6F35 ZIP IN

2016-07-08

: Sonnax 6F35-Zip-In 6F35-ZIP-IN 1815 file instruction uploads

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FORD 6F35
ZIP KIT ®
PART NUMBER 6F35-ZIP

QUICK GUIDE

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

installation Diagram
Main Control
Valve Body

NOTE: The components in this kit
are all related to the valve body.
It is not necessary to remove
pump for kit installation; pump
should only be removed if vacuum testing
pump locations is desired.

2
1

6b
Plastic Checkballs

1
6a*

*NOTE: These components are protected
by U.S. Patent No. 8,794,108.

1
3

CAUTION

1
5

Solenoid
Valve Body

Drill balance AFL
hole and seal with
.062" diameter plug,
peening in place.

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.
©2016 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

6F35-ZIP_Guide 06-17-16
Page 1

FORD 6F35 ZIP KIT®

Quick Guide

Zip Kit Contents & Installation Steps
Step 1 Replace 5 OE End Plugs
Place O-ring in groove, lubricate with Sonnax Slippery Stick™ O-LUBE
and roll on bench to size.

Step 4 B
lock Solenoid Pressure
Regulator Balance Port

Note: The end plug at the clutch bypass valve location is slightly different in design and the O-ring should be installed at the inboard land as
illustrated.

Drill indicated separator plate orifice with included .062" dia. drill bit.
Remove any burrs. Insert .062" dia. aluminum plug into drilled hole and
peen in place on both sides of plate. Ensure plate will still fit flush on
both castings.

Packaging Pocket 1

Packaging Pocket 4

• End Plugs (5)
• O-Rings (7) 2 extra

• Drill Bit, .062" dia.
• Aluminum Plug, .062" dia. (2) 1 extra

Step 2 Replace OE Control
Pressure Regulator Valve
Packaging Pocket 2

• Valve
• Sleeve
• Spring

Step 5 R
eplace OE Solenoid
Pressure Regulator
Valve Lineup
Remove and discard OE valve and spring. Keep outboard retainer clip
for reuse. Install Sonnax sleeve and valve as illustrated. Secure sleeve
in bore by installing included clip into sleeve groove at inboard port.
Install included spring and secure all in bore with OE retainer.
Packaging Pocket 5

Step 3 Replace TCC Regulator
Valve Bore Lineup
Remove and discard all OE components except the retainer clip. Keep
retainer clip for reuse.

Ensure that the shuttle valve between the inboard regulating

valve and end plug is installed with the blind bore facing
CAUTION
inboard and the rounded end nub facing the end plug.
Packaging Pocket 3

• Spring
• Valve
• Shuttle Valve
• End Plug
• O-Rings (2) 1 extra

• Sleeve
• Valve
• Spring
• Retainer Clip

Step 6a R
eplace OE SSA Damper
Piston
Remove and discard OE rubber-tipped damper piston. Install Sonnax
spring into Sonnax piston bore pocket. Install Sonnax damper piston,
pocket end over spring.

Step 6b Install Checkballs
Packaging Pocket 6

• Piston*
• Spring*
• Checkballs, .250" dia. (3)
*NOTE: These components are protected by Patent No. 8,794,108.

6F35-ZIP_Guide 06-17-16
Page 2

FORD 6F35
ZIP KIT ®
PART NUMBER 6F35-ZIP
6F35 Valve Body

Figure 1

INSTALLATION & TESTING BOOKLET

Technical Tips
Reprogramming
Many transmission performance complaints both prior to and after an overhaul
can be addressed by reflashing the PCM or TCM. This includes any shift and/
or converter clutch scheduling issues, shift bumps, flares, bangs, etc. Refer to OE
reflashing procedure for further information.
NOTE: The TCM on the Ford 6F35 is not part of the valve body or transmission, but located
in the engine compartment.

