4R44E 5R55E ZIP IN

2017-10-30

: Sonnax 4R44E-5R55E-Zip-In 4R44E-5R55E-ZIP-IN 2172 instructions part uploads

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FORD 4R44E, 4R55E, 5R44E, 5R55E
ZIP KIT
PART NUMBER 4R44E-5R55E-ZIP

QUICK GUIDE

Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents.

installation Diagram

Separator Plate

NOTE: Kit now

includes OE ratio
boost assembly to restore OE pressure curve.

6C
6A
Balance Pressure Regulator
Drill to .055" diameter.

Line-to-Converter Release
Drill to .062" diameter.

NOTE: Increased

strength spring is
optional, to provide
moderately increased
pressure.

Valve Body
1

CAUTION:

See note
CAUTION

on page 2.

5
5
5
8
4A

Plastic
Checkball
Shown in
4 places.

CAUTION:

See note
CAUTION on page 2.

8
8

6B
6D

OD Servo Apply
Drill to .072" diameter.

TCC Modification
Drill to .110" diameter.
TCC Modification
Drill to .062" diameter. Insert
aluminum plug & peen in place.

NOTE: See pages 1–2 in separate Installation
and Testing Booklet for installation tips and
additional optional modifications

7
TCC Modification
Remove smallest inboard
spring through casting
port on reverse side of
valve body.

In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum
testing and additional repair options for higher mileage units or for repairing specific complaints which are beyond the
scope of this kit.
©2017 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

4R44E-5R55E-ZIP-Guide_C 10-26-17
Page 1

FORD 4R44E, 4R55E, 5R44E, 5R55E ZIP KIT

Quick Guide

Zip Kit Contents & Installation Steps
Step 1

Replace OE Boost Assembly

Step 5

Replace OE Checkballs, EPC
Limit Valve & Lube Orifice Plug

NOTE: Kit now includes OE ratio boost assembly to restore OE

pressure curve. Increased strength spring is optional, to provide
moderately increased pressure.

Packaging Pocket 9

• Plastic Checkballs (4) • EPC Limit Valve, Reuse OE Spring
• Lube Orifice Plug • "L" Pins (2), Extra, for lost/missing OE pins

NOTE: For firmer shifts and significantly increased line pressure, use
Sonnax increased ratio boost valve kit 37947-03K, sold separately.

Packaging Pocket 1

• Valve • Sleeve • Spring

Step 2

Replace OE FWD Modulator Valve

NOTE: Insert PTFE seal in valve groove and size in bore first.

Packaging Pocket 2

Step 6

Drill Separator Plate in
Locations & Diameters Given

Packaging Pocket 10

6A. Balance Line Orifice Modification Drill Bit
Drill Bit, .055" dia.

• Forward Modulator Valve • PTFE Seal

6B. OD Servo Apply Orifice Modification Drill Bit
Drill Bit, .072" dia.

Step 3

6C. L
ine-to-Converter & TCC Modification
Drill Bit & Plug

Replace OE Solid Plug

CAUTION: If OE end plug has relief orifices and tabs, DO NOT
CAUTION INSTALL this Sonnax O-ringed end plug and spring. Reuse OE
end plug. Reference page 1, step 3 of Installation Booklet for details.

CAUTION: Included spring is OPTIONAL and provides firmer
CAUTION forward engagement. Remove if drive test proves forward
engagement is too harsh.
Packaging Pocket 3

NOTE: Drill two orifices and install and peen plug into plate as
shown on page 1.

• Drill Bit, .062" dia.

• Aluminum Plug .062"

6D. TCC Modification Drill Bit
Drill Bit, .110" dia.

• Forward Modulator End Plug • O-Ring, Large • Spring

Step 7
Step 4

Replace OE End Plugs

4A. Reverse Modulator O-Ringed End Plug
Packaging Pocket 4

• End Plug

• O-Rings, Medium (3) 1 Extra

4B. 2-3/3-4 Shift Valve O-Ringed End Plug
Packaging Pocket 5

• End Plug

TCC Modification

NOTE: Remove smallest inboard cooler bypass spring
through idicated casting port.

