6F50 ZIP IN

2015-04-24

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FORD 6F50, 6F55
ZIP KIT ®
PART NUMBER 6F50-ZIP

QUICK GUIDE

Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents.
CAUTION: Ensure shuttle valve is
installed with blind bore facing
inboard and rounded, closed
CAUTION end facing the end plug.

installation Diagram
6F50 Upper
Valve Body

1
1

2
1

6

Replace six
OE checkballs

3

1

1
6F50 Lower
Valve Body

1
CAUTION: FORD TSB 11-12-10
recommends removing this check
ball in some applications, replacCAUTION ing both separator plates and
reprogramming the PCM with
latest updates to prevent slip sensation or
sluggish acceleration from a stop.

6F50 Separator Plate

4
5

1

NOTE: Drill and
aluminum plugs for
this step not shown.

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.
©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

6F50-ZIP-Guide 04-24-15
Page 1

FORD 6F50, 6F55 ZIP KIT®

Quick Guide

Zip Kit Contents & Installation Steps
Step	 1 Replace Seven OE
End Plugs
Place O-ring into end plug groove. Lubricate with Sonnax Slippery
Stick™ O-LUBE and roll on bench to size.
Packaging Pocket 1

•	End Plugs (7) • O-Rings (11) 4 extra

Step	 4 R
 eplace OE Solenoid
Pressure Regulator
Valve Lineup
Remove and discard OE valve and spring. Keep outboard OE retainer
for reuse. Install Sonnax sleeve and valve as illustrated. Secure sleeve
into bore by installing Sonnax clip into sleeve groove at inboard port.
Install Sonnax spring and secure all components into the bore with
OE retainer.
Packaging Pocket 4

Step	 2 Replace OE Isolator
Valve & Spring
Remove and discard all OE components except the end clip. Save OE
end clip for reuse. Place one O-ring into plug groove and one O-ring
into isolator valve goove. Lubricate with Sonnax Slippery Stick O-LUBE
and roll on bench to size.
Packaging Pocket 2

•	End Plug

• Valve

• Spring

• O-Rings (3) 1 extra

•	Sleeve • Valve

• Spring

• Clip

Step	 5 B
 lock Solenoid Pressure
Regulator Balance Port
Drill indicated separator plate orifice with included .062" diameter drill.
Remove any burrs. Insert .062" diameter aluminum plug into drilled
hole and peen in place on both sides of plate. Ensure plate will sit
flush on both castings.
Packaging Pocket 5

•	Drill (.062" dia.) • Aluminum Plugs (2)

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

CAUTION: Ensure shuttle valve is installed with blind bore
facing inboard and rounded, closed end facing the end plug.
CAUTION

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

Step	 6 Replace OE Checkballs
	
	
	

CAUTION: OE valve body may contain 7 checkballs. Reference
Ford TSB 11-12-10 for recommended removal of one check
ball and replacement of separator plates for some vehicles.
CAUTION
CAUTION

Packaging Pocket 6

•	Checkballs (7)

PackagingCAUTION
Pocket 3

1 extra

1 extra

• Shuttle Valve

©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

6F50-ZIP-Guide 04-24-15
Page 2

FORD 6F50, 6F55
ZIP KIT ®
PART NUMBER 6F50-ZIP
6F50 Valve Body

Figure 1

INSTALLATION & TESTING BOOKLET

6F50 Valve Body ID & Tech Tips
Reprogramming
Many transmission performance concerns both prior to and after an overhaul can
be addressed by reflashing or reprogramming the PCM. Refer to OE reflashing
procedures.

Part Updates
Lead Frame

Ford has made numerous part updates to deal with drivability complaints, including changes to the range sensor, TSS and OSS. Ensure the latest updates are made.

Solenoid Body Identification & Strategy
Figure 2

1420710687754
SOL 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 lead frame attached to the valve body (Figure 3).

06D598C
SOL BODY ID

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.

6053001903

NOTE: The solenoid strategy is always 13 numeric digit. The solenoid body I.D. is a combination of numeric digits and any letters A–F.

Identification: The original solenoid body tag on transmission
case will look like this.
Figure 5

Clutch Apply Chart
Figure 3

Gear

Drive

1st
2nd
3rd
4th
5th
6th
Reverse

Direct
Clutch

Overdrive
Clutch

X
X
X
X

X

Forward
Clutch (Brakes)

Low/Reverse
Clutch (Brake)

X
X
X
X

X

Intermediate
Clutch (Brake)
X

X

X

Figure 4
7T4P-72369-AE

SOLENOID BODY SERVICE INFORMATION

1420710687754

SOLENOID BODY STRATEGY

06D598C

SOLENOID BODY STRATEGY

PCM
Commanded
Gear
Park
Reverse
Neutral
1st
2nd
3rd
4th
5th
6th
Low

KEY: X = On/Applied

©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

Figure 6
Shift Solenoid

SSA
(VFS) NL

Drive

Solenoid Body I.D.

X
Overrunning
Overrunning
Overrunning
Overrunning
Overrunning

X

Solenoid Apply Chart
Solenoid Strategy on Lead Frame 

One-Way

SSB
(VFS) NH

SSC
(VFS) NL

SSD
(VFS) NH

X

X
X
X
X

X

X
X
X

X

*
*
X
X

SSE
(on/off) NC
X
X
X*
X*

X
X
X

TCC
(VFS) NL

on/off
on/off
on/off

X
*

X*

* = Modulating

6F50-ZIP-Booklet 04-24-15
Page 1

FORD 6F50, 6F55 ZIP KIT®

TIME TESTED • INDUSTRY TRUSTED

6F50 Solenoid Body

Installation & Testing Booklet

1. Valve Body Removal from Case

Figure 7

2

11

5

8

(Figure 7)
a. D
 isconnect transmission range sensor.
b. Disconnect output speed sensor (OSS).
c. Disconnect turbine shaft speed sensor (TSS).
d. Remove 11 bolts and solenoid body. Handle
solenoid body with care to prevent damage.