Solenoid Body Identification & Strategy
The solenoid body strategy is a file programmed into the PCM to control the various
solenoids to prevent shift concerns. The original solenoid body tag on the transmission case indicates the solenoid strategy and solenoid body I.D. (Figure 2). These
must match the numbers on the connector boss on the lead frame (Figure 1 & 3).

Lead Frame

Figure 2

0340920964759

Anytime a new solenoid body is installed, a new strategy file is downloaded into the
PCM with a scan tool. A replacement tag (Figure 4) must be placed on the case as
well.
NOTE: The solenoid body strategy is always 13 numeric digits. The solenoid body I.D. is a
combination of numeric digits and any letters A–F.

SOL STRATEGY

36F0B8D
SOL BODY ID

Figure 5

Clutch Apply Chart

8036001201

Gear

Identification: The original solenoid body tag on transmission
case will look like this.

Reverse

Direct

Overdrive

Drive

Figure 3

X
X

One-Way

X
X

4th
5th

Intermediate

2nd
Solenoid body identification
and strategy on lead frame.

Low/Reverse

1st
3rd

Forward

X
X

Overrunning

6th

Overrunning
Overrunning

Overrunning

*Turns off above 4mph.

Figure 6

Solenoid Apply Chart
Gear
Figure 4
374P-7G342-BA

SOLENOID BODY SERVICE INFORMATION

SSA
(VFS) NL

Reverse

SOLENOID BODY STRATEGY

2nd

36F0B8D

3rd

4th

Drive

0340920964759

5th

SSE
(on/off) NC

TCC
(VFS) NL

X
X

X
X
X*

6th
KEY: X = On

SSD
(VFS) NH

Neutral
X

Identification: The replacement solenoid body tag on
transmission case will look like this.

SSC
(VFS) NL

Park

1st

SOLENOID BODY STRATEGY
SEE SHOP MANUAL SECTION 307-31

SSB
(VFS) NH

X*
X

* = Modulating

6F35-ZIP_Booklet 06-17-16
Page 1

TIME TESTED • INDUSTRY TRUSTED

FORD 6F35 ZIP KIT®

Solenoid Body

LPC
Solenoid

SSC

TCC

SSE

Installation & Testing Booklet

Figure 7

Figure 8
Solenoid
Body I.D.
Number

SSA
SSB

Solenoid
Body
I.D. &
Strategy
Numbers

Band
Number

Solenoid
Strategy
Number

SSD

6F35 Assembled Valve Body

Figure 10

Nut
Bolts

Grommet

7
1

3
8

Trasmission
Range
Sensor

12
9

Figure 9

Solenoid Band Number

Solenoid Body Identification
& Strategy (continued)
The solenoid strategy and identification number on
the cast aluminum solenoid body (Figures 7 & 8) must
also match those on the transmission case tag and lead
frame (Figures 2, 3 & 4).
The solenoids are factory calibrated and vary in flow
rate. These solenoids can be replaced separately, but
only if the replacement solenoid has the same band
number as that which it is replacing (Figures 7 & 9).
The band number is stamped on the solenoid can, and
is the last digit, which is either a 1, 2, 3, 4 or 5.

Zip Kit Instructions
OSS

Lead Frame

1. Valve Body Removal from Case
(Figure 10)
a. Disconnect the transmission range senor.

Figure 11

Lead Frame Removal

b. Disconnect the output speed sensor (OSS).
c. Remove the main control cover grommet.
2

d. Remove the case-to-valve body nut.
e. Remove the 22 valve body-to-case bolts.

f. Remove the valve body from the transmission.

2. Disassembly

a. To remove lead frame from valve body, remove
five small screws (Figure 11).
5

06-17-16 6F35-ZIP_Booklet
Page 2

CAUTION: Be careful not to bend or twist the
lead frame or solenoid terminals during
CAUTION
removal, as damage can occur.

FORD 6F35 ZIP KIT®
b. There are 14 solenoid retaining pins (two per
solenoid) that keep the solenoids in the casting.
Handle the casting with care so these do not fall
out and allow solenoids to come out and become
mixed up (Figure 12).

