K & -02K
Complaint Reverse drum, retainer & planet failure

U P G R A D E D P I S T O N R E TA I N E R S
Cause
Excessive clearance between the overdrive piston retainer and intermediate shaft reduces lube flow to the gear train
Case
Kit includes plugs to allow use in electronically controlled units. Piston Retainer
Correction
Seal compensates for variations in the case I.D. and oil is delivered to maximum load points on shaft. OEM and oversized drum contact surface allows salvage of drum.
SONNAX PART SUMMARY
onnax is now offering an upgraded standard replacement 12962N-01K and an oversized 12962N-02K piston retainer to allow rebuilders to salvage the expensive reverse drum. The oversize version requires only boring the I.D. of the drum using a lathe and then installing as normal. 5 1. O-ring prevents loss of lube oil. Many OEM supports do not seal well here. 3 2. Two O.D. oil delivery grooves repositioned at high load areas. 3. Two I.D. oil delivery grooves run full length of load bearing surface. 4. Band drum diameter, (standard and oversized) allows drum I.D. to be turned. 5. Higher quality aluminum to resist gauling. 4
Part No. 12962N-01K

6 Bolt Piston Retainer (OEM)
Part No. 12962N-02K

6 Bolt Piston Retainer (Oversized)
Note: Requires machining of reverse drum.
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Designed for Durability

BY BOB WARNKE
hroughout this material we have described insulates electrical current flow. improvements Sonnax has made to valves, The coating results in a polished bushings and various other parts. All of surface finish 30-50% more these items have been upgraded in some form, dense than the aluminum itself. Due to the anodizing process, whether in tolerance, material, or design. O-rings on the sleeve O.D. are required when the the surface is ten times harder Figure 4: Sonnax valves have a much effects of fluid and spring cycles etch away the bore than the internal aluminum and harder surface than (Figure 1, C-6). A seal at the outside diameter of a can be assembled with bronze, most OE valves, making them less likely sleeve insures that the con- steel or brass without etching to score. The radial grooves also help trolled oil supply works fully the material. reduce side loading. Making valves of steel vs aluon the valve. Air testing, Dyno testing and isolated valve body minum is an application and engineering concern. testing equipment can prove Hard-anodized valves have many benefits over steel, this. The o-ring grooves are but there may still be applications best for steel Figure 1: Often times cut into sleeves that have the design. For example, going to a heavier steel valve the bore for the boost valve sleeve is scored. If same O.D. as the original part; eliminated the Chrysler pressure regulator buzz scored badly, use a the seals are not used to com- (Figure 5, P.Reg.s). The opposite can also be true; a boost valve sleeve with o-rings. heavier steel valve delivers more impact as pensate for loose tolit comes to a stop erances. Knowing and takes more this, be assured that force to initiate using a sleeve withFigure 3a: If using the o- movement. Using Figure 5: Sonnax makes out the o-rings will ring design sleeve, not detract from make sure to lube the o- steel valves in an replacement valves out of steel any time steel ring before installing it original perform- into the valve body. The aluminum-housing offers an advantage. often a preance, but will not Sonnax Slippery Stick is can double the leak- Steel ismaterial for presferred perfect for this. age, because alu- sure regulator valves to gain either. Sonnax Figure 2: Sonnax manuminum expands at reduce oscillations and supplies many boost factures boost valve buzzing. sleeves, both with and twice the rate of sleeves with or withwithout o-rings. steel. out o-rings (Figure Sleeves with radial porting reduce side 2) for installers preference. loading on the valve spool. Pressure on An o-ring sleeve assembly procedure is only one side of a valve can force the spool shown in Figure 3. to wear into the casting. Radial porting Annular grooves are not added to the Figure 3b: Hone the sleeve bore of the valve Sonnax valves for appearance (Figure 4, body. This will smooth distributes the load and reduces wear. AOD-E). The grooves hold oil to support any rough edges that might cut the o-rings. High silicon, the valve, which then reduces the scrubDeltalloy 4032 alubing action against the bore. This increasminum sleeve con- Figure 6: Some valve es bore life, improves valve response and sleeves have radial portstruction further ing to reduce side loadreduces hung valves. increases bore life ing of the valve: another Hard anodizing on the aluminum Sonnax innovation. (Figure 6). Sonnax valves is an electro-chemical coatOnce the Sonnax Development Team ing, which penetrates into the valve and recognizes the cause of failure, redesigning leaves an outside layer as hard as tool Figure 3c: Before steel. Ordinary anodizing is a thin surface installing the sleeve, roll for durability is simply part of the process, it against a smooth layer often used for appearance (Figure 4, clean surface. This will not part of the cost. slightly flatten the oAOD-E). The hard coat resists heat, adds rings, and make it easier to lubrication, reduces corrosion and to install the sleeve.
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A904/A727
Poor cooler charge at idle Poor line control
42RE, 46RH & 47RH
Part Nos.12229-01K & 22229-01K
Complaint Slippage in reverse

R E G U L AT O R VA LV E A N D P R E S S U R E P L U G K I T S
Valve Body
Poor forward and reverse engagement

Spring
Cause
Excessive wear at the regulator valve pressure sleeve and low reverse boost pressure
Throttle pressure plug
Plug
22 22
Sleeve
9-0 1K (fo rA
72
7/4
2R
12
H/
46
22
RH
9-0
/47
1K
RH
(fo
Spring
rA
90
4)
Correction
These upgraded sleeve and plug kits restore the hydraulic integrity of the circuit Part No. 12229-01K
1 Plug 1 Sleeve
Throttle pressure plug
Plug Sleeve
End plates
SONNAX PART SUMMARY

ehicles with A904, A727, 42RH, 46RH & 47RH transmissions may have problems with slippage in reverse, poor cooler charge at idle, and high or low line control. These complaints are often due to excessive wear at the line pressure plug and sleeve. When this sleeve and plug wears, leakage past the plug prevents the pressure regulator valve from properly controlling line pressure. For A904 units, Sonnax has now made available 12229-01K regulator valve pressure sleeve and 22229-01K for A727, 42RH, 46RH & 47RH. For 22229-01K, the plug diameter has been reduced by 25% to increase reverse boost and an o-ring has been added to the sleeve to prevent line pressure cross leaks.
Part No. 22229-01K

1 Plug 1 Sleeve with O-ring
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A727
Pin bore wear Rear servo piston sticking/breakage Part No. 22912
(A727/46RH)
46RH, 47RH & A904
Part Nos. 22912, 22912A & -B
Complaint Burned bands, poor reverse

Cause Correction
Leaks caused by pin wear do not apply band sufficiently This billet aluminum piston resists breakage; rounded seal ridges prevent the piston from sticking in the case bore.
SERVO PISTON
Part No. 22912A

(A904/A999/42RH)
Servo Piston
Part No. 22912B

(47RH, 94-up with Split Band)
Each includes the following: 1 Rear Servo Piston

Seal
Retainer
Inspect for scored pin
Spring Piston Plug
46RH
Poor kickdown Late 2-3 upshifts Oversensitive 3-2 downshifts Part No. 22771-01K
1 Throttle Valve 1 Throttle Plunger 3 Spring Shims 1 Alternative Spring 1 Sleeve
42RH, 47RH, A727 & A904
Part No. 22771-01K
Complaint Shift timing concerns & throttle buzz

Cause Correction
Throttle valve and sleeve wear This hardened steel throttle valve repair kit salvages the valve body and restores throttle valve control.
T H R O T T L E VA LV E K I T
Throttle Valve
Valve Body
Shims
Throttle Plunger
Inspect for OEM spool etching here
Sleeve Alternative Spring
Inspect OEM for wear
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42RH
Soft TCC apply
46RH & 47RH
Part No. 22771A-01
Complaint Lock up shudder, overheated converter

Reduced cooler flow
U P G R A D E D 4 S P O O L E D S W I T C H VA LV E
Cause
The OEM valve stroke is insufficient to control circuit timing of apply and release pressures
Valve Body
Bracket
Switch Valve
Spring
Correction
Improve timing and flow to the apply and release circuits with this improved switch valve. Part No. 22771A-01
1 Switch Valve
Application Note: For units with boost tube only.
SONNAX PART SUMMARY
he circuit timing of applied vs. release pressure exhausted is critical for proper TCC operation. The OEM valve stroke contributes to soft TCC apply, shudder complaints, and increased damper spring loads. Replace the OEM switch valve with Sonnaxs switch valve 22771A-01. The new Sonnax switch valve improves the timing and flow to the apply and release circuits.
S O N N A X S W I T C H VA LV E
Line Pressure
O E M S W I T C H VA LV E
Line Pressure
TCC Apply Pressure
Exhausts at the same time that TCC is applied for firmer apply and no shudder
No TCC Apply Pressure
Exhausts before TCC is applied causing soft apply and shudder
Venting oil from release side of TCC and converter control valve
Venting oil from release side of TCC and converter control valve
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A727
Part No. 22700-Z
10 Shims (.010 thick)
46RH
Part No. 22700-Z
Complaint Excessive total transmission endplay

Cause Correction
Excessive endplay often due to worn gears, snap rings and/or splines This shim reduces transmission endplay for both 3 or 4 tanged OEM washers.
R E A R P L A N E T E N D P L AY S H I M
Reverse Planet
Ring Gear
Driving Shell
3 Tanged Thrust Washer
Shim for 3 or 4 tanged thrust washers
A727
3 Bearings
Requires machining of transmission case.
46RH & 47RH
Part No. 22556-BRG
Complaint Expensive case damage

Part No. 22556-BRG
M
A
Cause
CH
INI
The inner race of the over-running clutch comes in contact with the case causing damage This case repair bearing saves expensive cases and prevents further case damage.
QUIRE
Correction
C A S E R E PA I R B E A R I N G
Case
Repair Bearing
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46RH 46RE, 47RH & 47RE

Loss of lube oil to the gear train High replacement cost of the reverse drum
Part Nos. 22754N-01K & 22754N-02K
Complaint Reverse drum, retainer & planet failure

U P G R A D E D P I S T O N R E TA I N E R
Cause
Excessive clearance between the overdrive piston retainer and intermediate shaft reduces lube flow to the gear train
Case
Kit includes plugs to allow use in electronicallycontrolled units.
Piston Retainer
Correction
Seal compensates for variations in case I.D. and oil is delivered to maximum load points on shaft. OEM and oversized drum contact surface allows salvage of drum.
SONNAX PART SUMMARY
onnax is now offering an upgraded standard replacement 22754N-01K and an oversized 22754N-02K piston retainer to allow rebuilders to salvage the expensive reverse drum. Salvaging the drum requires only boring the I.D. of the drum using a lathe and then installing as normal. 5 1. O-ring prevents loss of lube oil. Many OEM supports do not seal well here. 3 2. Two O.D. oil delivery grooves repositioned at high load areas. 3. Two I.D. oil delivery grooves run full length of load bearing surface. 4. Band drum diameter, (standard and oversized) allows drum I.D. to be bored. 5. Higher quality wear-resistant aluminum to resist gauling. 4
Part No. 22754N-01K

6 Bolt Piston Retainer (OEM)
Part No. 22754N-02K

6 Bolt Piston Retainer (Oversized)
Note: Requires machining of reverse drum.
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46RH
Press-on race not available separately Reverse drum not salvageable Part No. 22750L
1 Press-on Roller Clutch Race
A727
Part Nos. 22750L & 22750N
Complaint Worn inner race

Cause Correction
OEM races overheat and pit These press-on and slide-on roller clutch races directly replace the OEM and allow re-use of reverse drums.
PRESS-ON & SLIDE-ON LOW ROLLER CLUTCH RACES

Reverse Drums
Part No. 22750N

1 Slide-on Roller Clutch Race
Press-On Roller Clutch Race
Slide-On Roller Clutch Race
46RH
Complaint
Part No. 22900-10
1 Lengthened Band Strut (.100")
A727 & 47RH
Part Nos. 22900-10 & -15
No reverse or slip after low/reverse drum resurfacing

Cause Correction
OEM strut of insufficient length to adequately hold drum after resurfacing These extended struts compensate for removed drum material, salvaging drums and double wrap bands.
Part No. 22900-15

1 Lengthened Band Strut (.150")
LENGTHENED REVERSE BAND STRUT
Band
Strut
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Converter Code Blues?
D
SONNAX PARTS:
o you have a 4L60-E with DTC P1870 that is back for the 2nd, 3rd, or even 4th time? The converter, solenoids, stator and bushings have all been replaced, maybe it was even re-flashed, but still the code is haunting you. Along with intermittent harsh 1-2 shifts, P1870, 740 or 039 can be caused by a worn TCC Regulator & isolator valve bore or a worn TCC apply valve bore. Maybe there is a CD4E with code 628 that is back...again! Perhaps the converter has been changed out, an aftermarket kit has been tried, solenoids, and maybe even the valve body, but it still "won't go away." Many times this is caused by the Bypass Clutch Control Valve bore or Bypass Sleeve wear. We have recognized one of the root causes of these problems and have developed the following products to help fix these units and get customers happily back on the road.
HELPS CURE:
Codes P1870, 740, 39 Converter shudder Blued or burnt converters Falling out of lock-up hot
APPLICATION:
84754-01K TCC Regulator Valve & Isolator Plug (93 - up) 84754-08K* TCC Regulator Valve & Isolator Valve Kit (91 & 92) 84754-16K* TCC Apply Valve Kit (oversized) 84754-22K TCC Apply Valve Kit (91-96) 84754-97K TCC Apply Valve Kit (97 and up) 84754-98K* TCC Apply Valve Kit (oversized) 77754-03K* TCC Regulator Valve Kit (93 - non EC3 97) 77754-04K* TCC Regulator Valve Kit (97 & up EC3 units) 77805-K TCC Apply Valve Kit (4L60 & NON PWM 4L60-E) 77805E-K TCC Apply Valve Kit (4L60-E PWM only) 34994-01K TCC Regulator Valve Kit 96201-06K 96206-01K 96206-03K 76948-04K 73840-BK* 92835-03K 92836-06K 92835-07 22771A-01
Bypass Clutch Control Sleeve & Plunger Valve Kit Bypass Clutch Control Sleeve & Plunger Valve Kit Bypass Clutch Control Sleeve & Plunger Kit Bypass Clutch Control Sleeve & Plunger Kit Bypass Pressure Regulator Kit Converter Apply Pressure Regulator Valve Kit Bypass Plug Pressure Regulator Sleeve Upgraded 4-Spool Switch Valve
4T60 & E
Codes P1870, 740, 39, 68 Falling out of lock-up hot Harsh 1-2 Converter shudder Blued or burnt converters
4L60-E
(PWM and NON-PWM)
4L80-E
Codes 628 & 1744 Converter shudder and overheat Improved converter apply pressure
AXOD & E, AX4S, AX4N, AOD-E, 4R70W & CD4E
Torque Converter Clutch Failure TCC lining in unit Unit overheat High line pressure Poor lube control
41TE, 42LE, 42RH, 46RH, 47RH
* These parts require reamers
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So Wheres the Connection?