Step 8

Replace OE Solenoid O-Rings

Packaging Pocket 11

• O-Rings, Small (4)

• O-Rings, Large (4)

• O-Rings, Small (2)

4C. 1-2/2-3 Shift Valve O-Ringed End Plug

Extra O-Rings for End Plugs in Step 4

NOTE: Reuse OE plunger valve inside plug.
Packaging Pocket 6

Packaging Pocket 12

• End Plug

• O-Rings, Medium (3) 1 Extra

• O-Rings, Small (2)
• O-Rings, Large (2)

4D. Converter Reg. Valve O-Ringed End Plug & Spring
Packaging Pocket 7

• End Plug • O-Ring, Large • Spring, Install only if OE is damaged
4E. O-Ringed End Plugs
Packaging Pocket 8

• End Plug, Large • O-Rings, Large (2)
• End Plugs, Small (2) • O-Rings, Small (4)
©2017 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

4R44E-5R55E-ZIP-Guide_C 10-26-17
Page 2

FORD 4R44E, 4R55E, 5R44E, 5R55E
ZIP KIT
PART NUMBER 4R44E-5R55E-ZIP

INSTALLATION & TESTING BOOKLET

Band Adjuster Lock Nut
35 to 45 ft-lb

Transmission Oil Pan Bolt
115 to 133 in-lb

Valve Body Rebuild Tips
& Techniques

Converter Housing-to-Case
27 to 39 ft-lb

Converter-to-Flywheel
22 to 30 ft-lb

Bore-by-bore tips for removal, installation, options and checks of valve body
components. The detailed steps below correlate to the quick guide steps.

Extension Housing-to-Case
27 to 39 ft-lb

Oil Pump-to-Cnvtr Housing
16 to 21 ft-lb

1. Replace OE Boost Assembly

Manual Lever Inner Nut
30 to 40 ft-lb

Manual Lever Outer Nut
30 to 40 ft-lb

Oil Cooler Line-toConnector Nut
18 to 23 ft-lb

Oil Cooler Line-toConnector 5/16" Tube Nut
26 to 32 ft-lb

Torque Specifications

Low-Reverse Servo
Transmission-to-Engine
28 to 38 ft-lb (Except 3.0L) Cover Bolt
33 to 44 ft-lb
(3.0L) 106 to 124 in-lb
Center Support-to-Case Bolt Separator Plate Bolt
80 to 115 in-lb
53 to 71 in-lb
TR Sensor
71 to 98 in-lb

Valve Body-to-Case Bolt
71 to 98 in-lb

Recommended Fluid & Capacities
Mercon V (XT-5-QM) ATF
4R44E 2WD, 2.3L
9.9 Qts (9.4L)

4R44E 2WD, 3.0L
10.0 Qts (9.5L)

4R44E 4WD
10.4 Qts (9.8L)
5R55E 2WD
10.0 Qts (9.5L)

Kit now includes an OE ratio boost assembly to restore OE pressure curve. The
increased strength spring is optional, and will provide moderately increased pressure
(approximately 5 psi in Drive and 6 psi in Reverse). For firmer shifts and significantly
increased line pressure, use Sonnax increased ratio boost valve kit 37947-03K, sold
separately. This increased ratio kit is NOT recommended for smaller 4-cylinder
applications, or if testing determines that the Sonnax EPC and engagement control
kit 37947-11K (sold separately) is necessary and installed.

2. Replace OE Forward Modulator Valve
By positioning the manual valve furthest into the bore, air pressure can be used to blow
the modulator valve out. If there is any visible wear or ridge in the bore, buff this area
with Scotch-Brite™ placed on a twisted wire and inserted into drill. Install the PTFE
seal onto the Sonnax valve. Invert the valve and push into the bore just far enough to
size the PTFE seal. After sizing the seal, install the OE forward modulator spring into
the end of the Sonnax valve and install into the bore (illustrated in Quick Guide).