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

Figure 12

Assembled Valve Body with Lead Frame Removed

c.
To remove solenoid body from valve body,
remove two bolts (Figure 12).

d. To remove separator plate from solenoid body,
remove two bolts (Figure 13).

3. Installation
Install Zip Kit parts as shown on diagram of separate
quick guide sheet included in this Zip Kit. Sonnax
recommends vacuum testing critical wear areas not
covered by this kit to determine whether additional
Sonnax parts are required (see page 4 & 5).

Solenoid
Retaining
Pins

4. Reassembly
NOTE: OE checkballs often damage the separator
plate (Figure 13), preventing proper sealing.
Replace the separator plate if necessary,
available through Ford (P/N DV6Z-7Z490-B).

Separator Plate

Figure 13

Separator Plate Removal

Figure 14

a. Bolt separator plate to solenoid body using two
bolts. Torque to 89 in-lb (Figure 14).
b. Bolt solenoid body to valve body with two bolts.
Torque to 89 in-lb (Figure 12).
c.
Attach lead frame to solenoid body assembly
using five small screws (Figure 11).

5. Valve Body Reinstall into Case
(Figure 10)
a. Install the 22 valve body-to-case bolts. Torque to
89 in-lb in the sequence indicated.
b. Install case-to-valve body nut and tighten to 89
in-lb.
c. Install the main control cover grommet.
d. Reconnect the output speed sendor (OSS).
e. Reconnect the transmission range sensor.
2

6F35-ZIP_Booklet 06-17-16
Page 3

TIME TESTED • INDUSTRY TRUSTED

FORD 6F35 ZIP KIT®

Installation & Testing Booklet

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.

Main Control Valve Body • Front
*Note: Plug bore opening with
thumb when vacuum testing
end plug ports.

Direct (3-5-R) Clutch
Regulator Valve
• Burnt 3-5 Reverse clutch
• Delayed Reverse
• 3rd & 5th Shift complaints
• 2-3 & 4-5 Shift flare

Control Pressure
Regulator Valve

*Plug port
on back

• Harsh shifts; CPC codes
• Bump up/down shifts
• Erratic shift quality
Replace with Sonnax Part No.
144740-04K

*Plug port
on back

Forward (1-2-3-4)
Clutch Regulator Valve
• Burnt 1-2-3-4 clutch
• Delayed Forward
• 1-2-3-4 Shift complaints

• Burnt 1-2-3-4 clutch
• Delayed Forward
• 1-2-3-4 Shift complaints
Replace with Sonnax
Part No. 144740-21
Requires F-144740-TL21 & VB-FIX

Low Reverse/Overdrive (4-5-6) Clutch
Regulator Valve
• Burnt L/R & 4-5-6 clutch
• Delayed Reverse
• 4-5-6 Shift complaints
• 3-4 Shift flare

Control Valve Body • Back
*Plug these ports (as
noted above) while
vacuum testing.

TCC Regulator Valve
• No TCC/slip, soft apply
• Harsh TCC apply
Replace with Sonnax Part No.
144740-19K Requires F-144740-TL19 & VB-FIX

Clutch Select Valve
• Various shift complaints
• Shift-related trouble codes
Note: Plug casting valley with foam, putty
or appropriately sized O-ring coated in
assembly lube to isolate circuit.



Note: Plug casting valley with foam, putty
or appropriately sized O-ring coated in
assembly lube to isolate circuit.