BY DENNIS MADDEN
or years, the major indicator for normal transmission operation (besides seat-of-the-pants diagnosis) was testing for proper line rise. Many units only had a line pressure tap. On the manufacturing level, the fewer taps on the transmission, the fewer potential leak points they had to consider. Then too, there was probably an accountant somewhere in the picture looking at the three additional 12 cent pressure tap plugs, thinking, that penny and a half really adds up in a years time. Regardless of why many transmissions are conspicuously short on pressure taps, the fact remains; at times, all we have to work with is line pressure. Dont underestimate the value of a line pressure tap though. On older, governor-controlled units a lot of different systems can be tested. For example, check for TV rise in a 4L60, or governor pressure in a 400 or C6. How? Simple, as TV pressure in a 4L60 rises, so does line pressure. If the TV cable is pulled and line pressure rises, the TV pressure is working, though it has to rise to the correct maximum level to really be okay. Keep in mind that if line pressure does not rise during this test, its no guarantee that the problem is TV related. For the governor test in the 400 and C6, once again have the pressure gauge attached to the line pressure tap. Now drive the vehicle with the shifter in Drive. As vehicle speed increases (keep the throttle steady), line pressure drops. On the 400 itll be a steady drop. The C6, however, will have a quick drop in pressure once it reaches about 15 20 mph. In both cases, governor pressure is manipulating line
pressure; its called cutback. On the 400, governor pressure works against the modulator valve, opposing the spring in the modulator. The faster the speed, the more governor pressure works on the modulator valve. The C6 is a bit different. The C6 has an actual valve that controls cutback calledthe cutback valve. Governor pressure works on the cutback valve so that after the vehicle gets moving, line pressure drops to a reduced level. The point is, that in both examples, we knew that governor pressure worked (at least to some degree) because of the influence it has on line pressure. This type of diagnosis is available on a lot of different transmissions, but knowing how the system works is crucial in order to take advantage of it. So whats the point? Over the years, a lot of technicians have used these scenarios to help diagnose problems. They have not always understood why the system behaves in a certain manner, that is, not understood the connection between line rise and pressure changes in other systems. This can lead to misunderstandings like, High line pressure causes late shifts. No, high TV pressure causes late shifts, but it also causes high line pressure. Sure there are anomalies that dont follow this rule, but as a general statement its correct. And besides, Im trying to make a point. If we take these misunderstandings, and apply them to newer, computercontrolled transmissions, we can find ourselves in much more trouble. For example, line pressure on transmissions that use electronic pressure control do not necessarily change line pressure
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based on throttle angle, or even engine load. Some systems, like Mitsubishis 20 and 30 series, maintain a constant high line pressure under all throttle angles except during a shift. Once the transaxle makes a shift, line pressure if fixed; it doesnt matter what is done with the throttle. Other units, some Fords for example, drop line pressure very low (close to idle pressure) once the transmission shifts to second gear or when it reaches a certain vehicle speed. Again, line pressure doesnt change with throttle, but it changes during the shifts. So wheres the connection? There isnt one! One fact that we know is that if enough line pressure is present to keep the friction components applied; any additional pressure is a waste. In fact, excess line pressure makes the engine work harder and uses more gas. In the old days, engineers didnt have the advantage of making line pressure behave anyway they wanted. They used cables and vacuum as the mechanism to influence line pressure. It made no difference whether the transmission was shifting or the shift was complete, line pressure was the same for a given throttle angle, or loadnot withstanding some governor control mentioned earlier. Because engineers now have the luxury (better known as technology) of doing whatever they want with line rise, they often design these systems to have just enough line pressure to keep the applied friction elements from slipping. This means theres no wasted gas turning a pump thats putting out more pressure than necessary. Now lets take our understanding of older systems and apply them to these newer computer-controlled transmissions. For example, a 4L80-E that shifts late, or not at all. The danger here is in thinking that line pressure plays any role in shift timing. Too often we take rules from the past and try to apply them to todays transmissions. Even though we dont see the same connection between line rise and how other systems work, line pressureand proper line riseis crucial for proper transmission function and longevity. Even though a lot of the rules have changed, some rules are still true: Check line pressure with a pressure gauge. The best line rise range will occur while the vehicle is stationary. Do not worry too much about line rise while driving the vehicle. Pressure behavior varies from model
to model. Even the same model car can have different line pressure behavior, based on the software level of the computer. If a line rise problem is suspected check the computer signal to the transmission first. A good service manual for the proper voltage or amperage specifications will be necessary. To effectively identify line rise problems, keep a journal of good working units. Once proper line rise is recognized, its a lot easier to spot incorrect line rise. The same thing goes for line pressure signals from the computer. Dont rule out the pressure control solenoid as the cause of the problem, even if it was replaced with a new one. New solenoids have been known to fail. If a line rise problem is determined to be internal be sure to look for a worn pressure regulator valve or pressure regulator valve bore. Its becoming increasingly common to find worn out valve bodies, causing line rise problems. Sonnax manufactures a large line of replacement regulator valves, as well as other valve body components that commonly wear out. The following is a list of available valves and valve body components, for both computer-controlled and non-computer controlled units.
PART NO.
92835-07 34910-03K 34910-01K 75918-01K 84754-24K & 25K 77917-06 & 07 K77898 77917-01K 77898E-K 34200-03K 96201-01K 76990K 36946-01K & 02K 36424-01K 56947-06K 56947-02K, 04K 73840-RK 71846-01K 74846-01K 93990 89031-01 89010-01 85991-01
APPLICATION DESCRIPTION
41TE 400 400 125-C 4T60&E 4L60&E 4L60 4L60 4L60-E 4L80-E AXOD&E, AX4N AOD C6 E4OD A4LD A4LD CD4E G4A-EL GF4A-EL RL4F02A A540 A130 ZF4HP14/18 Pressure regulator reducing sleeve Pressure regulator valve Boost valve kit TV & Reverse boost valve Reverse and modulator line boost valve kits Oversized pressure regulator valves Reverse boost valve kit TV boost valve Reverse boost valve kit Reverse boost valve kit Reverse boost valve kit Boost valve kit Reverse boost valve kits Reverse boost valve kits O.S. Pressure regulator valve & boost kits Reverse boost valve kits O.S. Pressure regulator valve kit Reverse boost valve kit Reverse boost valve kit Reverse boost sleeve Reverse boost sleeve Reverse boost sleeve O.S. Pressure regulator valve kit
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HONDA
Frequent roller bearing replacement
Part Nos. 88406-SP, B, C
Complaint 2nd gear damage from roller bearing

MAIN SHAFT 2ND GEAR THRUST WASHERS
Main Shaft 2nd Gear
Cause
Axial thrust load of hardened needle rollers on softer gear
Bronze Thrust Washer
Correction
These high quality bronze thrust washers are designed to more effectively withstand the axial thrust load of the mainshaft 2nd gear assembly.
SONNAX PART SUMMARY
Part No. 88406-SP Part No. 88406B Part No. 88406C

Each includes the following:
n Honda 4 speed transmissions, the mainshaft 2nd gear wears severely from contact with the 2nd clutch needle roller bearing. This bearing and gear also need frequent replacement due to wear. Replace the OEM bearing with Sonnax thrust washer 88406-SP, 88406B, or 88406C. These high quality bronze thrust washers are designed to more readily withstand the wear and axial thrust load of the mainshaft 2nd gear assembly.
Sonnax No.
Application AK, AS, F4, L4, CA, PL some G4 G4, K4, L5, PL5X
OD 2.028" 2.185" 2.185"
Thickness .084" .084" .103"
1 Bronze Thrust Washer

Note: The gear thrust surface must be in good condition. A worn gear will cause failure.
88406-SP 88406B 88406C
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A131
A130 & A132(L)
Part No. 89010-01
Complaint Soft upshifts, delayed reverse

Higher than normal pressures in reverse Repeated clutch failure Part No. 89010-01
1 Boost Sleeve
Note: For multiple applications, compare OEM valve dimensions with dimensions below.
.565" .482"
Cause Correction
These problems can be caused by severe wear of the boost sleeve, allowing TV and boost oil leakage The aluminum replacement boost sleeve restores hydraulic integrity and prevents cross leaks.
BOOST SLEEVE
Spring
Boost Valve The exsisting valve must match these dimensions to fit the sleeve
Boost Sleeve
A540-E
Complaint Soft upshifts, delayed reverse
Higher than normal pressures in reverse Repeated clutch failure Part No. 89031-01
1 Boost Sleeve
Note: For multiple applications, compare OEM valve dimensions with dimensions below.
.583" Valve Body .480"
Part No. 89031-01
Cause Correction
A worn boost sleeve may allow TV pressure to leak to reverse in drive ranges; in reverse, reverse boost oil may leak to the TV circuit This replacement boost sleeve will restore the hydraulic integrity and prevent cross leaks.
BOOST SLEEVE
Boost Sleeve
Spring Boost Valve The exsisting valve must match these dimensions to fit the sleeve Retaining Pin Adjustable Step
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F4A-EL
Low pump output Soft shifts
GF4A-EL
Part No. K74878
Complaint 2-3 shift flare

Cause Correction
Insufficient pump flow to pressure regulator valve This pump rebuild kit reduces restrictions & has a specially designed & stiffer spring to avoid bore hang-ups & improve pump volume.
PUMP REBUILD KIT
Part No. K74878

1 Discharge Valve 1 Compression Spring
Note: Fits 1 pan style unit and 2 pan 7 solenoid style units Compression Spring stiffer, oversized spring avoids bore hang-up problems & increases pump output
Pump Body
Plug
Discharge Valve restriction removed from valve to increase pump output
G4A-EL
Severe overheating Converter burn up Spool valve and spring bore hang-up concerns Part No. 71912-01K
1 Spool Valve 1 Spool Valve Spring 1 Pump Vane Expander
Note: Fits 2 pan 4 solenoid style units.
4EAT
Part Nos. 71912-01K & -02
Complaint 2-3 shift flare, low pump volume

Cause Correction
The pump is unable to produce sufficient volume This pump rebuild kit and pump vane expander kit increases oil pump volume by decreasing internal oil leakage.
PUMP REBUILD KIT

Spool Valve non-restrictive Spring designed to avoid hangup and raise exhaust volume/psi of pump
Pump Body
Part No. 71912-02

1 Pump Vane Expander
Pump Vane Expander holds vanes toward slide at low RPM
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GF4A-EL
Shudder in reverse Delayed reverse Poor 1-2 shift
G4A-EL
Part Nos. 71846-01K & 74846-01K
Complaint Low line rise ??

B O O S T VA LV E K I T S
Valve Body
Spring
Spring Retainer
Cause
Worn boost valve sleeves that allow EPC, TV boost or reverse pressures to cross leak into exhaust
End Plug
Boost Valve G4A-EL Boost Sleeve G4A-EL
Correction
These replacement boost valve kits are hardened and anodized to prevent wear and are tightly toleranced to restore the hydraulic integrity of the circuits. Part No. 71846-01K
(G4A-EL with TV Cable) Boost Valve GF4A-EL Boost Sleeve GF4A-EL
Boost Plug
SONNAX PART SUMMARY

ehicles with a G4A-EL or GF4A-EL transmission may have complaints of low line rise or low reverse boost. These problems can be caused by worn boost valve sleeves that allow EPC (GF4A-EL), TV boost (G4A-EL), or reverse pressures to cross leak or leak to exhaust. Sonnax has developed replacement boost valve kits for both the 71846-01K (G4A-EL) and the 74846-01K (GF4A-EL). The G4A-EL boost valves and sleeves are made from carbon steel and hardened to prevent wear. The GF4A-EL boost valve is made from anodized aluminum, and the sleeve is manufactured from Deltalloy 4032 to resist wear. These tightly toleranced parts will restore the hydraulic integrity of the circuits.
1 Boost Valve 1 Boost Sleeve 1 Boost Plug

Part No. 74846-01K

(GF4A-EL No TV Cable/with Elect.)
1 Boost Valve 1 Boost Sleeve

Note: Fits 2 pan 7 solenoid style units and can be modified to fit 1 pan F4AEL or F4EAT units.
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G4A-EL
Complaint Difficulty setting endplay
Part No. 71400-15
5 Shims (.015" thick)
Part No. 71400-15
Cause Correction
Oil Pump
Not enough of the popular 3-tanged selective thrust washer sizes This shim kit contains 5 shims to help set endplay and eliminate the need to carry quantities of all size variations of OEM washers.
FRONT SUPPORT PUMP SHIM

3-Tanged Selective Bearing Race
Roller Bearing
Shim
F4A-EL
Complaint
Burned clutches Slips or no 2-3 shifts Part No. 71828-TL Part No. 74828-TL
Each includes the following: 1 Drum Test Tool 1 Test Tool Cap 1 Test Tool Cap Screw 2 O-Rings
Note: 71828-TL is for G4A-EL applications and 74828-TL is for F4A-EL applications.
G4A-EL
Part Nos. 71828-TL & 74828-TL
Difficult to air check for drum leakage

Cause Correction
The only way to check for leaks is while the drum is in the case This drum test tool allows bench checking for drum leaks without having to disassemble and reassemble the transmission for testing.
3-4 DRUM TEST TOOL KIT

Weld Area Apply Pressure Orifices
Drum Test Tool
Test Here When Assembled 3-4 Drum
O-Rings
Test Tool Cap Screw
Test Tool Cap

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Sonnax Precision Reamers

SONNAX PARTS:
36833-TL 56947-TL 73840-BTL 73840-MTL 73840-RTL 76991-TL 77754-R2 77754-TL 77917-TL 77968-RM 84754-RM 84754-TL 85991-TL 96201-BST T36605-03
FOR USE WITH:

C6 Oversized Modulator Valve kit 36833-01K A4LD Pressure Regulator Valve kit 56947-06K CD4E Bypass CC Valve kit 73840-BK CD4E Valve Body Master Rebuild kit 73840-MK CD4E Pressure & TCC Regulator Valve kit 73840-RK AOD Oversized 1-2 Capacity Modulator Valve kit 76991-01K 4L60E TCC Regulator Valve kits 77754-03K and 77754-04K 4L60-E Actuator Feed Limit Valve kits 77754-09K and 34200-16K 4L60 & 4L60-E Oversized Pressure Regulator Valves 77917-06 and 77917-07 4L60 Oversized Throttle Valve kit 77968 4T60-E TCC Regulator Valve kit, 84754-08K ('91 and '92 models) 4T60-E TCC Apply Valve kit 84754-16K ZF4HP14/18 Oversized Pressure Regulator Valve kit 85991-01 AXOD-E Forward Control Valve 96201-16K C6 Oversize Case Bushing 36008A and 36008C
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Restoring theValve Body: Reamer Technique

BY MAURA STAFFORD
onnax offers various custom reamers and reamer bushings to simplify the repair of worn out valve body, pump, and transmission case bores. Each application may require minor adjustments to reaming speed and feed rate to achieve the proper surface finish and bore size. Some variables that contribute to how a reamer performs and the quality of the reamed hole are: The size of the bore being reamed. The type of material being reamed. The amount of material being removed. The basic instructions and tips below should help with reaming bores successfully. The first step is to adequately prepare the valve body so that it can be worked on properly. After removing the valves from the bore to be reamed, Make sure to use a light oil when clean the valve body reaming, such as Tap Magic or thoroughly with a Kerosene. As a last resort use ATF. mixture of mineral spirits and degreaser. After it has been cleaned, clamp the valve body to the bench with the open circuits up. Next, fill the bore with a cutting fluid such as Kerosene, Tap Magic, etc. Most Sonnax reamers are piloted by the existing valve body bore. However, some designs require a drill jig or reamer bushing to align and guide the reamer in the bore. Before inserting the reamer, soak the fluted end of the reamer with cutting fluid. Next, insert the reamer into the bore until the reamer tip contacts the first bore to be cut. Securely position the reamer in the forward-cutting directionto remove any reamer wobble. The chamfer at the reamer tip will help stabilize and center the reamer. Dont use With the reamer carefully these tools and securely positioned, use a speed for reaming.
Use a speed handle to spin the reamer. Use smooth, steady turns of 1 - 112 rotations per second.
handle to ream the bore in as level a manner as possible. The reaming action should be clockwise in a smooth and continuous motion, at approximately 1 to 112 revolutions per second. The reamer should actually pull itself through the bore, so little or no feed pressure should be applied to the reamer or the speed handle. Continue reaming until the tip of the reamer bottoms out in the bore. Spin the reamer five to ten times more after bore bottoming to allow for the
Continue to lubricate the reamer throughout the process.
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removal of any excess material and for better surface finish. Using low air pressure, blow the chips free before removing the reamer from the bore. To remove the reamer, continue turning while slowly pulling outward on the reamer. Remove any remaining debris from the bore with low air pressure and a mixture of mineral spirits and degreaser. Lubricate the replacement valve with ATF and fit it into the reamed bore. If it is snug, repeat the reaming procedure with an air drill at 500 RPM. Never turn the reamer backwards, as it will ruin the cutting edges. Do not drop or roll a reamer on a metal surface, either. Pushing with too much forward force on the reamer while reaming will result in poor surface finish, inadequate and sporadic material removal, and material being left behind as the reamer exits a bore. Take care to blow the chips free from
Reaming a valve body produces a lot of chips. Make sure you never rotate the reamer counter-clockwise to remove the reamer. Doing so will damage the flutes of the reamer.
PORTRAIT OF A REAMER
The following conditions will increase as your reamer becomes more and more worn: The cutting edges become rounded over and worn looking The cutting edges also appear jagged and not smooth It is harder to ream a hole and requires more force to push the reamer into the work piece The surface finish becomes rough The finished bore size is undersized When these conditions occur, the reamer needs to be sharpened or replaced
Cutting edge
Primary wear zone Sonnax reamers come with one, two, or three cutting diameters depending on the application.
It is important to remember that a reamer is a finishing tool and should be handled carefully. After use, the reamer should be oiled, especially the cutting edges, to prevent rusting. Always store the reamer separately in its plastic tube to prevent the cutting edges from being nicked or burred.
the reamer after each use of it. Inspect the cutting edges of the reamer frequently for burrs, and if there are burrs on the cutting edges remove them with a hone. A burr left on the cutting edge will cause rough surface finishes. It is also important to periodically inspect the reamer for signs of wear. Signs of wear to look for include cutting edges that are worn or rounded, jagged or rough; increased difficulty and more force required to ream a hole; a rough surface finish or undersized finished bore. If the reamer gives a rough surface finish or cuts undersized, the valve may not fit. At this time the reamer would need to be sharpened or replaced.
Remove as many chips as you can, with the reamer still in place.
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KM
SERIES (4 SPEEDS)
Part No. 41750-03
Complaint Delayed engagement, lube failures