3. Replace OE Solid Plug
If OE end plug has relief orifices and tabs (Figure 1), DO NOT INSTALL the
included Sonnax O-ringed end plug and spring. Reuse the OE end plug. If the
OE end plug is solid, discard and replace with the Sonnax O-ringed end plug and
optional spring if desired.

5R55E 4WD
10.3 Qts (9.8L)

Figure 1

Solid OE
End Plug
OE End Plug
with
Relief Orifices
and Tabs

Optional Step: Seal the “L” pin circuits at the forward and reverse modulator valve
bores (inboard at bores in steps 3 and 4). These locate and hold plugs which separate
and seal oil circuits. As the valves toggle, the plugs become loose and allow fluid to
pass around them. It is suggested to vacuum test the area for severe wear first (reference
page 7) to determine if refurbishing the bore is a better option. The following sealant
process requires cure time, so time must be allowed. Using Permatex® Surface Prep
Activator #24163 or a similar product, clean the middle plug and “L” pin area from
both sides and through the open bore. Air dry, then drip a small amount of Loctite®
609 or 3M #04732 sealant into the “L” pin opening. This must have a cure time to
hold properly. Epoxy is not suggested, as it is permanent. Loctite can be heated to
allow removal. To remove plugs once sealed, heat the area until the sealant melts, then
air dry. Flat stone the valve body surface and clean well to remove surface imprints.

4. Replace OE End Plugs

Forward Modulator Valve OE End Plugs

a. Most plugs require two O-rings and have a tapped hole to allow for easy
removal in the future. To install, lube the plug, slip on the O-rings and roll
the plug on a clean surface to seat the O-rings. Verify that the valves and
springs are in their original positions and install the end plugs with the tapped
hole facing out. Extra O-rings are supplied in case an O-ring is torn during
installation.
4R44E-5R55E-ZIP-Booklet_C 10-26-17
Page 1

TIME TESTED • INDUSTRY TRUSTED

4R44E-5R55E ZIP KIT

Installation & Testing Booklet

4. Replace OE End Plugs (continued)

Figure 2

b. The OE “U”-shaped retainer is used to hold the plug into the casting, and
should be inserted into the plug groove between the two O-rings. The outer
plug groove will protrude from the bore and is used to help retain the OE
solenoid bracket.
c. Remove the plug between the EPC solenoid and the 1-2/2-3 shift valve. The
plug may not come out easily after removing the “U”-shaped retainer. A rod
(.125" dia.) can be inserted into the opposite bore (113, page 7) to drive out
the plug. After the plug is removed, push the shift valve to the bottom of
the bore and retain it with a screwdriver. Install the small OE plunger valve
into the Sonnax O-ringed plug before installing into the bore. The large OE
“U”-shaped retainer should be installed with the longer leg closest to the
manual valve.
d. Pull out the “L” pin near the solenoid. The OE plug can be difficult to remove.
With a strong needle-nose pliers, turn the plug and hit it with the tip of your
pliers. Continue this until the spring drives out the plug. If the OE plug
will not come out, you must also remove the inner “L” pin retainer. You will
then have to drill an access hole to drive out the valves (Figure 2). A new
spring is supplied for the inner coast clutch valve in case the OE is damaged
during this process. Use the needle nose pliers to install the Sonnax end plug
(O-ring only) by holding the small nub. Twist while inserting the plug until
the O-ring is inboard of the “L” pin retainer port.

For bore 109 valve removal, drill .110" hole, entering
at bolt and exiting into spring pocket of bore 109.
This allows rod to drive out the valve.

e. These three plugs seal shift solenoid oil. The two smaller end plugs use four
small O-rings. The larger end plug is .630" in diameter, and uses two large
O-rings.

