4R44E 5R55E ZIP IN

2017-10-30

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

Open the PDF directly: View PDF .
Page Count: 10

PART NUMBER 4R44E-5R55E-ZIP QUICK GUIDE

Separator Plate Valve Body

Plastic

Checkball

Shown in

4 places.

Balance Pressure Regulator

Drill to .055" diameter.

Line-to-Converter Release

Drill to .062" diameter.

OD Servo Apply

Drill to .072" diameter.

TCC Modication

Drill to .062" diameter. Insert

aluminum plug & peen in place.

TCC Modication

Drill to .110" diameter.

TCC Modication

Remove smallest inboard

spring through casting

port on reverse side of

valve body.

NOTE: See pages 1–2 in separate Installation

and Testing Booklet for installation tips and

additional optional modications

NOTE: Kit now

includes OE ratio

boost assembly to re-

store OE pressure curve.

NOTE: Increased

strength spring is

optional, to provide

moderately increased

pressure.

CAUTION:

See note

on page 2.

CAUTIONCAUTION

CAUTION:

See note

on page 2.

CAUTIONCAUTION

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1

FORD 4R44E, 4R55E, 5R44E, 5R55E

ZIP KIT

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

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 specic complaints which are beyond the

scope of this kit.

installation Diagram

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

Zip Kit Contents & Installation Steps

Step Replace OE Boost Assembly

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

pressure curve. Increased strength spring is optional, to provide

moderately increased pressure.

NOTE: For rmer shifts and signicantly increased line pressure, use

Sonnax increased ratio boost valve kit 37947-03K, sold separately.

Packaging Pocket 1

• Valve • Sleeve • Spring

Step Replace OE FWD Modulator Valve

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

Packaging Pocket 2

• Forward Modulator Valve • PTFE Seal

Step Replace OE Solid Plug

CAUTION: If OE end plug has relief orices and tabs, DO NOT

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 rmer

forward engagement. Remove if drive test proves forward

engagement is too harsh.

Packaging Pocket 3

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

Step 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 • O-Rings, Small (2)

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

NOTE: Reuse OE plunger valve inside plug.

Packaging Pocket 6

• End Plug • O-Rings, Medium (3) 1 Extra

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)

CAUTIONCAUTION

Step

Replace OE Checkballs, EPC

Limit Valve & Lube Orice Plug

Packaging Pocket 9

• Plastic Checkballs (4) • EPC Limit Valve, Reuse OE Spring

• Lube Orifice Plug • "L" Pins (2), Extra, for lost/missing OE pins

Step

Drill Separator Plate in

Locations & Diameters Given

Packaging Pocket 10

6A. Balance Line Orifice Modification Drill Bit

Drill Bit, .055" dia.

6B. OD Servo Apply Orifice Modification Drill Bit

Drill Bit, .072" dia.

6C. Line-to-Converter & TCC Modification

Drill Bit & Plug

NOTE: Drill two orices 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.

Step TCC Modication

NOTE: Remove smallest inboard cooler bypass spring

through idicated casting port.

Step

Replace OE Solenoid O-Rings

Packaging Pocket 11

• O-Rings, Small (4) • O-Rings, Large (4)

Extra O-Rings for End Plugs in Step 4

Packaging Pocket 12

• O-Rings, Small (2)

• O-Rings, Large (2)

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2

Valve Body Rebuild Tips

& Techniques

Bore-by-bore tips for removal, installation, options and checks of valve body

components. The detailed steps below correlate to the quick guide steps.

1. Replace OE Boost Assembly

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.

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

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.