No cooler flow in park Pump, pump bushing, and converter hub wear Bushing spin out and/or converter overheating Part No. 41750-03
1 Manual Valve
Cause Correction
Line pressure exhausting and not charging the converter when the selector lever is in park This redesigned manual valve prevents line circuit oil from exhausting to the sump resulting in converter charge pressure in park.
M A N U A L VA LV E
Valve Body
Manual Valve
JATCO
Part No. 93897S
M
RL4F02A & RE4F02A
Part No. 93897S
Complaint Stripped planetary splines, no reverse

Cause
A
Accelerated wear of the internal spline that is stamped from low carbon steel This splined repair insert, welded to the planet, is made of hardened steel for improved wear resistance and weld-ability.
1 Planetary Carrier Insert
CH
INI
QUIRE
Correction
S P L I N E D R E PA I R I N S E R T
Planetary Carrier
Planetary Carrier Insert
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RL4R01A
Costly case replacement Part No. 69835
1 Governor Bore Sleeve
R4A-HL
Part No. 69835
Complaint No upshift, low line rise

Cause Correction
Worn and scored governor bores This replacement sleeve allows rebuilders to reuse cases with worn governor sleeves.
GOVERNOR BORE SLEEVE

Transmission Case Park Gear
Governor Bore Sleeve
RE4R01A
Part No. 69700-01
1 Servo Band Strut
RE4R03A & RL4R01A
Part No. 69700-01
Complaint Loss of 2nd and 4th gear

Cause Correction
The OEM strut splits in half under pressure from the servo piston This strut is made from higher quality material, has a wider crosssection and additional material at the corners to reduce stress.
SERVO BAND STRUT

Band
Servo
Strut
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L4N71B E4N71B & N4A-EL

Complaint ??Poor line rise, delayed reverse
Soft 1-2 related to poor line rise
B O O S T VA LV E K I T
Part No. 66942-01K
Cause
A worn boost valve allows TV or reverse oil leakage, causing poor line pressure rise during an increased load
Valve Body
Correction
This replacement boost valve and sleeve assembly has the same dimensions as the largest OEM boost valve to insure maximum allowable boost pressure. Part No. 66942-01K
1 Boost Sleeve 1 Boost Valve
Boost Valve
Reverse Orifice TV Slot
Boost Sleeve
SONNAX PART SUMMARY

ehicles with a L4N71B transmission commonly have poor line rise, soft shifts, and/or poor reverse boost. These complaints are often caused by the reciprocating boost valve wearing the inside diameter of the boost sleeve. When this occurs, oil that enters the throttle valve slot leaks past the boost valve and exhausts through the reverse orifice, resulting in poor or no line rise. Oil entering the reverse orifice will also leak past the worn sleeve to exhaust, resulting in poor reverse boost. The Sonnax replacement assembly 66942-01K eliminates the above problems with a closely-toleranced boost valve and sleeve. The sleeve is manufactured from Alcoa Deltalloy 4032 aluminum, which is specially designed to resist wear. The boost valve is manufactured from high quality anodized aluminum to prevent excessive wear on the inside diameter of the boost sleeve. These parts are held to extremely tight tolerances, thus restoring the hydraulic integrity of the assembly. This kit has been manufactured to the larger (turbo) spool diameters, insuring maximum allowable boost pressure for all units.
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JATCO
Part Nos. 69903-01K & 93903-01K
2-3 Complaint ?? bind up, high clutch failure

?? SERVO PIN
Overheated band Excess case servo pin bore wear Drop-in 3rd clutch oil pressure Excess oil loss at servo release during WAT
Spring Retainer
Servo Pin Viton O-ring installed
Spring
Servo Piston
Cause
The bore becomes out-ofround due to the band apply force and pin bore wear; this reduces 3rd servo release oil and high clutch apply force
SONNAX PART SUMMARY
Worn Piston
Correction
Servo pin has Viton seal to eliminate servo release oil loss.
n many Jatco units common complaints are 2-3 bind up, high clutch failure and overheated bands caused by a worn servo pin bore. Due to the inherent problems regarding sealing rings, line rise and shift timing, oil control is critical for this unit. Sonnax now offers a servo pin with an o-ring 69903-01K for RE4R01A & RE4R03A units and 93903-01K for RE4F02A & RL4F02A units to compensate for egg-shaped wear in the case bore. An o-ring is placed onto the servo pin, at the location of most bore wear.
RE4R01A AND 03A
RE4F02A AND RL4F02A
Part No. 69903-01K

RE4R01A & RE4R03A
1 Servo Pin 1 Viton O-ring
Part No. 93903-01K

RE4F02A & RL4F02A
No leakage here during WAT
With servo installed, WAT test here.
No leakage, here during WAT test
1 Servo Pin 1 Viton O-ring
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RL4FO2A
Part No. 93990
1 Boost Sleeve
RE4FO2A
Part No. 93990
Complaint Poor shift timing, insufficient line rise

Cause Correction
The regulator boost valve wears the inside diameter of the boost sleeve This replacement pressure regulator boost sleeve has been tightly toleranced to restore hydraulic integrity.
P R E S S U R E R E G U L AT O R B O O S T S L E E V E
Pressure Regulator Boost Valve
Pressure Regulator Boost Sleeve made from aircraft quality aluminum to prevent wear
Valve Body
Washer/Spring Seat
Retainer
ZF4HP-18
Complaint Neutralizes on 3-4 shift
Cause
Part No. 85701-01
2 Servo Cushion Washers
Part No. 85701-01
A broken cushion washer that gets stuck in the overdrive servo bore, not allowing band apply Replace the broken cushion washers with these replacement washers.
Correction
SERVO BELLEVILLE CUSHION WASHER

Servo Cushion Washers
Pin
Servo Piston
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ZF4HP14/18
Complaint Poor line pressure control
Reverse engagement complaints
Valve Body
Part Nos. 85991-01 & -TL
O V E R S I Z E D P R E S S U R E R E G U L A T O R V A LV E & T O O L K I T
Cause
A worn pressure regulator bore due to oscillation of the aluminum valve
Oversized PR Valve Reamer Jig
Reamer
Correction
Eliminate excessive leakage by reaming the valve body bore and installing the oversized replacement pressure regulator valve. Part No. 85991-01
1 Oversized PR Valve
R
O TO L
SONNAX PART SUMMARY
any vehicles with either a ZF4HP14 or ZF4HP18 transmission experience poor line pressure control due to a worn pressure regulator bore. This bore wear can be verified by testing line pressure and/or performing a Wet Air Test on the valve body. The current fix for this complaint is to replace the valve body, which is expensive and hard to find. These problems are often caused by wear from the oscillation of the aluminum valve in the valve body bore. Line/balance, modulated TV, and converter/cooler pressures then leak past the valve and exhaust to the sump or cross-leaks into other circuits.
QUIRE
Part No. 85991-TL

1 Reamer 1 Reamer Jig
Note: Required for installation of 85991-01.
Excessive leakage can be eliminated by installing the oversized Sonnax replacement pressure regulator valve 85991-01. The five spool diameters on this valve are slightly larger than the OEM valve, allowing the valve body bore to be modified to restore the hydraulic integrity of the assembly. The valve body bore can be made large enough to accept this replacement valve by reaming it with the specially designed Sonnax reamer tool kit 85991-TL. This hand reamer has three tightly-toleranced cutting diameters that will slightly enlarge the valve body bore in the area of the pressure regulator valve. The reamer (requires a guide) can be used with a standard speed handle and socket. This is much less expensive than replacing the worn valve body!
E 3-4 Clutch Reducing (2nd Port) Balance Line no leakage Line no leakage Exhaust To Mod TV Converter & Cooler Modulated Pressure
WET AIR TEST INFO

1. Before removing the valve body end plate, place a small amount of oil into the drive balance circuit (plug the opposite side of the valve body circuit). Follow with low air pressure. There should be no oil leakage into the line circuits. 2. With the end plate and springs removed, firmly hold the PR valve fully in the bore. Place a small amount of oil into either of the line orifices. Follow with low air pressure. There should be no oil leakage past the spool diameters or into exhaust circuits.
Plug
Oversized Pressure Regulator Valve
Valve Body
Springs
End Plate
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Super Hold Servos

The Sonnax Super Hold Series of Servos gives transmissions higher holding power, hydraulic integrity and cleaner, more positive shifts. From a street driven muscle car to top fuel dragsters, Sonnax servos cannot be beat.
4L60 & E
4th Gear Super Hold Dual Servo

Part No. 77767K
Our patented dual piston servo offers 40% more holding power in 4th gear giving full clamping force on the band and allowing racers to actually race in overdrive without burning the band. Crisper, cleaner 3-4. Great for Heavy duty applications Blue PTFE Coated, Viton O-Ring
Scarf Cut PTFE Seal
Scarf Cut PTFE Seal Viton O-Ring
Replacement Seal Kit Part No. 77767K-SK

4 assorted seals
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onnax is proud to offer High Performance and Drag Racing transmission rebuilders a full array of parts for Powerglide and many other High Performance transmissions. We have products ranging from hard-to-find OEM replacement parts to parts that will make your customers drag, street or strip vehicle lighter, faster and stronger. Many of our High Performance items have been developed with input from customers actively involved in racing. Consistency is the most important factor that all racers need, and Sonnax offers you consistency in all your rebuilds with guaranteed high quality in all the parts we make.
POWERGLIDE
No Leak Dual O-ring Servo Piston

Part No. 28821-01K
No leak Dual O-ring servo uses dual o-ring seals for superior, positive sealing. In applications with a distorted bore or case flex, O-rings will conform to the bore surfaces, a feature not possible with metal sealing rings. Precise slip fit with apply pin to further improve performance.
Replacement Seal Part No. 28821-OR

1 O-ring (2 required)
POWERGLIDE
Dual Teflon Ring Servo Piston

Part No. 28821-02K
Whether Teflon Seals, or Metal rings are your preference, we have the servo for you. This dual seal servo accepts both Teflon Seals or metal sealing rings. Made with the same high quality billet aluminum as our Oring servo, this servo will give you the same positive apply needed in high pressure racing conditions.
Replacement Seal Part No. 18608T

1 Teflon Seal (2 required)
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F O R D
C4 - C RATIO
P E R F O R M A N C E
C6 R-RATIO
S E R V O S
Shelby Mustang Servo Piston Part No. K13259C

As used with Shelby Mustang and other performance vehicles, this servo offers maximum holding power, giving cleaner, firmer 1-2 and 2-3 shifts. This is the largest in the servo family and works equally well in Performance C5 applications too. Cleaning up a 2-3 flare was never easier than installing this servo.
Servo Piston Kit Part No. K36528R

Since its introduction in 1969 with the 428 SCJ, the R code servo has remained the trick piece for C6 builders needing additional band apply force. Ford last offered an OEM replacement in 1992. Sonnax is reintroducing this servo kit with our unique no-leakservo pin. This pin uses an o-ring and a Teflon seal to eliminate back pressure and leakage due to worn case bores. Over 9 square inches of apply surface results in more band apply force. Three selective return springs allow for tuning of the shift quality
Replacement seal kit Part No. K13259C-SK

Gasket and seals
C6 - E RATIO
Servo Apply lever Part No. 36916E

Previously obsolete, this servo lever is made from 2014-T6 aluminum forging that will not distort or crack like the cast OEM lever. Perfect for firmer cleaner shifts when used with the Sonnax R code servo K36528R. Replaces OEM P/N C6AZ-7330-D.
Replacement seal kit Part No. K36528R-SK

Gasket and seals
E4OD & 4R100
Line Pressure Modulator Valve and Sleeve Kit Part No. 96948-01K
Ford Super Duty or Lightning trucks dont always have the 1-2, 2-3 shift firmness your looking for in a performance or heavy duty truck. This is easily addressed by Sonnaxs performance Line Pressure Modulator Sleeve and Valve kit. For use with any Heavy Duty or Performance E4OD and 4R100 transmissions, our valve kit increases shift firmness by using a larger .427 diameter valve increasing accumulator pressure resulting in a firmer shift.
AOD&E
Elevated Pressure Regulator Spring Part No. 76948-06

Low line pressure on high performance or heavy duty applications of Ford AOD-E and 4R70W transmissions result in forward clutch failure. A stronger pressure regulator spring is required to bring the line pressure up to 68 psi. Our elevated pressure regulator spring will insure the proper clutch engagment. A must for squad and muscle cars and any vehicles requiring frequent and hard acceleration.
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G E N E R A L
4L60
M O T O R S
Full Throttle Upshift Sleeve and Valve Kit Part No. 77966-94MK
The Sonnax Throttle Plunger Sleeve and Valve kit allows performance vehicles wideopen-throttle (WOT) 3-4 upshifts. Unlike other kits on the market, ours includes the Plunger Valve with annular grooves to prevent premature wear. The sleeve is made from aircraft quality aluminum and has the part-throttle orifice removed. The sleeve and plunger also improve detent downshifts.
TV Boost Valve Kit Part No. 77917-500

Commonly the OEM TV Boost sleeve is worn and either you will have insufficient line rise and/or experience burned 3-4 clutches or burned band. Our o-ringed sleeve and valve are made from hardened steel, restore hyrdaulic integrity and prevent cross-leaks between the sleeve and pump bore. No 4L60 rebuild should be without this kit.
Pressure Regulator Spring Shim Part No. 77917-RV

This spring shim easily installs under the pump slide springs to preload the springs increasing pump output and stabilizing pressure. This will not compensate for areas of pump leakage. Kit includes 10 spring shims
4L60
4L60 & E
4L60 & E, 200-4R
Performance Throttle Valve Spring Part No. 77968-01K

The OEM throttle valve (TV) spring is a bit weak resluting in low line pressures and insufficient throttle pressure for high performance applications. Our stronger TV spring helps to maintain higher line pressure and improved TV performance. This spring may be used with the OEM valve configuration or the Sonnax Upshift Sleeve and Plunger kit 77996-94MK.
Enhanced Performance 1-2 Accumulator Spring Part No. 77704S

Typically the OEM 1-2 accumulator spring is too weak for high performance rebuilds. Our enhanced performance spring provides a firmer 1-2 shift and may even cure the thunk sound during the shift. This spring achieves the same effect as the common shop practice of using a 350 direct accumulator spring, in which our spring may also be used.
High Output Pump Slide Spring Part No. 77722-01K

When engine speed exceeds 5800 RPM, the centrifugal force on the pump vanes acts to center the pump slide and reduce the pump volume. In high performance applications, it is critical to maintain maximum pump volume in order to hold line pressure and avoid 3-4 clutch failure. Our high output single spring is stiffer than the dual OEM springs and is able to hold the pump slide in a maximum volume position despite the high engine RPM.
MOST GM UNITS - AUTOMATICS & STANDARDS
Speedo Plug Part No. 35922-01K

During high performance rebuilds, the speedometer is often removed, and replaced by a freeze plug. However, the speedometer gear, besides being used for driving the speedometer, is also critical to lubricating the rear output shaft bushing. This new speedo plug supports the speedo gear and allows lube to flow as the original design intended. The gear shaft has to be cut to 1.320 long.
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P E R F O R M A N C E
OUTPUT SHAFT SUPPORT
P A R T S
STATOR SUPPORT SHAFT
Part No. 28080K

Application: Powerglide
Part No. 28154S

Associated Parts
Bored to accept bushing 35007 for Turbo applications.