5. R
eplace OE Checkballs, EPC Limit Valve
& Lube Orifice Plug

7. TCC Modification

Remove the smallest spring from the cooler bypass
Replace the four OE checkballs with the new Torlon® balls included, ensuring prop- valve bore. This spring can be pulled out from the
er location. Replace the OE lube orifice. Replace the OE EPC relief valve with the lower side of the casting, through the slot next to the
Sonnax domed relief, reusing the OE spring. The TCC relief and the EPC relief filter inlet (Figure 3).
springs are interchangeable. Two replacement “L” pins are included in case originals
are lost or damaged.
8. Replace OE Solenoid O-Rings
Replace small and large O-rings from the four
indicated solenoids (see Quick Guide). Lube the
a. Drill the pressure regulator balance orifice to .055" dia. with included drill. To O-ringed solenoid snout prior to bore installation.
prevent flashing, start the drill on one side and then finish from the opposite. It’s
always best to taper the orifice holes when done with a larger drill.

6. Drill Separator Plates

b. Drill the overdrive servo apply orifice to .072" dia. with included drill. This
will supply firmer 4th in 4R units and firmer 5th and 2nd in 5R units. Later
5R55E units are already this size.

Figure 3

c. Drill line pressure circuit to converter feed orifice in the plate to .062" dia.
with included drill. Late-model 5R55E units are already this size. Drill the
indicated converter clutch orifice to .062" dia., then insert the included .062"
aluminum plug and peen in place to close off the hole.
d. Drill the TCC exhaust hole to .110" dia. with included drill.

10-26-17 4R44E-5R55E-ZIP-Booklet_C
Page 2

4R44E-5R55E ZIP KIT

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

Separator Plate & Relief Valve Information
4R44E Plate

5R55E Plate: has
If there is a hole
here, use included EPC relief tee and
OE spring. If there is
no hole here, you
must use blow-off end
plug at forward
modulator valve
End plug
(Figure 5).
installs here.

bathtub checkball,
ahead of bolt hole.

Figure 4

This plate and part number
does not have an EPC relief
hole (Figure 3) and must be
used with OE part # 3L5Z7M203-JA end plug relief.

Figure 6

Figure 5

Rebuilding Cautions
• Do not combine aftermarket parts or procedures
with this kit.

• Do not use a stronger pressure regulator valve
spring or shim than the ones supplied.

• Do not drill line-to-lube through the casting at the
pressure regulator valve.

• Do not remove springs or block reverse engagement
control valve.

Troubleshooting Tips

No 2nd, 1-2 Slide or Soft 2nd
Gear Starts
These tips are not about common problems such as blown gaskets or dirty valve
bodies. These only include valve body problems not visible during a rebuild.

No/Slow Reverse
• The SSA solenoid must be turned on, allowing flow through the solenoid, or
direct clutch will not apply until EPC rises to 20 psi. The direct clutch psi
will then slowly rise following EPC until clutch holds.
• Always install new servo pistons. Both servos are charged on the release side
in reverse.
• Inspect the center support sleeve, sealing rings and direct drum sleeve for cracks.
• Ensure the vehicle has line rise, as reverse will not engage until line is 120 psi.

• Air test the rectangular circuit five openings in from
EPC solenoid. No cross leakage should be visible!
• Look for bore wear at the forward modulation
valve (repaired by 37947-11K, not included in this
Zip Kit), This valve controls the servo apply rate.
• If the plug that lives in the middle of OE assembly
(repaired by 37947-11K, not included in this Zip Kit),
is loose and bore leaks, a poor 1-2 and/or 2-3 results.

No 2nd or 4th, Erratic Direct
Clutch, No Upshift

Delayed Reverse & Forward

The solenoid regulator valve is likely out of position.
The separator plate must be aligned with pins. If not, the bolt threads will separate With SSB solenoid removed, the end of the casting to
edge of the long aluminum plug will measure 1.720"
the case from the plate, causing a line pressure leak.
when “L” pin is installed properly.