Torque Specifications

Band Adjuster Lock Nut

35 to 45 ft-lb

Transmission Oil Pan Bolt

115 to 133 in-lb

Converter Housing-to-Case

27 to 39 ft-lb

Converter-to-Flywheel

22 to 30 ft-lb

Extension Housing-to-Case

27 to 39 ft-lb

Oil Pump-to-Cnvtr Housing

16 to 21 ft-lb

Manual Lever Inner Nut

30 to 40 ft-lb

Manual Lever Outer Nut

30 to 40 ft-lb

Oil Cooler Line-to-

Connector Nut

18 to 23 ft-lb

Oil Cooler Line-to-

Connector 5/16" Tube Nut

26 to 32 ft-lb

Transmission-to-Engine

28 to 38 ft-lb (Except 3.0L)

33 to 44 ft-lb (3.0L)

Low-Reverse Servo

Cover Bolt

106 to 124 in-lb

Center Support-to-Case Bolt

80 to 115 in-lb

Separator Plate Bolt

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)

5R55E 4WD

10.3 Qts (9.8L)

Figure 1

Solid OE

End Plug

OE End Plug

with

Relief Orifices

and Tabs

Forward Modulator Valve OE End Plugs

FORD 4R44E, 4R55E, 5R44E, 5R55E

ZIP KIT

PART NUMBER 4R44E-5R55E-ZIP INSTALLATION & TESTING BOOKLET

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1

4R44E-5R55E ZIP KIT Installation & Testing Booklet

Page 2 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

4. Replace OE End Plugs (continued)

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. e

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. e 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. e OE plug can be dicult 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.

e. ese three plugs seal shift solenoid oil. e two smaller end plugs use four

small O-rings. e larger end plug is .630" in diameter, and uses two large

O-rings.

5. Replace OE Checkballs, EPC Limit Valve

& Lube Orice Plug

Replace the four OE checkballs with the new Torlon® balls included, ensuring prop-

er location. Replace the OE lube orifice. Replace the OE EPC relief valve with the

Sonnax domed relief, reusing the OE spring. The TCC relief and the EPC relief

springs are interchangeable. Two replacement “L” pins are included in case originals

are lost or damaged.

6. Drill Separator Plates

a. Drill the pressure regulator balance orice to .055" dia. with included drill. To

prevent ashing, start the drill on one side and then nish from the opposite. It’s

always best to taper the orice holes when done with a larger drill.

b. Drill the overdrive servo apply orice to .072" dia. with included drill. is

will supply rmer 4th in 4R units and rmer 5th and 2nd in 5R units. Later

5R55E units are already this size.

c. Drill line pressure circuit to converter feed orice in the plate to .062" dia.

with included drill. Late-model 5R55E units are already this size. Drill the

indicated converter clutch orice to .062" dia., then insert the included .062"

aluminum plug and peen in place to close o the hole.

d. Drill the TCC exhaust hole to .110" dia. with included drill.

Figure 2

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.

Figure 3

7. TCC Modication

Remove the smallest spring from the cooler bypass

valve bore. is spring can be pulled out from the

lower side of the casting, through the slot next to the

lter inlet (Figure 3).

8. Replace OE Solenoid O-Rings

Replace small and large O-rings from the four

indicated solenoids (see Quick Guide). Lube the

O-ringed solenoid snout prior to bore installation.

4R44E-5R55E ZIP KIT Installation & Testing Booklet

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3

TIME TESTED • INDUSTRY TRUSTED

Figure 4

If there is a hole

here, use includ-

ed EPC relief tee and

OE spring. If there is

no hole here, you

must use blow-off end

plug at forward

modulator valve

(Figure 5). End plug

installs here. Figure 5

This plate and part number

does not have an EPC relief

hole (Figure 3) and must be

used with OE part # 3L5Z-

7M203-JA end plug relief. Figure 6

4R44E Plate

5R55E Plate:

has

bathtub checkball,

ahead of bolt hole.

Rebuilding Cautions

• Do not combine aftermarket parts or procedures

with this kit.

• Do not drill line-to-lube through the casting at the

pressure regulator valve.

• Do not use a stronger pressure regulator valve

spring or shim than the ones supplied.

• Do not remove springs or block reverse engagement

control valve.

Troubleshooting Tips

ese tips are not about common problems such as blown gaskets or dirty valve

bodies. ese 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.

Delayed Reverse & Forward

e separator plate must be aligned with pins. If not, the bolt threads will separate

the case from the plate, causing a line pressure leak.