High strength Powerglide Output Shaft Support, made from 6061-T6 billet aluminum, with pre-installed roller bearing in place of the bushing. This part is purpose built for drag racing, eliminating the provisions for the governor. This true "bolt-on" modification for the Powerglide lowers weight dramatically, and keeps friction losses to a minimum.
BAND ADJUSTMENT SCREW
High quality heat treated alloy steel, provides added strength to give solid support to the torque converter stator. Roller burnish finish in the seal bore increases sealing for improved pressure. Spline and knurl areas induction hardened for wear resistance, and more pronounced knurl ensures more positive press fit. Specially designed for severe duty race applications.
NO FLEX REVERSE SPRING RETAINER
Part No. 28612K

Part No. 28709

Associated Parts 28320A reverse spring Application: Powerglide
Prevents deflection and bending that causes band slippage and transmission case breakage. Made of hardened and tempered alloy steel and yellow zinc plated for protection against corrosion. Features extra thread length to accommodate undersized clutch drums.
FORWARD CLUTCH HUB
Resists deflection caused by stiffer-than-OEM springs in transbrakeequipped Powerglides. Stamped from high strength, roll tempered steel. Resists deflection better than used OEM retainers made of mild steel.
FORWARD CLUTCH HUB W/O HOLES
Part No. 28304

Part No. 28304-SP

Designed for extra duty requirements of drag racing Powerglides. Machined from high quality medium carbon steel forging. Accepts five friction discs for added load capacity. All splines and thrust surfaces precision machined. Unique lube hole pattern designed to reduce drag on friction discs in low gear. Hub also features five lightening holes to reduce weight without compromising strength.
SHIFT LEVER
An extra strong alternative for 28304. Built to give extra strength in drag racing Powerglides where weight is not a consideration. Machined from high quality medium carbon steel forging. Accepts five friction discs for added load capacity. All splines and thrust surfaces are precision machined. Unique lube hole pattern designed to reduce the drag on the friction discs in low gear.
MODULATOR PLUG KIT
Part No. 28431

Part No. 28738-01K

Our shift lever is designed to work with competition type shifters and requires no modification to the case. It can be installed so that the lever is positioned up or down. Plated with Zinc Chromate for corrosion protection.
BORG WARNER RACE ONLY BAND
When building a racing Powerglide, it is necessary to plug the hole left by the vacuum modulator. Our vacuum modulator Plug kit is made from anodized aluminum and includes the necessary gasket.
28314K KEVLAR LINED BAND
Part No. 28314

Part No. 28314K

Borg Warner Powerglide Race Only Band is a no-holds-barred approach to the design of a race-only band. Features the latest in friction materials, and all new construction. This "Race Only" Band is not intended for highway use. Band application upon transmission down-shift with vehicle in motion is not recommended and can result in band failure.
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Our Borg Warner Kevlar lined band is specially engineered for muscle, street and strip applications. Similar to our 28314 Race Only band, this is all new construction and features the latest development in Kevlar materials.
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D I R E C T
PRECISION CASE BUSHING
R E P L A C E M E N T S
"FIP" CLUTCH DRUM BUSHING DIR. CLUTCH RETURN SPRING
Application:
Part No. 28002 Made to correctly locate the carrieroutput shaft assembly. Direct OEM replacement.
Application:
Powerglide
Powerglide
Part No. 28005X Save worn Powerglide pump covers with Finish In Place Clutch Drum Bushing. Use of this bushing allows rebuilders to refinish journal diameter up to .012" undersize.
Application:
Powerglide
Part No. 28320 Made from high tensile spring wire, cadmium plated. Spring ends are closewound and match ground to uniform length. Reliable replacement of OEM direct clutch return springs. 24 per kit.
DIR. CLUTCH DRUM THRUST WASHER
REAR SUN GEAR THRUST WASHER
CARRIER THRUST BEARING
Application:
Powerglide
Part No. 28406C Made of lead-bronze on steel backing, lead-tin plated. Designed with four oil grooves for increased surface lubrication. .078" thick, can be shimmed for precise clearance. Designed for racing applications.
Application:
Powerglide
Part No. 38208 Made from self-lubricating sintered bronze material. Direct replacement of hard-to-find OEM thrust washer.
Application:
Part No. 28438 Direct OEM replacement for the hardto-find carrier-tocase Powerglide thrust bearing.
Powerglide
REV. CLUTCH RETURN SPRING
SUN GEAR THRUST BEARING
STATOR SHAFT BUSHING
Application:
Powerglide
Part No. 28320A High tensile springs, with ends closewound and match ground for uniformity. Specifically made for transbrake equipped Powerglides. 17 per kit.
Application:
Powerglide
Part No. 28321 Allows replacement of obsolete part. Hardened bearing assembly comes complete with a premium quality Torrington bearing.
Application:
350/400
Part No. 35007 Bronze lined, bimetal bushing with 1.0" I.D. Directly replaces Turbo 350/400 and 700R4 OEM stator bushings. Designed for Sonnax Powerglide Stator Support Shaft 28154S with "Turbo" style input shafts.
SUN GEAR BUSHING
1.76 PINION PIN KIT
Application:
Powerglide
Part No. 8436 Direct OEM replacement for wedding band bushing. Restores alignment between front sun gear and input shaft.
Application:
Powerglide
Part No. 28435K High strength bearing grade pinion pin with unique key pin locking device for hassle free installation. 28435K contains 6 each: pinion pins, hardened thrust washers and steel retaining bolts.
ALTO RED EAGLE CLUTCH PLATES/STEELS
Sonnax is an authorized distributor of Alto Red Eagle clutch rings. Available for all applications.
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PARTS FOR REBUILDING POWERGLIDE PLANETARY GEARS

8413
Pinion 28435K
Needle Rollers 1.82 Needle Rollers 1.76 Pinion Thrust Washer 1.76 Front Pinion Thrust Washer 1.82 Pinion Thrust Washer 1.76 Rear
1.76:1 Pinion Assembly
28413 8415 8415A
Needle Rollers 28413 Front Thrust Washer 8415 Rear Thrust Washer 8415B
8415B
K 2 8 4 1 4 Pinion Roller Spacer Kit 1.76 8 4 1 5 A K Pinion Thrust Washer Kit 1.82 8 4 1 5 B K Pinion Thrust Washer Kit 1.76 2 8 4 3 5 K Washer, Bolt & Pinion Pin Kit 1.76
Roller Spacers K28414
Washer & Bolt 28435K
TV Cable Correctors
EDLEBROCK (GM APPLICATIONS WITH TV CABLE)
TV Cable Corrector Part No. AS3-03K

The position of the TV cable stud hole used on the Edelbrock carburetors offers far too much pull on the TV cable through the full range of throttle positions. If you adjust the TV cable at full throttle, line rise is too low, and the shift points are too early. If you adjust the TV cable for normal-throttle upshift timing the TV cable bottoms out before you reach full throttle which results in the TV cable falling out of adjustment after a few kickdowns. The end result is poor shift quality, timing and repeat clutch and band failure. Our TV cable corrector provides the proper TV geometry, resulting in correct TV rise at all throttle openings.
HOLLEY CARBURETORS (WITH GM AND FORD AOD TRANSMISSIONS)
Holley Carburetor TV Cable Corrector Part No. AS2-02K

With many GM transmissions with cables and most Ford AOD transmissions, it is common for the TV cable detent to be pulled out of adjustment at wide-open throttle (WOT). This is caused by the inaccurate geometry of the carburetor linkage plate. Our cable corrects adjusts the geometry of the TV linkage and allows WOT with pulling the TV out of adjustment.
MOST GM & FORD AOD TRANSMISSIONS
TV Cable Corrector Part No. AS1-01K

This simple TV Cable corrector allows true wide open throttle (WOT) without pulling the TV cable out of adjustment. Very similar to our Holley Carburetor TV Cable corrector, but for use on stock carburetors. A quick and inexpensive fix for any transmission with a TV cable.
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e have recognized the need for replacement clips, retainers, pins and others doo-dads that are commonly broken or lost. No longer will you have to dig through a pile of cores, attempt to rob a valve body or crawl under the bench to get that invisible part. We are now offering a variety of these helpful items so they will be conveniently within arms reach with our new Small Parts Program start up kit SSPP-01. The kit includes a variety of small parts for GM, Ford, Chysler and some foreign applications. Each part is also available separately and we are adding parts weekly. To keep up on the newest ones, watch out ads, visit our web site www.sonnax.com or ask your distributor for the latest Small Parts Program items.
PART NUMBER
DESCRIPTION
TRANS. APPLICATION
GM GM GM GM GM GM GM GM GM GM GM GM GM GM GM * 400 4L80-E 4L80-E 4L80-E 4L80-E 4L80-E 4L80-E 4L80-E 4L80-E 4L60 & 4L60-E 4T60 & 4T60-E 4T60 & 4T60-E 4T60 & 4T60-E 4T60 & 4T60-E 4L80-E
included in SSPP-01 Small Parts Kit
34910-06K* End Plug, O-Ringed, PR Valve Bag/5 34994-07 34994-09 34994-10* 34994-11 34994-12* 34994-13 34994-14K 34994-15* 77754-08* 84754-26* 84754-27* 84754-28 84754-29 Spring Pin, Coiled, Valve Body Bag/10 Spring Pin, Small, Pump, Bag/10 Snap Ring, .625" TCC Valve, Bag/10 TCC Valve Bore Plug, Bag/5 Retaining Pin, Lo/Rev Checkball, Bag/10 End Plug, Small, TCC Valve, Bag/5 End Plug, .684"Dia., TCC Valve, Bag/5 Snap Ring, TCC Valve, Bag/10 Clip, 3-2 Control Solenoid & Misc. Locations, Bag/10 Hair Pin Clip, 4-3 Manual TV Valve, Bag/10 E Ring, Rev. Boost Valve, Bag/10 Retainer, Boost Sleeve, Bag/10 Spring Pin, Coiled, Fwd/Rev Servo, Bag/10
34200-05K* End Plug, TCC & PR Valves, Bag/5
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(continued)
PART NUMBER
DESCRIPTION
TRANS.
APPLICATION
C6 A4LD A4LD A4LD AOD & AOD-E AOD & AOD-E ATX ATX AXOD & AXOD-E AXOD & AXOD-E AXOD & AXOD-E AXOD & AXOD-E 46RE, 31TH 41TE AW4/A340 AW4/A340 AW4/A340 AW4/A340 AW4/A340 AW4/A340
36946-05KSPP*Springs, Inner & Outer, 1-2 Accum., Bag/5 of each Ford 56947-11* 56947-12* 56947-13* Retaining Pin,Valve Body, Bag/10 Retainer Disc For Valve Body, Bag/10 Retainer, Rectangular, Valve Body, Bag/10 Ford Ford Ford Ford Ford Ford Ford Ford Ford Ford Ford Chrysler Chrysler X X X X X X .236", .198", .198", .193", .203", .195", Bag/10 Bag/10 Bag/10 Bag/10 Bag/10 Bag/10 Chrys/Toyota Chrys/Toyota Chrys/Toyota Chrys/Toyota Chrys/Toyota Chrys/Toyota
76811-01KSPP*Retainer Rings, Direct Drum/Shaft, Bag/5 76948-08* 86940-02* Spring, 1-2 Accumulator, Bag/10 Spring, Throttle Control Valve, Bag/5
86940-04SPP* Spring, 1-2 Accumulator Valve, Bag/5 96201-09* 96201-10 96201-11 Retainer, 3-2 Timing Valve, Bag/10 Clip, 1-2 Capacity Modulator Valve, Bag/10 Clip, Backout Valve, Bag/10
96945RSPP* Clip, 1-2 Servo Spring Retainer, Bag/5 Pairs 10000-03K* 92836-02* 97855-01* 97855-02* 97855-03 97855-04 97855-05 97855-06 E-Ring, Shift Linkage, Bag/10 Solenoid Diaphragm, Bag/9 Retainer, Retainer, Retainer, Retainer, Retainer, Retainer, Rectangular, Rectangular, Rectangular, Rectangular, Rectangular. Rectangular, .654" .592" .572" .832" .645" .551"
97855-07 97855-08 10000-08 10000-09 10000-10 10000-11 10000-12

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Pin, Downshift Plug, Bag/10 Stop, Throttle Valve, Bag/10 Check Check Check Check Check Ball, Ball, Ball, Ball, Ball, .250", .344", .312", .375", .218", Torlon, Torlon, Torlon, Torlon, Torlon, Bag/10 Bag/10 Bag/10 Bag/10 Bag/10
Chrys/Toyota AW4/A340 Chrys/Toyota AW4/A340 Misc. Misc. Misc. Misc. Misc.

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(continued)
PART NUMBER
DESCRIPTION
BRAND
Misc. Misc.
APPLICATION
AOD, AXOD & GM
AS1-01KSPP* Cable Corrector Kits, Stops & Springs, Bag/5 Kits O-LUBE* Slippery Stick, O-Ring Lubricant
Part No. Part No.
SWAT-P1
SSPP-01
Wet Air Test Plate
Sonnax Small Parts Start-up Kit
Part No.
OR-MK
Sonnax O-Ring Master Kit
This convenient Sonnax kit, with 15 Viton o-rings and 4 seals in bags of 25 each, will aid rebuilders when servicing valves or replacing o-rings damaged during installation. The kit includes o-rings for all currently available Sonnax sleeves and additional space for future orings that will be offered.
APPLICATION
34200-03K 34910-01K 34910-03K 34910-03K 34994-01K 36424-01K 36946-01K 36946-02K 36948-03K 36948-05K 56947-02K 56947-04K 73840-24
O-RING KIT
OR-014-25 OR-36946-25 34910-S-25 OR-76989-25 34994-S-25 OR-36424-25 OR-77898E-25 OR-77898E-25 OR-017-25 OR-017-25 OR17.5X1-25 OR17.5X1-25 OR-214-25
APPLICATION
73840-FWD 73840-LR 76833 76833E 76989K 76990K 76999-LRG 76999-SML 76999-MED 77767K 77805E-K 77805-K 77898E-4K
O-RING KIT
OR-214-25 OR-214-25 OR-012-25 OR-012-25 OR-014-25 OR14X1MM-25 OR-017-25 OR12X1MM-25 OR12X1MM-25 OR-214-25 77805-S-25 77805-S-25 OR-77898E-25
APPLICATION
77898E-K 77917-01K 77917-471 77917-500 92834-03K 92834-03K 96201-01K 96945S 96948-01K
O-RING KIT
OR-77898E-25 OR-16-15-25 OR-16-15-25 OR-16-15-25 92834-S-25 OR-92834-25 OR-017-25 OR-013-25 OR-017-25
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Sonnax Shims
SONNAX PARTS:
75410-10 84733-10 & -20 75890-30 77406-10 77409-15 34500-Z 36428-Z 36428-AZ 36414-01K 36402-Z 86539-Z5 73251-01K 12780-Z 22700-Z 32539-Z5 35539-Z5 39539-Z5 92965-Z5 71400-15
APPLICATION:
4T60 & 4T60-E 4T60 & 4T60-E 4T60 & 4T60-E 4L60, 4L60-E & 350/C 4L60 & 4L60-E 400 & 4L80-E C6 C6 C6 E4OD ATX CD4E A904 & 42RH A727 & 46RH
USE FOR:
Differential endplay Input clutch hub endplay Differential side gear Rear unit endplay Front unit endplay Front & rear unit endplay Total unit endplay (6-slot type) Total unit endplay (4-slot type) Salvage of worn sunshell Total unit endplay Preload for idler gear Total unit endplay Total unit endplay Total unit endplay
A404, A413, A470 & A670 Preload and endplay A404, A413, A470 & A670 Output shaft endplay A404, A413, A470 & A670 Differential Preload 41TE G4A-EL Transfer/output shaft gear endplay Total unit endplay
Sonnax has developed these shims to aid technicians in maintaining proper pre-load or unit endplay for many transmissions. Many times, OEM washer/shim kits are only partially used leaving piles of un-usable and unwanted shims. Or sometimes simple drivetrain wear will prevent OEM kits from properly setting endplay. The Sonnax shim kits help rebuilders make use of un-usable shims and allow accurate setting of endplay.
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Sonnax offers a full line of high quality ISO 9002 ring gears for use on flexplates, flywheels and converters. We can handle your needs from a single gear to full containers. GM Ford Chrysler Toyota Honda Mazda Mitsubishi VW Caterpillar Cummins Perkins Mercedes Borg Warner International John Deere Massey Ferguson Case
Sonnax offers manual clutch components for agricultural, industrial, and high-performance applications. All of our manual clutch hubs are made from Chrome-Moly steel forgings, which greatly improves fatigue resistance and service life. Components available include hubs, pins, springs, levers, and bushings. International Harvester John Deere Allis Chalmers Ford New Holland Massey Ferguson Kubota White Oliver Gleaner Case
Also available are high performance clutch hubs for Chrysler, Ford, G.M., Mitsubishi, Toyota, Honda, Volvo, Acura, and Nissan applications.
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Allison Replacement Products

SONNAX PART NUMBER GOVERNORS & GEARS
425 426 460 461 462 463 465 734 738 739 740 717180
8624939 6883938 643742 6881466 6885570 6885571 6885572 6881471 6882734 6882737 6882736 VH-VS AT AT, MT, HT AT, MT, HT V700 MT, HT, CLT CLBT MT MT MT MT For 738, 739 Gov VH-VS Glass filled nylon Governor Gear Kit (2 Nails, Roll Pin, Bagged) Fits Governors #460-5 Phenolic Governor Insert Governor Governor Governor Governor Governor Brass Gear Sleeve Assy (Sleeve, Gear, Stampings, 2 Nails) Governor, Brass Gear Governor, Brass Gear Brass Gear, Roll Pin in Box Governor, Partial Assembly
ALLISON PART NUMBER
SERIES
DESCRIPTION/APPLICATION
SUN & PINION GEARS

S6835936 S6884902 S6883901 S6835937 S23014304 S23014527 S23014306
6835936 6884902 6883901 AT AT MT Center Sun Gear Rear Sun Gear Rear Sun Gear
SHAFTS & GROUND SLEEVES