Servo Covers Blown Out of Case
Inspect for causes of high line psi such as pressure regulator bore or boost sleeve
wear, or line booster valve stuck inboard.

Servo Rubber Separated/Blown Off
This often occurs from pre-assembly damages, so inspect carefully before installing. The rubber lip separation occurs from heat and high pressure. Both servos are
pushed toward the cover in reverse, so check for cause of high line pressure.

No Coast Clutch Pressure
• Inspect the bore plug for wear at the TCC regulator
valve. Sonnax TCC regulator sleeve kit 37947–09K
(not included in this Zip Kit) eliminates the leak
and bore plug here.
• The bore for the coast clutch shift valve wears out.
Insert the valve: no side-to-side movement should
be visible.

4R44E-5R55E-ZIP-Booklet_C 10-26-17
Page 3

TIME TESTED • INDUSTRY TRUSTED

4R44E-5R55E ZIP KIT

Installation & Testing Booklet

Troubleshooting Tips (continued)

Shift Solenoids

No Overdrive Servo Apply psi
• The coast clutch shift valve may be out of position, the bore worn severely or
the dumbbell-shaped valve (opposite bore from the TCC modulator) is not
being retained correctly.
• This “L” pin falls out of position easily.
• Timing valve may be stuck toward the end plug or the spring is not on
center, which causes it to coil bind.
• Kickdown valve may be stuck or spring missing.

No OD Servo Release
(No Overdriven 2nd in 5R & No 4th in 4R)

It is very rare to have a shift solenoid problem on these
units. It’s more common to have a loss of solenoid oil
psi due to loose end plugs.

EPC Circuit Testing
The most effective method to isolate the EPC circuit is
to perform an wet air test with fluid while the body is
still bolted to the case. This can be done in the vehicle
or at the bench. A quick test adapter can be made from
an old 4R/5R EPC solenoid. The coil housing and
valve will be removed and a plug or epoxy used to seal
the inboard circuit (Figure 7).

Supply 40-60 psi of air into the adapter. No leaks
should be visible at the locations shown in Figure 8.
Any leakage is reduction of EPC pressure and line rise
OD Band Failure, No Overdrive Release psi
The 3-4 shift valve may not be positioned due to a loose SSC solenoid. Bracket must while in operation. Remember, though, as operating
temperature increases, valve clearance and the flow rate
hold it in flush.
(viscosity) of ATF increase. You can duplicate hot fluid
Broken Bands, No EPC Blow-Off, EPC psi Too High at the bench by filling the case and valve body with
solvent, then bolt up and test with the adapter.
Relief Tee near the pressure regulator is not opening or mismatched plate without a
hole here and no relief used at forward modulator end plug. The EPC spring bore
is often tapered, which alters spring operation. The Sonnax EPC and engagement
control kit 37947-11K (not included in this Zip Kit) addresses this problem.
Mismatched separator plate at 5R/4R identification (Figure 6).

Low EPC, Soft Shifts, Slip in 3rd
Multiple EPC leakage points. Use the Sonnax EPC and engagement control kit
37947-11K (not included in this Zip Kit), which address this entire circuit. Good
maximum EPC is 125-130 psi in OD and maximum of 144 in reverse. EPC should
not drop more that 15 psi during TCC apply.
Old 4R/5R
EPC Solenoid

Low EPC Pressure & No Lockup Control
If TCC modulator valve sticks, EPC will only obtain about 65 psi.

Figure 7

Flare on 2-3 Shift, 4R (3-4 on 5 Speed)
The servo pin bore is worn on the intermediate servo, or the spring on the piston is
too strong.

40-60 psi supplied to modified EPC solenoid/tool.

No 3rd or 4th
The 2-3 shift valve spring is missing or installed wrong. Also, the 1-2 shift valve
should stroke during wet air test (WAT) at the rectangular circuit five openings in
from EPC solenoid.