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

is often occurs from pre-assembly damages, so inspect carefully before install-

ing. e 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 2nd, 1-2 Slide or Soft 2nd

Gear Starts

• 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

e solenoid regulator valve is likely out of position.

With SSB solenoid removed, the end of the casting to

edge of the long aluminum plug will measure 1.720"

when “L” pin is installed properly.

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.

Separator Plate & Relief Valve Information

4R44E-5R55E ZIP KIT Installation & Testing Booklet

Page 4 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

Troubleshooting Tips (continued)

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)

Mismatched separator plate at 5R/4R identication (Figure 6).

OD Band Failure, No Overdrive Release psi

e 3-4 shift valve may not be positioned due to a loose SSC solenoid. Bracket must

hold it in ush.

Broken Bands, No EPC Blow-Off, EPC psi Too High

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. e EPC spring bore

is often tapered, which alters spring operation. e Sonnax EPC and engagement

control kit 37947-11K (not included in this Zip Kit) addresses this problem.

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.

Low EPC Pressure & No Lockup Control

If TCC modulator valve sticks, EPC will only obtain about 65 psi.

Flare on 2-3 Shift, 4R (3-4 on 5 Speed)

e servo pin bore is worn on the intermediate servo, or the spring on the piston is

too strong.

No 3rd or 4th

e 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 ve 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

e balance spool or innermost bore for the pressure regulator is worn out.

Shift Solenoids

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

e most eective method to isolate the EPC circuit is

to perform an wet air test with uid while the body is

still bolted to the case. is can be done in the vehicle

or at the bench. A quick test adapter can be made from

an old 4R/5R EPC solenoid. e 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

while in operation. Remember, though, as operating

temperature increases, valve clearance and the ow rate

(viscosity) of ATF increase. You can duplicate hot uid

at the bench by lling the case and valve body with

solvent, then bolt up and test with the adapter.

Figure 7

Old 4R/5R

EPC Solenoid

Figure 8

“Tired” valve bodies leak at any

or all of these locations.

40-60 psi supplied to modied EPC solenoid/tool.

4R44E-5R55E ZIP KIT Installation & Testing Booklet

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5

TIME TESTED • INDUSTRY TRUSTED

Apply Component Chart

GEAR

Shifter

Position

Front Band

Intermediated

Band

Reverse Band

Coast Clutch

‘95-‘96

Coast Clutch

‘97-‘00

Direct Clutch

Forward Clutch

Front

One-Way

Clutch

Reverse

One-Way

Clutch

4R44E/

4R55E 5R55E

Drive

Coast

Drive

Coast

Reverse Reverse Reverse A A* A H OR†

1st 1st

Overdrive

A* A H OR†H OR

2nd

Overdrive

A A OR OR H OR

2nd 3rd

Overdrive

A A* A* A H OR†OR OR

3rd 4th

Overdrive

A* A* A A H OR†OR OR

4th 5th

Overdrive

A A A OR OR OR OR

Manual 2

Position

Manual 2

Position 2A A A A H OR OR OR

Manual 1

Position

Manual 1

Position 1A A A A H OR H OR

Planetary Component FRS FS RP FRS FRS FS FR FRS RP

Figure 9

A = Applied

H = Holding

OR = Overrunning

* = Applied, TCS on

† = Ineffective, TCS on

FRS = Front Sun Gear

FS = Forward Sun Gear

RP = Reverse Planet Assembly

FR = Forward Ring Gear

Apply Component Chart Key:

Solenoid Apply Chart

Transmission

Range Selector

Lever Position

Powertrain Control Module

(PCM) Gear Commanded

Shift Solenoids

SSA SSB SSC SSD/CCS

4R44E/4R55E 5R55E

Park/Neutral Park/Neutral Park/Neutral On Off Off Off

Reverse Reverse Reverse On Off Off Off

Overdrive

(TCS Off)

1 1 On Off Off Off

2 On Off On Off

2 3 On On Off Off

3 4 Off Off Off Off

4 5 Off Off On Off

Overdrive

(TCS On)

1 1 On Off Off Off

2 On Off On On*

2 3 On On Off On*

3 4 Off Off Off On

Manual 2nd 2 3 On On Off On

3A4AOff Off Off On

Manual 1st

1 1 On Off Off On

2AOn Off On On

2A* On On Off On

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.