6835937 23014304 23014527 23014306 AT AT MT MT Center Sun Shaft Ground Sleeve (w/ Bushing & Bearing) Ground Sleeve (w/ Bearing) Ground Sleeve (w/ Bearing)
DRIVE HUBS
S6834221 S6834222 S23017267
6834221 6834222 23017267 MT MT MT Fourth Clutch Driving Hub Forward Clutch Hub Fourth Clutch Driving Hub
TURBINE SHAFT
S23019222 S29501160 SP6883044 SP6438326 SP23019201 SP23019201-2 S23045906 S29501358 S9436642
23019222 MT, 644, 654 Turbine Shaft
GASKETS, OIL PANS, FILTER KITS & PAN PLUG

29501160 6883044 6438326 23019201 23019201 23045906 29501358 9436642 AT, MT AT, MT AT AT, MT AT, MT AT, MT Pan Gasket (Armstrong TS-9003) 1 Piece Oil Filter, Deep Pan (Made/Sealed Power) Oil Filter, Shallow Pan (Made/Sealed Power) Deep Pan Filter Kit (w/ 1 Piece Gasket) (Contains Sealed Power Filter, O-Rg, Gskt) Deep Pan Filter Kit (w/ 2 Piece Gasket) Deep Oil Pan, Ribbed with Heater Hole Deep Oil Pan, Dual Fill Tube Locations Plug for Deep Pan Heater Hole
STEEL PLATES
56711 56711A 56713 56715 56715A MI-F-3060K* MI-F-HDB500K*
23047771 23047772 6834679 6834488 6834720 HT700 HT700 HT700 HT700 HT700 Steel, Steel, Steel, Steel, Steel, First Clutch, 38 Tooth, .103 Thick First Clutch, 38 Tooth, .120 Thick Forward Clutch, 14 Tooth 2nd Clutch, 16 Tooth, .103 Thick 2nd Clutch, 16 Tooth, .120 Thick
LOCK-UP CLUTCH LINING

3060 World Series 3060 World Series Friction Ring-Kevlar Friction Ring-Kevlar
* Sonnax offers a relining service for these lock-up converter clutches.
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Torrington Bearing Kits from Sonnax

SONNAX TORRINGTON TRANSMISSION KIT KIT QTY. DESCRIPTION SONNAX TORRINGTON TRANSMISSION KIT KIT QTY. DESCRIPTION
SBK-F1 TBK-F1
FORD AOD 1ST DESIGN 1980-1992 EARLY
1 1 1 1 2 1
REV CL/FORWARD CLUTCH DIRECT CL/OUTPUT RING CARRIER RING/CASE OUTPUT/RING CASE FWD CL/LONG SUN & LONG/SHORT RUN INT CL/REV CL REVERSE CL/FORWARD CL DIRECTCL/OUTPUT RING CARRIER/DIRECT CLUTCH OUTRING/CASE in '92 only OUTPUT RING/CAS not used in '92 FWD CLUTCH/LONG SUN; LONG/SHORT SUN INT CLUTCH/REVERSE CL INT CLUTCH/PUMP DIRECT CLUTCH/INT CL OUTPUT GEAR/STATOR SUPP OUTPUT GEAR/TRANS HOUSING CARRIER/RING GEAR REAR SUN/FINAL DRIVE RING CLUTCH HSG/CL HUB; CL HUB/INPUT SUN GOVERNER ASSY SUPPORT FINAL DRIVE CARRIER/CASE FINAL DRIVE SUN/CARRIER FINAL DRIVE RING/PARK GEAR FRONT SUPPORT/CLUTCH HSG FRONT CARRIE/RR CARRIER CL HUB/INPUT CARRIER;INPUTCARRIER&SUN FRONT SUPPORT/OD SUN OD CARRIER/OD RING CTR SUPPORT/CL HUB OD RING/CTR SUPPORT; RR RING & RR SUPP. FWD CLUTCH/LONG SUN CARRIER/DIRECT CLUTCH INT CLUTCH/REVERSE CL. DIRECT CL/OUTPUT RING OUTPUT RING/CASE REVERSE CL/FORWARD CL LONG/SHORT SUN CL HUB/INPUT CARRIER INPUT CARRIER/IN SUN RR RING/RR SUPPORT REV CARRIER/LO ROLLER COL FRONT INT/FRONT SUN REAR SUN/REAR INT OVERDRIVE SET FRONT CARRIE/FRONT SUN INT CL/OIL PUMP-use as a sub for FB-42313 (9428664) from '69-'83 OUTPUT RING/REAC CAR '84-'85 OUTPUT SHAFT/CASE BUICK FR RING/OUTPUT CARRIER SUN/INTERNAL GEAR SUN/INTERNAL GEAR SUN/INTERNAL GEAR INT GEAR/OUTPUT SHAFT CTR SUPPORT/SUN, RACE/RACE CENTER SUPPORT/SUN GEAR CENTER SUPPORT/SUN GEAR
SBK-G11 TBK-G11
GM 440-T4 (4T60) 4T60-E PARTIAL 1984-UP
SBK-F2 TBK-F2
FORD AOD-E 2ND DESIGN 1992-UP
1 1 1 1 1 2 1
1 1 1 1 1 1 1 1 1 1 1 1 2 1
FD CARRIER/CASE REAC SUN/FD INT CHANNEL PLATE/4TH HUB FD INT/PARK GEAR GOVERNOR FD SUN/CARRIER IN CARRIER/REAC CARRIER SPROCKET SUPPORT/IN SHAFT REAC CARRIER/RAC SUN INPUT SHAFT TO 3RD CLUTCH STARTOR SHAFT/FR CLUTCH FRONT CL/IN SUN Output carrier/ring; Output shaft/case REAC CARRIER/SUPPORT DRIVEN SPKT/CASE SUN GEAR/REACT INPUT & SINL DRV FINAL DR SUN INTERNAL DIFF CARR/CASE SPEED0/GOVERNOR GEAR FINAL DRIVE SUN/DIFF CARR REV CARRIER/LO ROLLER CL FRONT INT/FRONT SUN REAR SUN/REAR INT FRONT CARRIE/FRONT SUN #1 IN A606/ #1 & 7 IN A604 #2 Replaces: 4431962 & in A604 #7 use as sub for 4412209 #6 #7 in A606 only OD PISTON/HUB BRG CAM/OUTPUT BRG BACKING PLATE/PLANET BRG
SBK-G12 TBK-G12
GM 700-R4 (4L60-E) 1982-UP
SBK-F3 TBK-F3
FORD ATX w/o Shims 1981-1994 FORD AXOD & AXOD-E (AX4S) 1986-up
1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 2 2 1
SBK-G13 TBK-G13
GM GM 3T40 (125) 1965-UP
1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1
SBK-F4 TBK-F4
SBK-G15 TBK-G15
GM 200/200C/235 1981-1989 CHRYSLER 41TE & 42LE 1988-UP
SBK-C14 TBK-C14
SBK-F5 TBK-F5
FORD E40D 1989-UP
SBK-C16 TBK-C16
CHRYSLER 42RH/46RH 1988-UP
SBK-F6 TBK-F6
FORD 4R70W 1993-PRESENT
SBK-F7 TBK-F7
FORD C6 1966-1994 GM 200-4R 1976-1985
SBK-G8 TBK-G8
SBK-G9 TBK-G9
GM 350 1969-1985
SBK-G10 TBK-G10
GM 400/3L80 (4L80 Partial) 1965-1995
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145
transmission replacement parts SHOWCASE

SONNAX NO. INDUSTRY NO. DESCRIPTION APPLICATION
GOVERNORS & SPEEDO PARTS
200 203 203B 204 207 213D 213G 350 352 400 402 425 702 729 730 731 3187 3188 3189 3190 3191 3192 3193 4067 418A 419A 57415X
65410 65440
GOVERNOR, 76-79, 1 SPRING GOVERNOR COVER KIT WITH O RINGS GOVERNOR COVER- COVER ONLY GOVERNOR GEAR KIT 79-87 13 TOOTH (GAS & DIESEL)
200 200 200 200 200 200 200 350 350 400 400 425, ALLISON AT & MT SERIES 4L60 4L60 4L60 4L60 SUBARU SUBARU NISSAN VW AUDI AUDI AUDI ATX ATX ATX ATX - 2 Lug Split
K65411 65410B 32410A 35410 K35411 34410 K34411 K34411A K77411 77410D 77410A 77410 66411P 66411M 83411 79980 K79411 79988C K79983 86444 57225A 86413 57415X
GOVERNOR GEAR KIT, 76-79, 14 TOOTH GOVERNOR, 79-87, 13 TOOTH, 1 SPRING, DIESEL GOVERNOR, 79-87,13 TOOTH,, 2 SPRINGS, GAS GOVERNOR GOVERNOR GEAR KIT -350 GOVERNOR, 2ND DESIGN GOVERNOR GEAR KIT -400 GOVERNOR GEAR KIT (NAILS & ROLL PIN) GOVERNOR GEAR KIT GOVERNOR, DIESEL GOVERNOR, GAS, CORVETTE & OTHERS GOVERNOR, 250,305 & 350 GAS ENGINES GOVERNOR GEAR, 75-80, 11 TOOTH, GLASS GOVERNOR GEAR, 80-84 12 TOOTH, STEEL GOVERNOR GEAR, 19 TOOTH, GLASS FILLED NYLON GOVERNOR GEAR, 18 T.FITS 010-325-041 &041A GOV. GOV. GEAR, 13T. GLASS FITS 089-325-041 &041B GOV GOV. GEAR,HOLLOW VERSION 16T. GLASS FITS 087-325-041 GOV GOV. GEAR, SHANK VERSION, 16T.GLASS, FITS 087-325-305B GOV SHIM, R:E3FZ-4067-A USE WITH 418A SPEEDO/GOVERNORDRIVE GEAR GOVERNOR GEAR KIT SPEEDO/GOVERNORDRIVE GEAR, 2 LUG, SPLIT
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SHAFTS
68917 68918 68919 75876 75877 82810 84874 96855 65917S
68917 68918 68919 75876 75875 84874 96855 65917S
SHAFT, STATOR SUPPORT W4B025, SNAP RING, 4" SHAFT, STATOR SUPPORT, W4B025 PRESS IN SHAFT, STATOR SUPPORT, W3A040, SNAP RING, 4.6" PUMP DRIVE SHAFT,LATE, 15TOOTH, 82 & UP, LOCKUP PUMP SHAFT, 15T,(REPLACES 80-81, 20T) NON LOCKUP STATOR SHAFT SHAFT,OIL PUMP DRIVE SHAFT, PUMP DRIVE, SHAFT,STATOR SUPPORT
MERCEDES MERCEDES MERCEDES 125 125 ZF 4HP22 4T60 AXOD 200-R4
FASTENERS & HARDWARE
B41 B42 B61 B62 B63 B78 B79 N61 TO-FN-1 TO-FN-2 26761 26761
CONVERTER BOLT M10 X 1.5mm CONVERTER BOLT M10 X 1.25mm CONVERTER BOLT RWD APPLICATIONS CONVERTER BOLT, FWD APPLICATIONS CONVERTER BOLT 3/8 -24, 9/16 CONVERTER BOLT RWD METRIC APPLICATIONS CONVERTER BOLT FWD METRIC APPLICATIONS CONVERTER NUT M10 X 1mm CONVERTER BOLT M8 X 1.25mm CONVERTER BOLT M9 X 1.25mm CONVERTER NUT 3/8 X 24 FLANGED
MITSUBISHI/KM 4SPD MITSUBISHI/KM 4SPD CHRYSLER CHRYSLER 350 GM GM AXOD, AXOD-E & CD4E TOYOTA TOYOTA AOD, AOD-E, 4R70W, C6 & E4OD
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PUMP PARTS
1280 1937 4662 4734 96925 56201A-K
75926
PUMP VANE R:8631280 PUMP VANE RING,R:8631279 VANE, PUMP, R: 8644662
125, 200-4R & 4L60 125 4T60 200-4R AXOD A4LD & C3
65929A 96925
VANE GUIDE,10-VANE, R:8654734 PUMP VANE PUMP GEAR SET
BEARINGS & BUSHINGS
FD-B-1 FD-B-2 GM-B-2 GM-N-14H GM-N-16 R16 12860-01K 35007 56008 65405 76427A 96423
86001 96001 75005A 35400C 35403B R16 3075 56008 65405 76427A 96423
BUSHING, STATOR SUPPORT E1EP-7N805-A BUSHING, STATOR SUPPORT E6SP-7N805-AA BUSHING, STATOR SUPPORT THRUST BEARING DIR CLUTCH TO PUMP COVER THRUST BEARING, INPUT RING GEAR SUPPORT BALL BEARING, CTR SUPPORT PLATE & PLATE, OVERDRIVE BUSHING, STATOR SUPPORT SHAFT BUSHING, OUTPUT SHAFT PILOT BEARING, THRUST 78-87 FRONT INT GEAR TO CARRIER BEARING DIR. CLUTCH OUTER BEARING,THRUST LOW SPRAG INNER RACE
ATX AXOE & AXOD-E 125 & 4T60 350 350 C6 & E4OD 42RH, 46RH, 47RH 350, 400 & 4L60 E4OD 200 AOD C6 & E4OD
FLEX PLATES
CH-FP-1 CH-FP-2 CH-FP-3 CH-FP-4

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12971 12970 22980 22981
10 3/4 OFFSET HOLES 10 3/4 EVEN SPACED HOLES 11 3/4 OFFSET HOLES 11 3/4 EVEN SPACED HOLES
CHRYSLER CHRYSLER CHRYSLER CHRYSLER

sonnax

MISCELLANEOUS
125RA 13236 2178 22960 35354 36429A 36429E 36429E-K 36743H 420A 75785 77731-08 8041 8368 84812 84989 84812 75785 36429E K36429E 36743 22960 35354
RIGHT AXLE STAB - 1 1/32" SERVO COVER GASKET SEAL,INPUT HOUSE TO OUTPUT SHAFT, R:8642178 OVERRUN CLUTCH SPRING & ROLLER KIT CASE SAVER, 4 PER RACE, LOW/REVERSE SPRAG RACE, LOW/REVERSE SPRAG LOW/REVERSE SPRAG RACE/BRNG KIT HUB,CTR SUPPRT,USE W/ R16 BRG BALL & SPRING KIT,FORD E5AZ-7A205-A SLEEVE, CASE COVER, REAR PLANET OIL DEFLECTOR CHANNEL PLATE SLEEVE, LUBE DAMPNER, R:8658368 SPRING, ANTI-SHUDDER
125 C6 4L60 TF6 & TF8 APPLICATIONS 350 C6/1970-87 C6 & E4OD C6 & E4OD C6 & E4OD AOD, AOD-E & 4R70W 125C 4L60 4T60 4T60 4T60
ANCILLARY ITEMS
31295 31295-CASE O-LUBE ZERO-1 MI-AC-180 MI-AC-180HD MI-AC-320 MI-AC-320HD MI-DI-FD1 MI-DI-FD2 MI-TP-CH1 MI-TP-GM1
LUBE, ASSEMBLY, 1 LB TUB LUBE,ASSY.,CASE/12 1-LB TUBS SLIPPERY STICK ORING LUBRICANT ZERO CLEANER, 1/2 GAL ABRASIVE CLOTH ROLL 50YDS, 180 GRIT STD ABRASIVE CLOTH ROLL 50YDS, 180 GRIT H/DUTY ABRASIVE CLOTH ROLL 50YDS, 320 GRIT STD ABRASIVE CLOTH ROLL 50YDS, 320 GRIT H/DUTY M10-1 RETHREAD DIE 3/8 - 24 UNF RETHREAD DIE 5/16 -24 UNF BOTTOMING TAP 3/8 - 16 UNC BOTTOMING TAP
All All All All All All All All AXOD & CD4E FORD RWD RWD CHRYSLERAPPLICATIONS GM APPLICATIONS
sonnax 149
Sealing the Seals, Bore Prep is More

