6F35 ZIP IN
2017-07-24
: Sonnax 6F35-Zip-In 6F35-ZIP-IN 3686 instructions part uploads
Open the PDF directly: View PDF 
.
Page Count: 10
PART NUMBER 6F35-ZIP QUICK GUIDE
©2017 Sonnax Industries, Inc. 6F35-ZIP_Guide_C 07-24-17
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 specic complaints which are beyond the
scope of this kit.
3
5
2
1
1
1
1
1
Main Control
Valve Body
6b
Plastic Checkballs
6a
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.
Drill solenoid pressure regulator
balance hole and seal with .062"
diameter plug, peening in place.
4
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 different 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
Step Block Solenoid Pressure
Regulator Balance Port
Drill indicated separator plate orice 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
1
2
3
4
Step Replace OE Solenoid
Pressure Regulator
Valve Lineup
Ensure Sonnax retainer clip is fully seated
in the sleeve groove after installation.
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 Accumulator
Piston
Remove and discard OE rubber-tipped damper piston. Install Sonnax
spring into Sonnax piston bore pocket. Install Sonnax accumulator
piston, pocket end over spring.
NOTE: OE accumulator pistons should be ush or
approximately .030" lower than the casting surface.
It is common for the rubber insert to lose tension.
Step Install Checkballs
Packaging Pocket 6
• Piston
• Spring
• Checkballs, .250" dia. (3)
5
6a
6b
Zip Kit Contents & Installation Steps
The parts listed here may be protected
by patent number 8,794,108.
©2017 Sonnax Industries, Inc. 6F35-ZIP_Guide_C 07-24-17
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 reashing the PCM or TCM. is includes any shift and/
or converter clutch scheduling issues, shift bumps, ares, bangs, etc. Refer to OE
reashing 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 Identication & 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 ID (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 ID 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
Identication: 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
Identication: The replacement solenoid body tag on
transmission case will look like this.
Figure 3
Solenoid body identication
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
©2017 Sonnax Industries, Inc. 6F35-ZIP_Booklet_C 07-24-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
FORD 6F35 ZIP KIT® Installation & Testing Booklet
07-24-17 6F35-ZIP_Booklet_C ©2017 Sonnax Industries, Inc.
Page 2 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
TIME TESTED • INDUSTRY TRUSTED
Solenoid Body Identication
& Strategy (continued)
e solenoid strategy and identication 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.
Figure 7
LPC
Solenoid SSC TCC SSE SSA
SSB
Solenoid Body
SSD
Band
Number
Figure 8
Solenoid
Strategy
Number
Solenoid
Body ID
Number
Figure 9
Solenoid Band Number
Figure 10
6F35 Assembled Valve Body
Lead Frame
OSS
Trasmission
Range
Sensor
4
1
3
1
2
5
9
8
7
6
11
12
10
13
16
19
14
17
20
15
18
21
22
Nut
Grommet
Bolts
Figure 11
Lead Frame Removal
1
2
3
5
4
Solenoid
Body ID &
Strategy
Numbers
FORD 6F35 ZIP KIT® Installation & Testing Booklet
©2017 Sonnax Industries, Inc. 6F35-ZIP_Booklet_C 07-24-17
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 14).
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
1
2
Assembled Valve Body with Lead Frame Removed
Solenoid
Retaining
Pins
Figure 14
Separator Plate Removal
2
1
Figure 13
Separator Plate
FORD 6F35 ZIP KIT® Installation & Testing Booklet
07-24-17 6F35-ZIP_Booklet_C ©2017 Sonnax Industries, Inc.
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
* Part numbers with an asterisk (*)
are included in this Zip Kit.
Main Control Valve Body • Back
Plug these ports
(as noted above)
while vacuum testing.
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*
= Several Locations
Note: Plug casting valley with foam, putty
or appropriately sized O-ring coated in
assembly lube to isolate circuit.
TCC Regulator Valve
• No lockup
• TCC slip or harsh 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/Overdrive
(4-5-6) Clutch
Regulator Valve
• Burnt Low Reverse & Overdrive 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.
Intermediate (2-6)
Clutch Regulator Valve
• Burnt 2-6 clutch
• 2nd & 6th Shift complaints
• 1-2 & 5-6 Shift are
Forward (1-2-3-4)
Clutch Regulator Valve
• Burnt 1-2-3-4 clutch
• Delayed Forward
• 1-2-3-4 Shift complaints
Clutch Select Valve
• Various shift complaints
• Shift-related trouble codes
Test: Invert OE dampener piston and
test off center of the rubber tip.
FORD 6F35 ZIP KIT® Installation & Testing Booklet
©2017 Sonnax Industries, Inc. 6F35-ZIP_Booklet_C 07-24-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5
TIME TESTED • INDUSTRY TRUSTED
Solenoid Valve Body
For specic vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.
20
25
15
0
10
5
30
VACUUM
TEST
Test
Together
Direct (3-5-R) Clutch
Latch Valve
• Burnt 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
• Burnt 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
• Burnt Low Reverse & 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
07-24-17 6F35-ZIP_Booklet_C ©2017 Sonnax Industries, Inc.
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 specic vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.
Pump Body
20
25
15
0
10
5
30
VACUUM
TEST
Plug
Orice
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
©2017 Sonnax Industries, Inc. 6F35-ZIP_Booklet_C 07-24-17
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 Low Reverse/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
07-24-17 6F35-ZIP_Booklet_C ©2017 Sonnax Industries, Inc.
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