TCC Applied Prematurely, Harsh Shifts
If the solenoid is restricted or grounded, the TCC valve can stroke and apply the
converter clutch.

Poor Converter Charge, Delayed Engagements
The balance spool or innermost bore for the pressure regulator is worn out.

10-26-17 4R44E-5R55E-ZIP-Booklet_C
Page 4

“Tired” valve bodies leak at any
or all of these locations.

Figure 8

4R44E-5R55E ZIP KIT

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

2nd

Overdrive

2nd

3rd

Overdrive

3rd

4th

Overdrive

4th

5th

Overdrive

Manual 2
Position

Manual 1
Position

Planetary Component

A
A*

A
A

FRS

OR†

†

A*
A

Coast

Overdrive

Drive

1st

OR†

FRS

Apply Component Chart Key:
A = Applied
H = Holding
OR = Overrunning

Reverse
One-Way
Clutch

Coast

1st

Front
One-Way
Clutch
Drive

Reverse

Forward Clutch

Reverse

Direct Clutch

Reverse

Coast Clutch
‘97-‘00

Shifter
Position

Coast Clutch
‘95-‘96

5R55E

Reverse Band

4R44E/
4R55E

Front Band

GEAR

Intermediated
Band

Apply Component Chart

RP
Figure 9

FS = Forward Sun Gear
RP = Reverse Planet Assembly
FR = Forward Ring Gear

* = Applied, TCS on
†
= Ineffective, TCS on
FRS = Front Sun Gear

Solenoid Apply Chart
Powertrain Control Module
(PCM) Gear Commanded

Transmission
Range Selector
Lever Position

4R44E/4R55E

5R55E

Park/Neutral

Reverse

Reverse
1

Overdrive
(TCS Off)

Overdrive
(TCS On)

Manual 2nd

Shift Solenoids
SSA

SSB

SSC

SSD/CCS

Park/Neutral

Off

Reverse

Off

On*

Off

On*

Off

1
Manual 1st

1
2

2 A*

Apply Component Chart Key:

Figure 10

A = When a manual pull-in occurs above calibrated speed, the transmission will not downshift
until the vehicle speed drops below this calibrated speed.
* = Model and calibration dependent.

4R44E-5R55E-ZIP-Booklet_C 10-26-17
Page 5

TIME TESTED • INDUSTRY TRUSTED

4R44E-5R55E ZIP KIT

Installation & Testing Booklet

Solenoid & Bolt Locations

Bolt
Color Code

Bolt Lengths

No. Bolts
Required

Red

20mm

Green

30mm

Yellow

35mm

Blue

40mm

Orange

45mm

Purple

55mm

Install bolts in sequence indicated by numbers. Colors indicate bolt lengths, see chart for details.

Coast Clutch Solenoid
(CCS/SSD) 22–48 ohms

Shift Solenoid B (SSB) 22–48 ohms
EPC Solenoid 3.1–5.7 ohms

TCC Solenoid 8.9–16 ohms

13
23
16

8
4

12
20

21
15

10
18

27
22

Shift Solenoid C (SSC) 22–48 ohms

Shift Solenoid A (SSA) 22–48 ohms

OE Spring Identification Chart
Bore Valve Springs

O.D.

Wire
Dia.

Free
Length

Coils

Color

101

Forward Control

.338" .032"

.665"-.775"

6.5

White

102

Pressure Regulator, Outer

.745" .055"

1.065"

Plain/Lt. Purp.

Bore Valve Springs

O.D.

Wire
Dia.