BY DENNIS MADDEN
eaks, whether theyre internal or external, have always been a source of aggravation for transmission rebuilders. Especially when the unit doesnt leak when it goes out, but comes back with a leak. Sometimes its a parts problem. Many times though, the problem relates to surface preparation. Surface preparation varies based on the type of seal that is used and where the seal works or lives. Sometimes, surface preparation is as simple as cleaning all the gunk, like old silicone, dirt or varnish off the sealing surface. Other times the sealing surface must be sanded or honed. And then theres the ol Scotch-Brite routine, which has its own set of challenges, but well save that for last. Lets first talk about sealing rings for rotating components like drums and shafts. There are four basic types of sealing rings used here: cast, which can be iron, or some type of alloy; Teflon, which can also have different materials added to it for specific applications; Vespel, which is a plastic material; and rubber. With the exception of the cast ring, all of these rings are designed to run on a very smooth surface. On some applications, the ring does not rotate in its groove, it either rotates with the shaft or remains stationary with the support. Indeed, some rings, like the second clutch rings on a 4T60-E have locking tabs to prevent them from rotating. Its easy to see why a smooth ring bore with these rings is desirable. For all three of these rings, no bore prep is necessary; just keep the bore smooth. Cast rings, on the other hand, rotate in their groove. If theyre on a shaft, like a turbine shaft for example, the rings hold onto the stator support. If the ring groove is in a stationary part like a 400 center support, then the ring will rotate with the drum. Here, there is more lat-
itude for sanding small grooves or scratches in the ring bore. If the original ring was Teflon, Vespel, or rubber, and is replaced with cast, sand the ring bore a bit; 220-280 grit works fine. This will help the ring hold onto the bore surface. Now lets look at rings and seals that work in a piston, such as an accumulator or servo. Surface prep here is a bit different because the seals and rings slide, or scrape against the sealing surface. The type of rings to seals here are cast, Teflon, and rubber. The rubber seals vary from lathe-cut, O-ring, D-ring, to lip seals. Sure, every now and again theres an oddity like the double-lip seal, but essentially rubber seals come in these four varieties. The rules for these seals are different than the rings we covered earlier. Teflon still rides on a smooth surface. Cast rings also ride on a smooth surface but there is some latitude for sanding the bore for small scratches and scrapes if the piston contacted the bore wall. Rubber, however, works differently in this application than it does as a sealing ring, working with a rotating part. Here, the seal works like a squeegee, wiping the oil from the seals point of contact. The problem comes when replacing a Teflon seal, which rides on a smooth surface, with rubber. This squeegee effect can tear away at the rubber seal. The first real problem I recall with this change was the accumulator seals on the 440-T4. The idea of using rubber seals was great because the Teflon seals used at first didnt work very well. The pistons went in fine, the transmission worked great, and everyone was happy for about a month. What we found was that the seals had what looked like little bite marks on them (not to mention all the debris in the pan from the second clutch). The industry learned
150
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than Elbow Grease and Sandpaper

through trial and error that the accumulator bores were too smooth. To fix the problem, simply rough up the seal surface of the bore. We all tried a bunch of different products, and most everyone agrees that the Scotch-Brite pads work the best. End of the story, right? Not quite. After years of using this product were finding more and more problems associated with using these pads than we did fifteen years ago. Why? Two reasons. First, any forward-thinking company wants to increase their product line to cover a wider range of customer needs. Consequently, 3M, the maker of Scotch-Brite has increased the types of materials out of which they make their abrasive pads. A small list of materials includes: emery, garnet, aluminum oxide, silicon carbide, alumina-zirconia, diamond and Cubitron Ceramic Aluminum Oxide Mineral (I threw in all these fancy words so any engineers reading this would feel at home). Some of these products are less suited for our needs and may not offer the right finish for rubber seals. After all these years, were still finding that the simple green pad still works the best. The green pad is a polyester fiber with a urethane resin. In the resin is aluminum oxide mineral, which is the abrasive material. It offers abrasive characteristics close to using 280 grit emery. It offers a finish of about 20 in (Microinches), depending on how hard the pad is pressed while working the bore. The official name 3M uses for this pad is #96. They also have a pad that is thinner, so its easier to handle, yet offers the same abrasive properties of #96. They call it #07521. The second part of this problem deals with nothing more than cleanliness. Any time an abrasive pad is used for prepping a metal surface, some of the abrasive material will break off, embedding itself into the metal or falling loose on the surface. Unless the accumulator bore is cleaned well enough, little cutting edges are now working against the rubber seals. Even if the bore were cleaned out well, whered the abrasive debris go? On the bench? On a rag that will be used for some other part of the transmission? In the solvent tank were valve bodies are cleaned? Could this explain some of the valve body hang-ups weve been seeing lately? Some rebuilders are now using a separate cleaning area for boreprep operations, leaving all the grit they accumulate in one area. Another consideration is to do the final cleanup with an aerosol solvent like Brake-Kleen. This insures that parts are not being cleaned with contaminated solvent. As with many problems, when it comes right down to it, the answer to bore preparation for rings and seals is very simple. Use an abrasive pad that offers the right finish for the seal and the surface its working on, and make sure its clean when the job is finished. Naturally, with a Sonnax bore sleeve, bore prep isnt an issue. Each bore is finished to accept the type of seal with which its used. Sonnax offers a wide range of bore sleeves and pistons, which include:
34989-02K 4L80-E
Page 45 Intermediate Servo Sleeve and Piston Intermediate Servo Sleeve and Piston
35709-01K 350
Page 10 Page 65 4R44E, 4R55E, 5R55E
56532-01K A4LD, C3, Reverse sleeve
77998-01K 4L60,
Page 34 4L60-E
3-4 Accumulator Sleeve and Piston
96511K, 12K, 13K, 123K

Page 91
AXOD, Accumulator Sleeves and Pistons AXOD-E, AX4S
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PRODUCT INDEX sonnax

NO.
RED SONNAX PART NUMBERS DENOTE NEW PRODUCTS IN THIS CATALOG RED SONNAX PART NUMBERS DENOTE NEW PRODUCTS IN THIS CATALOG DESCRIPTION PROBLEM SOLVED PAGE
APPLICATION
GENERAL MOTORS
34006-SP 34016-W 34105-01K 34105-02K 34200-01K 34200-03K 34200-16K 34301-078 34301-094 34500-Z 34910-01K 34910-03K 34910-05K 34989-02K 34994-01K 34994-02K 35012S 35410-T 35709-01K 35718-01K 35718-02K 65754-01K 65754-02K 65754-03K 6578-01 65797 74926 75410-10 75890-30 75918-01K 77000-HBK 77406-10 77409-15 77701-076 77704S 4L80-E, 400 4L80-E 400 400 4L80-E 4L80-E 4L80-E 4L80-E 400, 4L80-E 400 400 400 4L80-E 4L80-E 4L80-E 4L60 & E 350, 400, 4L60 350 350 350 200 200 200 200/ C 325-4L 4L60 & E, 200-4R 4L60 & E 4T60 & E 4T60 & E 125-C 4L60-E 4L60 & E, 350/C 4L60 & E 4L60 & E 4L60 & E BUSHING, CASE, No Walk Out BUSHING, FRONT STATOR SUPPORT OVERSIZED ACCUMULATOR PIN KIT OVERSIZED ACCUMULATOR PIN & REAMER KIT BOOST VALVE & SLEEVE KIT, w/ Balance Plug & O-Rings FACTORY STYLE BOOST VALVE KIT, w/bal. Plug ACTUATOR FEED LIMIT VALVE KIT FORWARD CLUTCH DRUM WASHERS SHIMS, FRONT UNIT END-PLAY, (.010" Thick) REVERSE BOOST VALVE KIT PRESSURE REGULATOR VALVE KIT FACTORY STYLE REVERSE BOOST VALVE KIT FRONT SERVO PISTON & SLEEVE KIT TCC REGULATOR VALVE KIT 1-2 SHIFT VALVE SPRING OVERSIZED REAR CASE BUSHING GOVERNOR CIRCUIT TEST TOOL INTER. SERVO SLEEVE KIT OVERSIZED ACCUMULATOR PIN KIT OVERSIZED ACCUMULATOR PIN & REAMER KIT THROTTLE VALVE SLEEVE KIT THROTTLE VALVE SLEEVE KIT THROTTLE VALVE SLEEVE KIT NYLON BUSHING, Intermediate PUMP SLIDE PIVOT PIN 1-2 ACCUMULATOR SPRINGS DIFFERENTIAL CARRIER TO CASE SHIM HARDENED SIDE GEAR THRUST WASHER TV & REVERSE BOOST VALVE KIT TORX PLUS BIT w/ 2 piece case REAR UNIT END PLAY SHIM FRONT UNIT END PLAY SHIM CHECK VALVE FIRMER 1-2 ACCUMULATOR SPRING Flanged bushing will not walk out Reduces leakage by minimizing journal clearance Eliminates cross leaks, 2-3 shift slide & burned bands Start-up kit includes reamer, 10 pins & 10 retaining rings Eliminates high line pressure & buzzing noises Eliminates high line pressure & buzzing noises Reduces wrong gear starts, no 4th, 3-neutral condition Corrects front unit endplay Reduces end-play and prevents burned forward clutches Reduces delayed reverse & modulated drive Reduces high line pressure to insure pressure control Reduces delayed reverse Reduces delayed engagement and low line pressure Reduces converter shudder, reduces burned converters Reduces 2nd gear starts, no 3rd or 4th Saves cases with spun bushing surface Tests for worn governor bore & leakage in governor circuit Reduces delayed engagement Eliminates cross leaks, 2-3 shift slide & burned bands Start-up kit includes reamer, 10 pins & 20 retaining rings Prevents poor line rise and no detent downshifts due to oil loss Eliminates sticky and erratic throttle valve operation Annular cleaning grooves added to valve Eliminates oil leakage and premature band failure Reduces high line pressure at idle Restores OEM 1-2 shift Corrects differential endplay and improves planetary life Allows differential to be services when side gear thrust washers wear out Improves line pressure rise and upshift quality Allows removal of bell housing bolts without striping bolt head Corrects excessive rear unit end play; reduction of drivetrain noise Allows proper adjustment of front unit endplay Extends 3-4 clutch life and improves 2-3 shift feel Firms up soft 1-2 shift 12 48 13 13 46 46 47 45 12 11 11 11 45 49 48 16 16 10 13 13 9 9 9 16 25 25 37 37 8 10 26 26 21 25
152
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NO.
RED SONNAX PART NUMBERS DENOTE NEW PRODUCTS IN THIS CATALOG DESCRIPTION PROBLEM SOLVED PAGE
APPLICATION
GENERAL MOTORS
77731-01 77731-02K 77731-03 77731-04 77731-05 77731-08 77731-RK 77754-01K 77754-02K 77754-03K 77754-04K 77754-09K 77754-R2 77754-TL 77767K 77767K-SK 77777K-K 77777L-K 77777M-K 77805E-K 77805-K 77872-01 77898E-3K 77898E-4K 77898E-6K 77898E-K 77911-01 77911-02 77917-01K 77917-02K 77917-03K 77917-04K 77917-06 77917-07 4L60 & E 4L60 & E 4L60 & E 4L60 & E 4L60 & E 4L60 & E 4L60 & E 4L60-E 4L60-E 4L60-E 4L60-E 4L60-E 4L60-E 4L60-E 4L60 & E
(continued) PINION GEAR, REAR PLANET PINION PINS, REAR PLANET NEEDLE ROLLER BEARINGS ROUND WASHER, REAR PLANET BATWING WASHER, REAR PLANET OIL DEFLECTOR, REAR PLANET REAR PLANETARY REBUILD KIT OVERSIZED ACCUMULATOR PIN KIT OVERSIZED ACCUMULATOR PIN & REAMER KIT TCC REGULATOR VALVE KIT '92-'97 (NON EC3) TCC REGULATOR VALVE KIT '97 (EC3) ACTUATOR FEED LIMIT VALVE KIT REAMER, TCC REGULATOR VALVE KIT TOOL KIT FOR AFL VALVE KIT PISTON, SERVO, 4TH GEAR, The Sonnax Super-Hold Servo SEAL REPLACEMENT KIT ACCUMULATOR VALVE TRAIN ASSEMBLY ACCUMULATOR VALVE TRAIN ASSEMBLY ACCUMULATOR VALVE TRAIN ASSEMBLY TCC APPLY VALVE TCC APPLY VALVE SHORTENED TV LINK FACTORY STYLE BOOST VALVE KIT, .490" dia. REVERSE BOOST VALVE & SLEEVE KIT, .470" dia. FACTORY STYLE BOOST VALVE KIT, .470" dia. REVERSE BOOST VALVE & SLEEVE KIT, .490" dia. 2ND APPLY SERVO SAVER SLEEVE METAL CLAD VITON SEALS, Press-in TV BOOST VALVE KIT, .423" Bore dia. FACTORY STYLE TV BOOST VALVE KIT, .423" Bore dia. FACTORY STYLE TV BOOST VALVE KIT, .471" Bore dia. FACTORY STYLE TV BOOST VALVE KIT, .500" Bore dia. OVERSIZED PRESSURE REGULATOR VALVE & REAMER KIT OVERSIZED PRESSURE REGULATOR VALVE & REAMER KIT Replaces worn planetary gear 17 Replaces gauled pinion pins in Rear Planetary Assemblies Replaces worn needle roller bearings Replaces worn washers Replaces worn batwing washers Replaces damaged deflector and can update early planets to late Parts necessary to rebuild Rear Planetary Assemblies Prevents burned forward clutch, or delayed engagement Start-up kit includes reamer & 10 pins Improves converter apply pressure to reduce code 1870, Reduces harsh 1-2 shift Reduces code P1870 & intermittent harsh 1-2 shift Reduces wrong gear starts, solenoid codes 3-4 clutch failure Required for use with 77754-03K & 77754-04K Required for use with 77754-09K & 34200-16K Increases holding power by 40% over OEM Seals for 77767K Improves accumulator control and reduces harsh 1-2 shift, Light Weight Cars Improves accumulator control and reduces harsh 1-2 shift, Medium Weight Cars Improves accumulator control and reduces harsh 1-2 shift, Heavy Vehicles Falling out of lock up hot, code 1870 Improves lock-up control 28 Insures readjustment of throttle cable by installer Improves line rise and shift firmness Corrects insufficent line-rise and 3-4 clutch failure Corrects insufficent line-rise and 3-4 clutch failure Improves line rise and shift firmness Increases servo apply areas to improve 1-2 shift Restores hydraulic seal at 2nd apply servo piston Eliminates clutch/band failure due to TV pressure oil leakage Eliminates clutch/band failure due to TV pressure oil leakage Eliminates clutch/band failure due to TV pressure oil leakage Eliminates clutch/band failure due to TV pressure oil leakage Corrects pressure regulator valve leakage Corrects pressure regulator valve leakage 33 20 32 32 32 32 17 17 18 18 18 18 33 17 17 17 17 17 17 13 13 29 29 27 29 27,47 26 26 24 24 24 28
4L60 & E 4L60 & E, 200-4R 4L60 & E, 200-4R 4L60 & E, 200-4R 4L60-E (PWM ONLY) 4L60 & E (NON-PWM) 4L60 4L60-E 4L60-E 4L60-E 4L60-E 4L60 & E 4L60 & E 4L60 4L60 4L60 4L60 4L60 4L60-E
sonnax
153