• Burnt 2-6 clutch
• 2nd & 6th Shift complaints
• 1-2 & 5-6 Shift flare

 

Forward (1-2-3-4)
Clutch Latch Valve

  

Intermediate (2-6)
Clutch Regulator Valve

Solenoid Pressure
Regulator Valve
• Harsh shifts
• No/Slipping shifts
• Low clutch pressure
Replace with Sonnax Part No.
144740A-01 Requires 144740-TL

End Plugs
• Burnt clutches/brakes
• Various shift complaints
NOTE: : Vacuum test end plugs at
outboard port while sealing bore
opening with thumb.
Replace with Sonnax Part No.
144740-03K*
NOTE: Several Locations =



Clutch Select Valve
• Various shift complaints
• Shift-related trouble codes
*Part numbers with an asterisk (*)
are included in this Zip Kit.
06-17-16 6F35-ZIP_Booklet
Page 4

FORD 6F35 ZIP KIT®

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

25
0
30
VACUUM
TEST

For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

Solenoid Valve Body
Low Reverse/Overdrive
(4-5-6) Clutch Latch Valve
• Burned L/R & overdrive clutch
• Delayed reverse
• 4-5-6 Shift complaints
• 3-4 Shift flare
Replace with Sonnax Part No.
144740-21 Requires F-144740-TL21 & VB-FIX

Test
Together

Intermediate (2-6) Clutch
Latch Valve
• Burned 2-6 clutch
• 2nd & 6th Shift complaints
• 1-2 & 5-6 Shift flare
Replace with Sonnax Part No.
144740-21 Requires F-144740-TL21 & VB-FIX

Test
Together

Direct (3-5-R) Clutch
Latch Valve
• Burned direct clutch
• Delayed reverse
• 3rd & 5th Shift complaints
• 2-3 & 4-5 Shift flare
Replace with Sonnax Part No.
144740-21 Requires F-144740-TL21 & VB-FIX

Test
Together

6F35-ZIP_Booklet 06-17-16
Page 5

TIME TESTED • INDUSTRY TRUSTED

FORD 6F35 ZIP KIT®

Installation & Testing Booklet

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

Pump Body
Pressure Regulator Valve
• Harsh/Soft shifts
• High/Low line pressure
• Burnt clutches
Replace with Sonnax Part No.
144510-03K Requires F-144510-TL3C & VB-FIX

Plug
Orifice

TCC Control Valve
• Incorrect TCC apply/release
• Inadequate lube & cooling
• Transmission overheat
• Converter codes
Replace with Sonnax Part No.
144510-07K Requires F-144510-TL7C & VB-FIX

06-17-16 6F35-ZIP_Booklet
Page 6

FORD 6F35 ZIP KIT®

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Main Control Valve Body
NOTE: Depending upon vehicle application,
the OE springs shown may not be present.

101
110
109
108
102

107

103
106
104

105

Solenoid Valve Body

203

202
201

Main Control Valve Body Descriptions

I.D. No. Description
101

Control Pressure Regulator Valve

102

TCC Regulator Valve

103

Clutch Bypass Valve

104

Solenoid Pressure Regulator Valve

105

Manual Valve

106

Low Reverse/Overdrive (4-5-6) Clutch
Regulator Valve

107

Forward (1-2-3-4) Clutch Latch Valve

108

Forward (1-2-3-4) Clutch Regulator Valve

109

Intermediate (2-6) Clutch Regulator Valve

110

Direct (3-5-R) Clutch Regulator Valve

Solenoid Valve Body Descriptions

I.D. No. Description
201

Direct (3-5-R) Clutch Latch Valve

202

Intermediate (2-6) Clutch Latch Valve

203

L/R Overdrive (4-5-6) Clutch Latch Valve

6F35-ZIP_Booklet 06-17-16
Page 7

TIME TESTED • INDUSTRY TRUSTED

FORD 6F35 ZIP KIT®

Installation & Testing Booklet

OE Exploded View
Pump Body
NOTE: Depending upon vehicle application, the OE springs shown may not be present.

301
302

Pump Body Descriptions

I.D. No.

304

Description

301

Line Pressure Relief

302

Pressure Regulator Valve

303

TCC Control Valve

304

TCC Relief Ball

303

06-17-16 6F35-ZIP_Booklet
Page 8

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