Free
Length

Coils

Color
Orange

109

TCC Regulator, Outer

.285" .040"

.787"

9.5

109

Coast Clutch. Bottom Bore

.222" .023"

.840"

9.5

Red

110

TCC Modulator

.238" .023"

1.230"

11.5

White/Yellow

102

Pressure Regulator, Inner

.412" .032"

1.135"

9.5

Lt. Green

111

Thermal Outer, Big

.575" .042"

1.045"

4.5

White

103

Forward Modulator

.236" .026"

.738"

White

111

Thermal, Middle

.264" .026"

1.232"

13.5

Lt. Green

103

EPC Boost

.293" .040"

1.210"

Orange

111

Inner Limit (smallest)

.200" .018"

.840"

Blue

105

Reverse Modulator, Outer

.210" .018"

1.080"

10.5

Plain

112

3-4/4-5 Shift

.280" .032"

1.162"

Plain
Orange

105

Reverse Modulator, Inner

.210" .018"

1.080"

10.5

Plain

113

Throttle Downshift

.263" .028"

.700"

6.5

106

2-3/3-4 Shift

.275" .030"

1.052"

Plain

114

Manual Low

.320" .032"

.985"

7.5

Yellow

107

1-2/2-3 Shift

.284" .033"

.730"

Lt. Purple

115

Kickdown

.262" .028"

.670"

Orange

108

Solenoid Regulator

.218" .030"

.830"

8.5

Yellow

N/A

Steel EPC Relief Tee

.292" .040"

.982"

13.5

Plain

109

TCC Regulator, Inner

.187" .028"

.720"

White

N/A

Plastic TCC Relief Tee

.292" .040"

.982"

13.5

Plain

10-26-17 4R44E-5R55E-ZIP-Booklet_C
Page 6

4R44E-5R55E ZIP KIT

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

Critical Wear Areas & Vacuum Test Locations
NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed
to with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear and Sonnax parts noted for replacement.
For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

0
30
VACUUM
TEST

Boost Valve Assembly
• Soft shifts
• Delayed Reverse
• Low line pressure
• Poor modulator control

Pressure Regulator Valve
• Delayed engagement due to poor converter fill
• High/Low line pressure
• Low cooler flow at idle
• Overheated converters

Replace with Sonnax Part No.
37947-01K OE Ratio
37947-03K* Increased Ratio

Replace with Sonnax Part No.
37947-05K Requires 37947-TL5

EPC Boost Valve,
Forward Modulator Valve
& Reverse Modulator Valve
• Poor shift quality
• Delayed Forward/no Reverse
• 2nd Gear starts
Replace with Sonnax Part No.
37947-11K Requires 37947-TL11

TCC Modulator Valve
• No TCC apply
• Code 1741
• Low cooler flow
• Poor converter fill & delayed engagements
• Engine stall on Forward engagement

To vacuum test this port: invert
valve and prop outboard with a
Torlon checkball.

Replace with Sonnax Part No.
37947-07K Requires 37947-TL5
*Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately.

4R44E-5R55E-ZIP-Booklet_C 10-26-17
Page 7

TIME TESTED • INDUSTRY TRUSTED

4R44E-5R55E ZIP KIT

Installation & Testing Booklet

OE & Sonnax Reinstallation Valve Body Exploded View
Sonnax Parts

Valve Body Descriptions

I.D No.

102

Description

101

Forward Engagement
Control Valve

102

Boost Valve Assembly
& Pressure Regulator Valve

103

EPC Boost Valve
& Forward Modulator Valve

104

Manual Valve

105

Reverse Modulation Valves

106

2-3 or 3-4 Shift Valve

107

1-2 or 2-3 Shift Valve

108

Solenoid Regulator Valve

109

Coast Clutch Valve
& Converter Regulator Valve

110

Converter Clutch
Modulator Valve

111

Cooler Limit Valve, Bypass Valve
& Thermostat Bypass Valve

112

3-4 or 1-2 & 4-5 Shift Valve

113

Throttle Downshift Control Valve

114

Manual Low Valve

115

Kick Downshift Control Valve

103

NOTE: Sonnax replacement
parts are boxed and in blue
in this diagram.
There are six “L” pins in this
OE valve body. Sonnax gives
you two new “L” pins in this
Zip Kit to replace any that
may be damaged.

104
101

105

115
106

114
113

107
108
112
109

111

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Page 8

110

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