6F35 ZIP IN

2016-07-08

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

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PART NUMBER 6F35-ZIP QUICK GUIDE

*NOTE: These components are protected

by U.S. Patent No. 8,794,108.

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

FORD 6F35

ZIP KIT®

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

installation Diagram

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.

Main Control

Valve Body

Plastic Checkballs

6a*

Drill balance AFL

hole and seal with

.062" diameter plug,

peening in place.

Solenoid

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.

CAUTIONCAUTION

FORD 6F35 ZIP KIT® Quick Guide

Step Replace 5 OE End Plugs

Place O-ring in groove, lubricate with Sonnax Slippery Stick™ O-LUBE

and roll on bench to size.

Note: The end plug at the clutch bypass valve location is slightly differ-

ent in design and the O-ring should be installed at the inboard land as

illustrated.

Packaging Pocket 1

• End Plugs (5)

• O-Rings (7) 2 extra

Step Replace OE Control

Pressure Regulator Valve

Packaging Pocket 2

• Valve

• Sleeve

• Spring

Step 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

inboard and the rounded end nub facing the end plug.

Packaging Pocket 3

• Spring

• Valve

• Shuttle Valve

• End Plug

• O-Rings (2) 1 extra

CAUTIONCAUTION

Step Block Solenoid Pressure

Regulator Balance Port

Drill indicated separator plate orice 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 t ush on

both castings.

Packaging Pocket 4

• Drill Bit, .062" dia.

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

Step Replace 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

• Sleeve

• Valve

• Spring

• Retainer Clip

Step Replace 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 Install Checkballs

Packaging Pocket 6

• Piston*

• Spring*

• Checkballs, .250" dia. (3)

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

Zip Kit Contents & Installation Steps

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

Technical Tips

Reprogramming

Many transmission performance complaints both prior to and after an overhaul

can be addressed by reashing the PCM or TCM. is includes any shift and/

or converter clutch scheduling issues, shift bumps, ares, bangs, etc. Refer to OE

reashing 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 Identication & Strategy

e solenoid body strategy is a le programmed into the PCM to control the various

solenoids to prevent shift concerns. e original solenoid body tag on the transmis-

sion case indicates the solenoid strategy and solenoid body I.D. (Figure 2). ese

must match the numbers on the connector boss on the lead frame (Figure 1 & 3).

Anytime a new solenoid body is installed, a new strategy le 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.

Figure 1

6F35 Valve Body

Lead Frame

Figure 2

0340920964759

SOL STRATEGY

36F0B8D

SOL BODY ID

8036001201

Identication: The original solenoid body tag on transmission

case will look like this.

Figure 4

374P-7G342-BA

SOLENOID BODY SERVICE INFORMATION

0340920964759

SOLENOID BODY STRATEGY

36F0B8D

SOLENOID BODY STRATEGY

SEE SHOP MANUAL SECTION 307-31

Identication: The replacement solenoid body tag on

transmission case will look like this.

Figure 3

Solenoid body identication

and strategy on lead frame.

Clutch Apply Chart

Gear Direct Overdrive Forward Low/Reverse Intermediate One-Way

Reverse X X

Drive

1st

X X* X

2nd

X X Overrunning

3rd

X X Overrunning

4th

X X Overrunning

5th

X X Overrunning

6th

X X Overrunning

Figure 5

*Turns off above 4mph.

Solenoid Apply Chart

Gear SSA

(VFS) NL

SSB

(VFS) NH

SSC

(VFS) NL

SSD

(VFS) NH

SSE

(on/off) NC

TCC

(VFS) NL

Park X X

Reverse X X

Neutral X X

Drive

1st

X X X

2nd

X X X

3rd

X X X

4th

X X*

5th

X X*

6th

X X*

Figure 6

KEY: X = On * = Modulating

FORD 6F35

ZIP KIT®

PART NUMBER 6F35-ZIP INSTALLATION & TESTING BOOKLET

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

FORD 6F35 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Solenoid Body Identication

& Strategy (continued)

e solenoid strategy and identication 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).

e solenoids are factory calibrated and vary in ow

rate. ese 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).

e 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

1. Valve Body Removal from Case

(Figure 10)

a. Disconnect the transmission range senor.

b. Disconnect the output speed sensor (OSS).

c. Remove the main control cover grommet.

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

ve small screws (Figure 11).