NO.
APPLICATION
GENERAL MOTORS
77917-471 77917-500 77917-TL 77918S-K 77966-93K 77966-94K 77966-94MK 77968 77968-RM 77998-01K 77999 77999-02K 84573-01K 84573-02K 84733-10 84733-20 84754-01K 84754-08K 84754-12K 84754-14K 84754-16K 84754-17K 84754-19K 84754-22K 84754-23K 84754-24K 84754-25K 84754-30K 84754-97K 84754-98K 84754-DJ2 84754-RM 84754-TL 84881 84881A 84995-01 4L60 4L60 4L60 & E 4L60 & E 4L60 4L60 4L60 4L60
(continued) TV BOOST VALVE KIT, (.471" Bore dia.) TV BOOST VALVE KIT, (.500" Bore dia.) REAMER AND GUIDE for PR Valves STATOR SUPPORT SHAFT KIT, with 4 bushings TV SLEEVE & PLUNGER KIT (for 93) TV SLEEVE & PLUNGER KIT (for 94) TV SLEEVE & PLUNGER Heavier duty OVERSIZED THROTTLE VALVE REAMER TOOL 3-4 ACCUMULATOR SLEEVE KIT OVERSIZED ACCUMULATOR PIN KIT OVERSIZED ACCUMULATOR PIN & REAMER KIT OVERSIZED ACCUMULATOR PINS OVERSIZED ACCUMULATOR PIN & REAMER KIT INPUT CLUTCH HUB SHIMS INPUT CLUTCH HUB SHIMS TCC REGULAR VALVE & ISOLATOR VALVE KIT TCC REGULATOR VALVE & ISOLATOR VALVE MODULATED LINE BOOST VALVE KIT REVERSE BOOST VALVE KIT TCC APPLY VALVE KIT, oversized MODULATED LINE BOOST VALVE KIT REVERSE BOOST VALVE KIT TCC APPLY VALVE KIT (OEM SIZE) 1-2 SHIFT VALVE REVERSE & MODULATED LINE BOOST VALVE KIT REVERSE & MODULATED LINE BOOST VALVE KIT BOOST VALVE & SLEEVE KIT TCC APPLY VALVE KIT, oversized TCC APPLY VALVE KIT (OEM SIZE) REAMER GUIDE REAMER TOOL REAMER AND GUIDE PUMP SLIDE PIVOT PIN PUMP SLIDE PIVOT PIN REPAIR PLATE, Channel Plate Eliminates clutch/band failure due to TV pressure oil leakage Eliminates clutch/band failure due to TV pressure oil leakage Reduces pump scrap rate Eliminates sleeve rotation by mechanical fastening Increases line rise and prevents no direct downshift Increases line rise and prevents no direct downshift Increases line rise and prevents no direct downshift Eliminates excessive leakage in worn valve body bore Required reamer for 77968 Saves cases with worn 3-4 accumulator bores Eliminates cross leaks, 2nd gear starts & burned bands Start-up kit includes reamer and 10 pins Allows re-use of original, worn piston 13 Includes 10 Accumulator Pins and Reamer Corrects endplay, extends bearing & bushing life Improves seal life by reducing drum travel, adjusts for component wear Helps eliminate Code 740 & 1870, Converter Shudder Helps eliminate Code 740, Converter Shudder Improves line rise Reduces soft shudder Reduces 1870,converter shudder, overheat, and codes 39, 740 & 1870 Updated valve spool stability Reduces reverse delay or shudder Reduces 1870, falling out of lock up, overheat, and codes 39, 740 & 1870 Reduces 1-2 shuttle shift Reduces 2nd & 3rd clutch distress Salvages valve body cores Reduces harsh engagement Reduces 1870, converter shudder, overheat, and codes 39, 740 & 1870 Reduces 1870, falling out of lock up, overheat, and codes 39, 740 & 1870 Required for 84754-97K Required for 84754-08K Required tool for 84754-16K & 84754-97K Reduces low or high line pressure Reduces low or high line pressure Eliminates oil leakage; easy Side Cover installation 43 44 41 41 41 40 41 35 35 36 13 36 36 40 40 42 42 41 42 42 41 35 43
18 18 33 21 20 20 20 19 19 34 13 13
4L60 4L60 & E 4L60-E 4L60 & E, 200-4R, 325-4L 4L60 & E, 200-4R, 325-4L 4T60 & E 4T60 & E 4T60 & E 4T60 & E 4T60-E (PWM-'93 & Up) 4T60-E (PWM-'91-'92) 4T60 & E 4T60 & E 4T60 & E (91 through '96) 4T60 & E 4T60 & E 4T60 & E (91 through '96) 4T60-E 4T60 & E 4T60 & E 4T65-E 4T60-E (97 & up) 4T60-E (97 & up) 4T60-E 4T60-E (PWM-'91-'92) 4T60 & E 4T60 & E 4T60 & E 4T60 & E
154
sonnax

NO.
APPLICATION
GENERAL MOTORS
95200-01 K77898 K77898A K84956-SP
(continued) PRESSURE REGULATOR SPRING REVERSE BOOST VALVE KIT FACTORY STYLE REVERSE BOOST VALVE KIT SPRING, ACCORDIAN, Heavy Duty Roller Clutch Reduces erratic line pressue due to spring breakage 49 Reduces delayed reverse or shudder in reverse 18 Reduces delayed reverse or shudder in reverse 18 Prevents 1-2 roller clutch failure 34
SATURN TAAT 4L60 4L60 4T60-E (1993 & Up)
FORD
36008A 36008B 36008C 36008D 36402-Z 36414-01K 36424-01K 36424-03K 36428A-Z 36428-Z C6, E4OD C6, E4OD C6, E4OD C6, E4OD E4OD C6 E4OD, 4R100 E4OD, 4R100 C6 C6 REAR CASE BUSHING, Oversized O.D. REAR CASE BUSHING, Standard O.D. OVERSIZED REAR CASE 4 GROOVE BUSHING, late model REAR CASE BUSHING, late model SHIMS, REVERSE PLANET END-PLAY SUNSHELL SAVER SHIM BOOST VALVE & SLEEVE KIT w/Plug, Sleeve & 2 O-Rings FACTORY STYLE REVERSE BOOST VALVE KIT SHIMS, REVERSE PLANET END-PLAY, 4 slots SHIMS, REVERSE PLANET END-PLAY, 6 slots PUMP GEARS FORWARD PLANETARY REPAIR SLEEVE CENTER SUPPORT GASKET Silicone Printed OVERSIZED MODULATOR VALVE & REAMER SYSTEM DRILL JIG & REAMER REVERSE BOOST VALVE & SLEEVE KIT, gas ratio REVERSE BOOST VALVE & SLEEVE KIT, diesel ratio FACTORY STYLE REVERSE BOOST VALVE & SLEEVE KIT FACTORY STYLE REVERSE BOOST VALVE & SLEEVE KIT LINE PRESSURE MODULATOR PLUNGER VALVE & SLEEVE LINE PRESSURE MODULATOR PLUNGER VALVE & SLEEVE ACCUMULATOR CONTROL VALVE KIT BORE SIZING TOOL BOOST VALVE KIT BUSHING, BELL HOUSING, Finish-In-Place THRUST WASHER AND SPRAG END CAP KIT REAR BAND ANCHOR PIN KIT REVERSE SERVO SLEEVE KIT Increases lubrication and bearing area 55 Increases lubrication and bearing area 55 Saves cases with spun bushing surface 55 Increased lubrication and bearing area 55 Allows precise end-play adjustment, reduces wear Prevents unwanted forward planet/sunshell contact Eliminates poor reverse boost and soft shifts Eliminates poor reverse boost and soft shifts Allows precise end-play adjustment, reduces wear Allows precise end-play adjustment, reduces wear Improves low line pressure and reduces excessive pump noise Repair E4OD/C6 planetary carriers with a worn or damaged pilot dia. Eliminates leakage between center support and hub Salvages worn cases while still in vehicle; Improves line rise response Drill jig and reamer for 36833-01K Prevents cross leakage, which causes insufficient line rise Prevents cross leakage, which causes insufficient line rise Increases line pressure rise; reduces erratic shift timing (diesel ratio) Eliminates reverse shudder caused by poor line rise (gas ratio) Improves 1-2 & 2-3 shift firmness Improves 1-2 & 2-3 shift firmness 58 Reduces loss of 2nd, 3rd or 4th gear 57 For use with 36948-09K Improves line rise, engagement, and shift quality Eliminates front seal leakage Reduces bronze-in-the-pan Prevents 1-2 bind-up created by a dragging band Reduces forward clutch & reverse band failure 69 68 65 57 71 68 64 52 56 56 52 52 59 54 64 54 54 53 53 53 53 58
36438A-01K & E4OD 36438AX-01K 36440-01 C6, E4OD 36743G 36833-01K 36833-TL 36946-01K 36946-02K 36946-03K 36946-04K 36948-03K 36948-05K 36948-09K 36948-12 37947-01K 56001X 56250-01K 56521-K 56532-01K E4OD C6 C6 C6 C6 C6 C6 E40D (Late) E40D (Early) E4OD, 4R100 E4OD, 4R100 4R44E A4LD, 4R55E, 5R55E A4LD A4LD A4LD, C3, 4R44E, 5R55E
sonnax
155

NO.
APPLICATION
FORD
56600 56600B
(continued) A4LD A4LD A4LD A4LD A4LD A4LD A4LD A4LD A4LD A4LD A4LD A4LD CD4E CD4E CD4E KIT CD4E CD4E CD4E CD4E CD4E CD4E CD4E AOD-E, 4R70W AOD-E AOD AOD-E AOD-E (95 & Earlier ) AOD-E, 4R70W AOD-E, 4R70W AOD-E, 4R70W AOD-E, 4R70W ('97 and up) AOD AOD REARSPRAG INNER RACE (2.50 Dia.) REAR SPRAG INNER RACE (2.70 Dia.) LOW SPRAG UPDATE KIT (4.0 case) (includes 56600B) DRILL JIG Inner races MANUAL VALVE INDEX LARGE RATIO BOOST VALVE KIT FACTORY STYLE BOOST VALVE KIT, Large ratio SMALL RATIO BOOST VALVE KIT FACTORY STYLE BOOST VALVE KIT, Small ratio PRESSURE REGULATOR VALVE KIT PRESSURE REGULATOR VALVE REAMER KIT SPRING, ANTI-SHUDDER ENDPLAY SHIM KIT O-RINGED ACCUMULATOR PISTON AND SPRING KITS BYPASS CLUTCH CONTROL BYPASS TOOL KIT O-RINGED ACCUMULATOR PISTON AND SPRING KITS O-RINGED ACCUMULATOR PISTON AND SPRING KITS MASTER REBUILD KIT MASTER TOOL KIT PRESSURE REGULATOR VALVE KIT PRESSUE REGULATOR TOOL KIT STATOR SUPPORT SLEEVE DIRECT DRUM SHAFT Retaining Ring OVERDRIVE SERVO PIN with Washer and O-Ring OVERDRIVE SERVO PIN with Washer and O-Rings MAIN PRESSURE REGULATOR VALVE PRESSURE REGULATOR VALVE & SLEEVE KIT BYPASS TCC CONTROL SLEEVE & PLUNGER VALVE ELEVATED PRESSURE REGULATOR SPRING MAIN PRESSURE REGULATOR VALVE OVERSIZED THROTTLE VALVE PLUNGER OVERSIZED THROTTLE VALVE BORE REAMER Improved race for 2.8, 2.9, 3.0 cases; insures tight fit Improved race for 4.0 cases; insures tight fit Salvages cases with worn or loose races For installing 56600 and 56600B; eliminates risk of damaging case Eliminates burned forward clutch and delayed forward engagement Prevents insufficient line rise related to worn boost sleeve Prevents insufficient line rise related to worn boost sleeve Prevents insufficient line rise related to worn boost sleeve Prevents insufficient line rise related to worn boost sleeve Corrects soft shifts, low line pressure The bore must be resized by the reamer 67 Eliminates shudder when clutch does not release Reduces excessive endplay Reduces soft/harsh shift complaints caused by bore wear and piston sticking Reduces Code 628/1744, lube failure, and hard part damages, improves TCC apply and release control Required for 73840-BK Reduces soft/harsh shift complaints caused by bore wear and piston sticking Reduces soft/harsh shift complaints caused by bore wear and piston sticking Consists of Bypass and Regulator kits described above Reduces Code 628, lube failure, and hard part damage Eliminates high line/converter charge psi, increases cooler/lube flow, allows line to lube at rest Required for 73840-RK Prevents converter release oil circuit leakage Improves lube flow to direct drum bushing Eliminates forward clutch and overdrive band failure Eliminates oil circuit leaks at overdrive band Prevents low line pressure Prevents poor reverse boost 81 Eliminates delayed TCC apply & reduces shudder Reduces forward clutch failure by raising line pressure to 68 lbs. Prevents low line pressure Prevents uncontrollable throttle pressure, increases line rise Removes excess material for valve body to accept the plunger 80 77 81 75 75
69 69 69 69 70 66 66 66 66 67
56600B-01K 56600-DJ 56947-01 56947-02K 56947-03K 56947-04K 56947-05K 56947-06K 56947-TL 56995A 73251-01K 73840-24 73840-BK 73840-BTL 73840-FWD 73840-LR 73840-MK 73840-MTL 73840-RK 73840-RTL 76204-01 76811-01K 76833 76833E 76948-01 76948-02K 76948-04K 76948-06 76948-09 76970 76970-RM
70 93 97 94-96 94 97 97 94-96 94-96 94-96 94 82 77 76 82 81
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NO.
APPLICATION
FORD
(continued) AOD AOD AOD AOD AOD AOD AOD AOD ATX ATX ATX ATX ATX AXOD & E, AX4N, AX4S AXOD & E AXOD AXOD & E, AX4N, AX4S AXOD & E, AX4N, AX4S AXOD & E, AX4N, AX4S AXOD & E, AX4S AXOD & E, AX4S AXOD & E, AX4S AXOD-E, AX4S AX4N AXOD & E AXOD & E AXOD & E AXOD & E AXOD & E AXOD & E AXOD & E, AX4N, AX4S AXOD & E AXOD & E AXOD & E FACTORY STYLE THROTTLE VALVE KIT THROTTLE VALVE PLUG & SLEEVE KIT FACTORY STYLE BOOST VALVE KIT BOOST VALVE & SLEEVE KIT 1-2 CAPACITY MODULATOR VALVE KIT REAMER & DRILL JIG VALVE END PLUG KIT VALVE END PLUG KIT, with O-Rings OVERSIZED GOVERNOR PIN GOVERNOR CIRCUIT TEST TOOL SHIM, SELECTIVE, Idler Gear Assy, (.005" thick) SLEEVE, THROTTLE PLUNGER SLEEVE, THROTTLE CONTROL VALVE, Hard Coat Finish BOOST VALVE & SLEEVE KIT with O-Rings, 3.8L MANUAL VALVE, Hard Coat Finish, Lengthened Spool Dia. BYPASS CLUTCH CONTROL SLEEVE & PLUNGER VALVE KIT FACTORY STYLE BOOST VALVE KIT, 3.8L BOOST VALVE & SLEEVE KIT with O-Rings, 3.0L FACTORY STYLE BOOST VALVE KIT, 3.0L VALVE SAVER CAP FORWARD CONTROL VALVE KIT BORE SIZING TOOL BYPASS CLUTCH CONTROL SLEEVE & PLUNGER VALVE KIT BYPASS CLUTCH CONTROL SLEEVE & PLUNGER KIT ACCUMULATOR BORE SLEEVE KIT, N-D Accumulator ACCUMULATOR BORE SLEEVE KIT, Master Kit ACCUMULATOR BORE SLEEVE KIT, 3-4 Accumulator ACCUMULATOR BORE SLEEVE KIT, 1-2 Accumulator PISTON, SERVO, Low - Intermediate RETAINING RING, Rear Ring Gear REPAIR SLEEVE, CHANNEL PLATE, Hardened & Ground SERVO TUBE BRACKET 1-2 SERVO SPRING RETAINER CLIP SERVO PIN Eliminates uncontrollable throttle pressure Eliminates uncontrollable throttle pressure Increases line rise and reduces clutch failure Increases line rise and reduces clutch failure 73 Restores line pressure for all shifts and salvages valve body Reamer and drill jig for 76991-01K Eliminates governor oil leakage Eliminates governor oil leakage 74 Prevents late, erratic, or no 1-2 & 2-3 shift caused by pin wear Allows easy testing of governor oil circuit Special thickness allows proper preload setting Eliminates wear & prevents Hard Coat Finish excess leakage Eliminates wear & prevents excess leakage Eliminates 2-1 down-shift clunk and clutch/band failure Eliminates delayed forward engagement, forward clutch burnout Improves TCC apply & release oil control Eliminates 2-1 down-shift clunk and clutch/band failure Eliminates 2-1 down-shift clunk and clutch/band failure Eliminates 2-1 down-shift clunk and clutch/band failure Allows re-use of 3-2 control valve Reduces slipping in forward and reverse Required for 96201-16K Improves TCC apply & release oil control Reduces cooler circuit oil loss and Code 628 Saves expensive and unit specific channel castings Saves expensive and unit specific channel castings Saves expensive and unit specific channel castings Saves expensive and unit specific channel castings Restores seal integrity of worn OEM servo piston Prevents retaining ring popping out Eliminates internal leakage of channel plate Eliminates tube blow out, which causes a no forward complaint Fixes 3-2 neutral/delayed engagement due to broken clip Increased length to properly set servo travel 84 84 84 83 83 87 90 86 87 87 87 93 85 85 89 92 91 91 91 91 86 88 90 88 86 86 76 76 74 72 72 73
76989-03K 76989K 76990-03K 76990K 76991-01K 76991-TL 76999-04K & 76999-05K 76999-SML, MED, -LRG 86412-01 86412-T 86539-Z5 86940-01 86940-03 96201-01K 96201-05 96201-06K 96201-08K 96201-12K 96201-13K 96201-15K 96201-16K 96201-BST 96206-01K 96206-03K 96511K 965123K 96512K 96513K 96728 96730-RR 96803 96806 96945R 96945S
sonnax
157