Apply Component Chart Key:

4R44E-5R55E ZIP KIT Installation & Testing Booklet

Page 6 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

Solenoid & Bolt Locations

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

Bolt

Color Code Bolt Lengths No. Bolts

Required

Red 20mm 4

Green 30mm 1

Yellow 35mm 2

Blue 40mm 16

Orange 45mm 4

Purple 55mm 1

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" 4 Plain/Lt. Purp.

102 Pressure Regulator, Inner .412" .032" 1.135" 9.5 Lt. Green

103 Forward Modulator .236" .026" .738" 14 White

103 EPC Boost .293" .040" 1.210" 12 Orange

105 Reverse Modulator, Outer .210" .018" 1.080" 10.5 Plain

105 Reverse Modulator, Inner .210" .018" 1.080" 10.5 Plain

106 2-3/3-4 Shift .275" .030" 1.052" 13 Plain

107 1-2/2-3 Shift .284" .033" .730" 7 Lt. Purple

108 Solenoid Regulator .218" .030" .830" 8.5 Yellow

109 TCC Regulator, Inner .187" .028" .720" 12 White

20 28

16 8

17 19

24 26

Shift Solenoid B (SSB) 22–48 ohms

EPC Solenoid 3.1–5.7 ohms

Coast Clutch Solenoid

(CCS/SSD) 22–48 ohms

TCC Solenoid 8.9–16 ohms

Shift Solenoid C (SSC) 22–48 ohms Shift Solenoid A (SSA) 22–48 ohms

Bore Valve Springs O.D. Wire

Dia.

Free

Length

Coils Color

109 TCC Regulator, Outer .285" .040" .787" 9.5 Orange

109 Coast Clutch. Bottom Bore .222" .023" .840" 9.5 Red

110 TCC Modulator .238" .023" 1.230" 11.5 White/Yellow

111 Thermal Outer, Big .575" .042" 1.045" 4.5 White

111 Thermal, Middle .264" .026" 1.232" 13.5 Lt. Green

111 Inner Limit (smallest) .200" .018" .840" 12 Blue

112 3-4/4-5 Shift .280" .032" 1.162" 12 Plain

113 Throttle Downshift .263" .028" .700" 6.5 Orange

114 Manual Low .320" .032" .985" 7.5 Yellow

115 Kickdown .262" .028" .670" 7 Orange

N/A Steel EPC Relief Tee .292" .040" .982" 13.5 Plain

N/A Plastic TCC Relief Tee .292" .040" .982" 13.5 Plain

OE Spring Identification Chart

4R44E-5R55E ZIP KIT Installation & Testing Booklet

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 7

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 specic vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

VACUUM

TEST

*Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately.

Pressure Regulator Valve

• Delayed engagement due to poor converter ll

• High/Low line pressure

• Low cooler ow at idle

• Overheated converters

Replace with Sonnax Part No.

37947-05K Requires 37947-TL5

TCC Modulator Valve

• No TCC apply

• Code 1741

• Low cooler ow

• Poor converter ll & delayed engagements

• Engine stall on Forward engagement

Replace with Sonnax Part No.

37947-07K Requires 37947-TL5

Boost Valve Assembly

• Soft shifts

• Delayed Reverse

• Low line pressure

• Poor modulator control

Replace with Sonnax Part No.

37947-01K OE Ratio

37947-03K* Increased Ratio

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

To vacuum test this port: invert

valve and prop outboard with a

Torlon checkball.

4R44E-5R55E ZIP KIT Installation & Testing Booklet

Page 8 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

Valve Body Descriptions

I.D No. 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

OE & Sonnax Reinstallation Valve Body Exploded View

101

102

106

105

104

103

107

108

109

110

111

115

114

113

112

Sonnax Parts

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.

4R44E 5R55E ZIP IN

Navigation menu

Versions of this User Manual:

Views

Navigation