CAUTION: Be careful not to bend or twist the

lead frame or solenoid terminals during

removal, as damage can occur.

CAUTIONCAUTION

Figure 7

LPC

Solenoid SSC TCC SSE SSA

SSB

Solenoid Body

SSD

Band

Number

Figure 8

Solenoid

Strategy

Number

Solenoid

Body I.D.

Number

Figure 9

Solenoid Band Number

Figure 10

6F35 Assembled Valve Body

Lead Frame

OSS

Trasmission

Range

Sensor

Nut

Grommet

Bolts

Figure 11

Lead Frame Removal

Solenoid

Body

I.D. &

Strategy

Numbers

FORD 6F35 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

b. ere 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).

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).

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).

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 ve 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.

Figure 12

Assembled Valve Body with Lead Frame Removed

Solenoid

Retaining

Pins

Figure 14

Separator Plate Removal

Figure 13

Separator Plate

FORD 6F35 ZIP KIT® Installation & Testing Booklet

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

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.

Main Control Valve Body • Front

Forward (1-2-3-4)

Clutch Regulator Valve

• Burnt 1-2-3-4 clutch

• Delayed Forward

• 1-2-3-4 Shift complaints

Note: Plug casting valley with foam, putty

or appropriately sized O-ring coated in

assembly lube to isolate circuit.

TCC Regulator Valve

• No TCC/slip, soft apply

• Harsh TCC apply

Replace with Sonnax Part No.

144740-19K Requires F-144740-TL19 & VB-FIX

*Plug port

on back

Control Pressure

Regulator Valve

• Harsh shifts; CPC codes

• Bump up/down shifts

• Erratic shift quality

Replace with Sonnax Part No.

144740-04K

Solenoid Pressure

Regulator Valve

• Harsh shifts

• No/Slipping shifts

• Low clutch pressure

Replace with Sonnax Part No.

144740A-01 Requires 144740-TL

* Note: Plug bore opening with

thumb when vacuum testing

end plug ports.

*Plug port

on back

Direct (3-5-R) Clutch

Regulator Valve

• Burnt 3-5 Reverse clutch

• Delayed Reverse

• 3rd & 5th Shift complaints

• 2-3 & 4-5 Shift are

Forward (1-2-3-4)

Clutch Latch Valve

• 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/Over-

drive (4-5-6) Clutch

Regulator Valve

• Burnt L/R & 4-5-6 clutch

• Delayed Reverse

• 4-5-6 Shift complaints

• 3-4 Shift are

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.

Control Valve Body • Back

* Plug these ports (as

noted above) while

vacuum testing.

Intermediate (2-6)

Clutch Regulator Valve

• Burnt 2-6 clutch

• 2nd & 6th Shift complaints

• 1-2 & 5-6 Shift are

Clutch Select Valve

• Various shift complaints

• Shift-related trouble codes





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 =

* Part numbers with an asterisk (*)

are included in this Zip Kit.

FORD 6F35 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Solenoid Valve Body

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

VACUUM

TEST

Test

Together

Direct (3-5-R) Clutch

Latch Valve

• Burned direct clutch

• Delayed reverse

• 3rd & 5th Shift complaints

• 2-3 & 4-5 Shift are

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 are

Replace with Sonnax Part No.

144740-21 Requires F-144740-TL21 & VB-FIX

Test

Together

Low Reverse/Overdrive

(4-5-6) Clutch Latch Valve

• Burned L/R & overdrive clutch

• Delayed reverse

• 4-5-6 Shift complaints

• 3-4 Shift are

Replace with Sonnax Part No.

144740-21 Requires F-144740-TL21 & VB-FIX

FORD 6F35 ZIP KIT® Installation & Testing Booklet

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

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.

Pump Body

VACUUM

TEST

Plug

Orice

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

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

FORD 6F35 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

101

102

103

104

105

106

107

110

108

109

201

202

203

Solenoid Valve Body

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

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

OE Exploded View

Main Control Valve Body

NOTE: Depending upon vehicle application,

the OE springs shown may not be present.

FORD 6F35 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View

Pump Body

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

301

302

303

304

Pump Body Descriptions

I.D. No. Description

301 Line Pressure Relief

302 Pressure Regulator Valve

303 TCC Control Valve

304 TCC Relief Ball

6F35 ZIP IN

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