NO.
APPLICATION
FORD
(continued) AX4N, HI-PERF., E40D, 4R100 AXOD & E C6, E4OD C6, E4OD C6, E4OD LINE PRESS. MODULATOR PLUNGER VALVE & SLEEVE SPRING, INTERMEDIATE, SERVO INSTALLATION TOOL, Rear Case Bushing REAMER, for Oversized Rear Case Bushing REAMER FIXTURE, for Oversized Bushing Reamer Improves 1-2 & 2-3 shift firmness 58, 92 Eliminates delayed forward engagement & downshift clunk Draws the replacement bushing into place Custom designed 1-5/8" reamer Required for use with 36008A Flange can be reversed to switch between units 86 55 55 55
96948-01K 96995A T36008A T36605-03 T36605-04
CHRYSLER
12229-01K 12502-01 12780-Z 12962N-01K 12962N-02K 22229-01K 22556-BRG 22700-Z 22750L 22750N 22754N-01K 22754N-02K 22771-01K 22771A-01 22900-10/15 22912 22912A 22912B 32539-Z5 32710-01 35539-Z5 39539-Z5 92003-01K 92003-TL A904 41TE, 42LE, A670, A904 42RH, A904 42RH, 42RE 42RH, 42RE A727, 42RH, 46RH, 47RH A727, 46RH, 47RH A727, 46RH 46RH, 47RH A727, 46RH 46RH, 46RE, 47RH, 47RE 46RH, 46RE, 47RH, 47RE 42RH, 46RH, 47RH 42RH, 46RH, 47RH A727,46RH, 46RE 47RH, 47RE A727, 46RH A904, A999, 47RH 47RH, ('94 & up) (w/split band) A404, A413, A470, A670 A404, A413, A470, A670 A404, A413, A470, A670 A404, A413, A470, 41TE, 42LE, A670 41TE, 42LE 41TE, 42LE REGULATOR SLEEVE & PRESSURE PLUG KIT FRONT PUMP BUSHING SHIM, END-PLAY, (.010" Thick) UPGRADED PISTON RETAINER OVERSIZE UPGRADED PISTON RETAINER REGULATOR SLEEVE & PRESSURE PLUG KIT CASE REPAIR BEARING SHIM, END-PLAY, (.010" Thick) PRESS-ON LOW ROLLER CLUTCH RACE SLIDE-ON LOW ROLLER RACE, 12 elements UPGRADED PISTON RETAINER OVERSIZE UPGRADED PISTON RETAINER THROTTLE VALVE KIT 4 SPOOLED SWITCH VALVE LENGTHENED BAND STRUTS SERVO PISTON UPGRADED SERVO PISTON UPGRADED SERVO PISTON UPGRADED SHIM, TRANSFER GEAR, (.005" Thick) STRUT, Heavy Duty, Reverse Band SHIM, PINION, (.005" Thick) SHIM, DIFFERENTIAL BEARING, (.005" Thick) INPUT CLUTCH HUB BUSHING BUSHING INSTALLATION TOOL Reduces slippage in reverse 109 Restores clearance for proper operation Reduces transmission end-play for 3 or 4 tanged OE washers Reduces reverse drum, retainer & planet failure Allows salvage of reverse drum 107 Reduces slippage in reverse 109 Saves expensive cases; prevents further case damage Reduces transmission end-play for 3 or 4 tanged OE washers Allows resuse of reverse drums with worn inner races Direct OEM replacement Reduces reverse drum, retainer & planet failure 113 Allows salvage of reverse drum 113 Improves shift timing; salvages valve body with wornTV plunger Converter shudder, improved apply & release control Allows resurface of drum, available either .100" or .150" longer Prevents reverse band slippage; prevents piston breakage Reduces piston cocking/sticking in bore; prevents reverse band slippage Prevents reverse band slippage; prevents piston breakage .005" thickness allows use with leftover Chrysler kit spacers High quality steel resists strut bending or breakage .005" thickness allows use with leftover Chrysler kit spacers Used to reset preload when reworking differential assembly Tighter toleranced bushing prevents leaks in underdrive circuit Used with 92003-01K input clutch hub bushings 110 111 114 110 110 110 100 100 100 100 103 103
102 106 107
112 112 114 114
158
sonnax

NO.
APPLICATION
CHRYSLER
92004-L 92004-SP 92834-03K 92835-02K 92835-03K 92835-07 92836-01K 92836-02 92836-03 92836-03K 92965-30 92965-37 92965-45 92965-Z5
(continued) 41TE (1996 & Up), 42LE 41TE (Up thru 1995) 41TE, 42LE 41TE, 42LE 41TE, 42LE 42LE 41TE, 42LE 41TE, 42LE 41TE, 42LE 41TE, 42LE 41TE 41TE 41TE 41TE BUSHING, OVERDRIVE CLUTCH HUB, Steel-Backed BUSHING, OVERDRIVE CLUTCH HUB, Steel-Backed ACCUMULATOR BORE SLEEVE AND PISTON KIT SOLENOID SWITCH VALVE PLUGS TCC REGULATOR VALVE PRESSURE REGULATOR SLEEVE BY-PASS PLUG SOLENOID DIAPHRAGM SOLENOID SWITCH BRASS CONTACT SOLENOID REPAIR KIT SPACER, OUTPUT & TRANSFER SHAFT, (.030" Thick) SPACER, OUTPUT & TRANSFER SHAFT, (.037" Thick) SPACER, OUTPUT & TRANSFER SHAFT, (.045" Thick) SHIM, OUTPUT & TRANSFER SHAFT, (.005" Thick) Prevents shaft breakage and lube loss 103 Prevents shaft breakage & lube loss 103 Reduces 1-2 shudder, coast down clunk, and CVI's 104 Reduces erratic TCC operation and switch valve codes Prevents high converter apply pressure and lock-up piston failure Prevents high line pressure and improves lube control & shift feel Eliminates fluid loss and directs fluid through cooler Replaces worn diaphragms Replaces worn contacts Reduces pressure switch codes Allows more accurate preload setting Allows more accurate preload setting 106 Allows more accurate preload setting 106 Allows more accurate preload setting 106 104 101 102 105 105 105 105 106
HONDA
88406B 88406C 88406-SP Some G4 G4, K4, L5 PL5X AK, AS, F4, L4 CA,PL BRONZE THRUST WASHER, Mainshaft 2nd Gear Assy. BRONZE THRUST WASHER, Mainshaft 2nd Gear Assy. BRONZE THRUST WASHER, Mainshaft 2nd Gear Assy. Replaces OEM roller bearing; withstands wear Replaces OEM roller bearing; withstands wear Replaces OEM roller bearing; withstands wear 118 118 118
MAZDA
71151-K 71400-15 71828-TL 71846-01K 71912-01K 71912-02 74828-TL 74846-01K K74878 4EAT, G4A-HL, G4A-EL, F4A-EL & F4EAT 4EAT / G4A-EL G4A-EL G4A-EL 4EAT / G4A-EL 4EAT / G4A-EL F4A-EL GF4A-EL, F4A-EL F4A-EL,GF4A-EL PUMP DRIVE TOOL FRONT SUPPORT PUMP SHIM, (.015" Thick) 3-4 DRUM TEST TOOL KIT w/ Tool Cap, Screw & O-Rings BOOST VALVE KIT PUMP REBUILD KIT, Valve, Spring & Expander PUMP VANE EXPANDER RING 3-4 DRUM TEST TOOL KIT w/ Tool Cap, Screw & O-Rings BOOST VALVE KIT PUMP REBUILD KIT Enables rebuilders to charge pump and analyze units on the bench Use with selective washer to set transmission end play Allows bench checking for drum leaks (not catalogued) 122 122 Improves line rise, reduces delayed reverse, and prevents soft shifts and shudder Increases oil pump volume by reducing internal oil leakage Decreases internal leakage Allows bench checking for drum leaks 122 Improves line rise, reduces delayed reverse, and prevents soft shifts and shudder Improves pump volume and line pressure 121 120 121 120 120
MITSUBUSHI
41750-03 KM 20 & 30 Series MANUAL VALVE Insures converter charge and cooler flow in park 126
NISSAN
66942-01K L4N71B BOOST VALVE & SLEEVE Reduces delayed reverse 128
sonnax 159

NO.
APPLICATION
NISSAN(continued)
69700-01 69835 69903-01K 93897S 93903-01K 93990 Jatco Various RL4R01A RE4R01A, RE4R03A RL4F02A RE4F02A, RL4F02A RE4F02A SERVO BAND STRUT GOVERNOR BORE SLEEVE SERVO PIN SPLINED REPAIR INSERT, w/ hardened splines SERVO PIN PRESSURE REGULATOR BOOST SLEEVE Higher quality material with improved load strength; reduces cracking of strut Press in sleeve, no machining required Reduces 2-3 bind up and high clutch failure Replaces stipped or damaged planetary splines Reduces 2-3 bind up and high clutch failure Eliminates poor shift timing and poor line rise 127 127 129 126 129 130
TOYOTA
89010-01 89031-01 A130, A131, A132(L) A540 BOOST SLEEVE BOOST SLEEVE Helps prevent delayed reverse, reduces soft 1-2 or 2-3 shift, and increases line rise Reduces delay shudder, soft 1-2 or 2-3 upshifts, and increases line rise 119 119
ZF
85701-01 85991-01 85991-TL ZF4HP-18 ZF4HP14/18 ZF4HP14/18 SERVO CUSHION WASHER, BELLEVILLE TYPE OVERSIZED PR VALVE OVERSIZED PR VALVE TOOL KIT Reduces neutralizing on 3-4 shift 130 Reduces high, uncontrollable line pressure; improves converter charge Reduces reverse engagement complaints 131 131
HIGH PERFORMANCE
35922-01K 36916E 76948-06 77704S 77722-01K 77767K 77767K-SK 77917-500 77917-RV 77966-94MK 77968-01K 96948-01K K36528R K36528R-SK K13259C K13259C-SK GM Units C6 AOD-E, 4R70W 4L60 & E 4L60 & E 4L60 & E 4L60 & E 4L60 4L60 & E 4L60 4L60 E4OD, 4R100 C6 C6 C4 C4 SPEEDO PLUG SERVO APPLY LEVER, E RATIO ELEVATED PRESSURE REGULATOR SPRING 1-2 ACCUMULATOR SPRING, ENHANCED PERFORMANCE PUMP SLIDE SPRING PISTON, SERVO, 4TH GEAR, The Sonnax Super-Hold Servo SEAL REPLACEMENT KIT TV BOOST VALVE KIT, (.500" Bore dia.) SPRING SPACER FULL THROTTLE UPSHIFT SLEEVE & VALVE KIT THROTTLE VALVE SPRING LINE PRESSURE MOD. VALVE KIT, .427" dia R-RATIO SERVO SEAL KIT C-RATIO SERVO SEAL KIT Plug allos lubrications to output shaft Auto and Standard Will not distort or crack Reduces forward clutch failure by raising line pressure to 68 lbs. Firms up soft 1-2 shifts Maintains pump in high volume at high RPM Increases holding power by 40% over OEM Seals for 77767K Eliminates clutch/band failure due to TV pressure oil leakage Preloads the spring for increased pump output Increases line rise and prevents no direct downshift Improves and maintains higher line pressure Improves 1-2 & 2-3 shift firmness More band apply force, unique servo pin Replacement seal kit for K36528R Firmer 1-2 & 2-3 shifts Replacement seal kit for K13259C 135 134 134 135 135 132 132 135 135 135 135 134 134 134 134 134
OTHERS
36605-01 AS1-01K 1356 Transfer AOD, AXOD & GM CASE SAVER SPACER TV CABLE CORRECTOR KIT Eliminates no movement or neutral condition Prevents TV cable out of adjustment at wide-open throttle (not catalogued) 138
160
sonnax

NO.
APPLICATION
OTHERS
AS2-02K AS3-03K FM-01K FM-03K O-LUBE OR-MK SWAT-P1 SSPP-01
(continued) GM & AOD (w/cables) EDLEBROCK ALL AUTOMATICS ALL AUTOMATICS Multiple Applications Multiple Applications Multiple Applications Multiple Applications TV CABLE CORRECTOR KIT (w/ Holley Carburetor) TV CABLE CORRECTOR KIT SONNAFLOW DIGITAL FLOW METER DIAGNOSTIC LEAD O-RING LUBRICANT MASTER O-RING KIT WET/AIR TEST PLATE SMALL PARTS PROGRAM Prevents TV cable out of adjustment at wide-open throttle 138 Prevents TV cable out of adjustment at wide-open throttle 138 Detects restricted coolers, clogged filters and allows flow check while driving 78-79 Allows Sonnaflow readings on a lab scope for advanced diagnostics 78-79 Aids in installation of O-ringed sleeves and general transmission assembly 141 Allows re-servicing of O-ringed boost sleeves 141 Allow easy isolation of oil circuits when performing wet/air test 141 Miscellaneous box of retainers, clips, springs, etc. 139-141
WA R R A N T Y
POLICY
Sonnax warrants to the owner that it will repair or replace, at Sonnaxs option, each part manufactured or supplied by Sonnax, when that part is found to be defective in material or in factory workmanship, under normal use and service. The Warranty period shall extend for six (6) months from the date of sale. Defective or malfunctioning parts must be returned to Sonnax. All returns must be approved by Sonnax and clearly display the assigned return authorization number (R.A.) on the packaging. Returns must be accompanied with the purchasers copy of the original invoice to validate the date of purchase. The Warranty does not cover: Removal and replacement-labor costs Loss of time, inconvenience or other consequential damage Any Sonnax part that has been: - Subject to misuse, negligence, alteration or accident - Improperly installed in the judgement of Sonnax, so as to adversely effect its performance and reliability THIS WARRANTY IS THE ONLY WARRANTY APPLICABLE TO NEW PARTS MANUFACTURED BY SONNAX, AND IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. Sonnax does not authorize any person to create for it any other obligation or liability in connection with these parts. Sonnax shall not be liable for any incidental or consequential damage resulting from breach of Warranty.
sonnax
161
Innovative
Engineered
Tested
Buy Genuine Sonnax Parts

Automatic Drive P.O. Box 440 Bellows Falls, VT 05101-0440 U S A 800-843-2600 802-463-9722 fax: 802-463-4059 www.sonnax.com info@sonnax.com

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Quality Engineered Products

100 Chrysler 118 Foreign

132 High Performance

PRODUCT CHARTS AND LISTINGS

:Tool required for installation

Quality Engineered Products

:New Sonnax part introduced in this catalog

2001 SONNAX INDUSTRIES

:New Sonnax part soon to be available

DESIGN BY SONNAX CREATIVE DEPARTMENT

SONNAX FAMILY VALVE CHART

92835-03K, 101 92835-02K, 104 92835-03K, 101 92836-01K 105

800/843-2600 802/463-9722 fax: 802/463-4059 www.sonnax.com info@sonnax.com

SONNAX FAMILY VALVE CHART

ACC. PIN KITS

ACC. SLEEVE KITS

36428-Z & A-Z 52 36402-Z 64

73840-24, -LR & -FWD 97

Buy Buy Genu Genu iine S ne So onna nnax x Par Parts ts

2001 Sonnax Industries, Inc.

800/843-2600 802/463-9722 fax: 802/463-4059 www.sonnax.com info@sonnax.com

Valve and Bore Inspection

2001 Sonnax Industries, Inc.

800/843-2600 802/463-9722 fax: 802/463-4059 www.sonnax.com info@sonnax.com

Figure 2: 4L60-E AFL limit valve bore wear.

EXHAUST Figure 5: Measurement Tools

Figure 3: Inspect bore which controls exhaust.

2001 Sonnax Industries, Inc.

800/843-2600 802/463-9722 fax: 802/463-4059 www.sonnax.com info@sonnax.com

Figure 7: Wet Air Test

2001 Sonnax Industries, Inc.

800/843-2600 802/463-9722 fax: 802/463-4059 www.sonnax.com info@sonnax.com

Technical Information/ Diagnostic Resources

2001 Sonnax Industries, Inc.

800/843-2600 802/463-9722 fax: 802/463-4059 www.sonnax.com info@sonnax.com

Part No. 75918-01K

SONNAX PART SUMMARY

1 Sleeve 1 TV Valve 1 Reverse Valve 1 End Plug 1 Retaining Ring

2001 Sonnax Industries, Inc.

800/843-2600 802/463-9722 fax: 802/463-4059 www.sonnax.com info@sonnax.com

Part Nos. 65754-01K, -02K & -03K

Complaint Soft 1-2 shift, poor detent and up-shift control

Poor upshift quality Burned bands and clutches

Throttle Valve Plunger

Roll Pin Annular Grooves Shift Throttle Valve Orifice

Detent Orifice Identification Grooves (2 Grooves Shown)

Throttle Valve Sleeve

SONNAX PART SUMMARY

2001 Sonnax Industries, Inc.

800/843-2600 802/463-9722 fax: 802/463-4059 www.sonnax.com info@sonnax.com

Part No. 35709-01K

Spring Seat Pin

Piston with Teflon seal installed

Part No. 77700-HBK

1 Torx Plus Bit

Torx Plus Bit

2001 Sonnax Industries, Inc.

800/843-2600 802/463-9722 fax: 802/463-4059 www.sonnax.com info@sonnax.com

Part Nos. 34910-01K, -03K & -05K

Complaint High line pressure, poor line rise

Boost Valve Boost Sleeve "Factory style"

SONNAX PART SUMMARY

Part No. 34910-05K