9

1
4

6

10

2. Disassembly (Figures 9 & 10)

7

3

Transmission
Range Sensor
Output Speed
Sensor (OSS)

Turbine Shaft Speed
Sensor (TSS)

6F50 Disassembly & Reassembly Bolts
Bolt Color Code

Figure 8

Bolt Length

Purple

62mm

Orange

35mm

Green

42mm

Blue

62mm

Red

95mm

Yellow

80mm

a. Remove the solenoid filter plate (Figure 9) from
the back of the solenoid body. Discard and
replace as the seals will leak if re-used.
b. Remove the 10 (blue) 62mm bolts, transmission
range sensor detent spring and main control
valve body (Figure 10).
c. Remove the three (orange) 35mm bolts and
seven (purple) 62mm bolts to disassemble the
valve body (Figure 10).

3. Installation

Torque

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 3 and 4).

106 in-lb

4. Separator Plate Update

6F50 Filter Plate

Figure 9

Reference Ford TSB 11-9-11. Some vehicles 2009–
2011 using MERCON LV (indicated on dipstick)
require a separator plate and checkball update to
eliminate driveability issues.

5. Reassembly
Install the three (orange) 35mm bolts and seven
(purple) 62mm bolts (Figures 8 and 10). Torque to
106 in-lb.

6. Valve Body Reinstall to Case
Figure 10

6F50 Solenoid Body
1

2

10

7

b. Install a new solenoid filter plate (Figure 9).
c. Install solenoid body and secure with 11 bolts
(Figure 7). Hand tighten, then tighten in the
sequence shown to 106 lb-in.
d. Reconnect transmission range sensor.
e. Reconnect output speed sensor (OSS).
f. Reconnect turbine shaft speed sensor (TSS).

8

9

5

04-24-15 6F50-ZIP-Booklet
Page 2

a. Install valve body into transmission using 10 (blue)
62mm bolts. Hand tighten first, then tighten in
indicated sequence to 106 lb-in (Figure 10).

3

4

6

©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

FORD 6F50, 6F55 ZIP KIT®

TIME TESTED • INDUSTRY TRUSTED

Critical Wear Areas & Vacuum Test Locations

20

15

10

25

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.

5

0
30
VACUUM
TEST

Upper Valve Body • 6F50 Shown
Pressure Regulator
Valve

Direct Clutch Regulator Valve
•	Burnt direct clutch	
•	3rd & 5th Shift complaints
•	Delayed Reverse		
•	2-3 & 4-5 Shift flare
Replace with Sonnax Part No.
124740-26K (1.35 Ratio) Requires F-124740-TL26 & VB-FIX
124740-21K (1.83 Ratio) Requires F-124740-TL21 & VB-FIX

•	High/Low line pressure
•	Slipping/Burnt clutches
•	Harsh/Soft shifts/apply
•	Transmission overheat
•	Low/No cooler/lube flow
Replace with Sonnax Part No.
124740-12K Requires F-124740-TL12 & VB-FIX

Plug port
on back.

Isolator Valve



Intermediate
Clutch Regulator
& Gain Valve

TCC Control Valve



•	Burnt intermediate clutch
•	2nd & 6th Shift complaints
•	1-2 & 5-6 Shift flare
Replace with Sonnax Part No.
124740-17K Requires
F-124740-TL17 & VB-FIX

•	Incorrect TCC apply/release
•	Transmission overheat
•	Low/No cooler/lube flow
Replace with Sonnax Part No.
124740-14K Requires
F-124740-TL14 & VB-FIX



Plug port
on back.



TCC Regulator
Apply Valve

Multiplex Manual
Valve
•	Various shift complaints
•	Shift related trouble codes



•	No TCC/slip, soft apply
•	Harsh TCC apply
Replace with Sonnax Part No.
124740-24K Requires
F-124740-TL24 & VB-FIX

•	Low line pressure
•	Slipping/Burnt clutches
•	Soft shifts/apply
Replace with Sonnax Part Nos.
124740-16 (Spring Only)
124740-03K (Isolator Valve Kit)*

Multiplex Shift Valve

L/R Overdrive Clutch
Regulator Valve
•	Burnt L/R and/or overdrive clutch
•	4-5-6 Shift complaints
•	Delayed Reverse
•	3-4 Shift flare

Plug port
on back.

Plug port
on back.



•	Various shift complaints
•	Shift related trouble codes

O-Ringed End Plug Kit
•	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.
124740-02K*
NOTE: Several Locations =



©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

*Part numbers with an asterisk (*) are included in this Zip Kit.

6F50-ZIP-Booklet 04-24-15
Page 3

TIME TESTED • INDUSTRY TRUSTED

FORD 6F50, 6F55 ZIP KIT®

Installation & Testing Booklet

Critical Wear Areas & Vacuum Test Locations

20

15

10

25

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.

5

0
30
VACUUM
TEST

Lower Valve Body • 6F50 Shown

Direct Clutch Latch Valve

Plug port
on back.

•	Burnt Direct clutch
•	Delayed Reverse
•	3rd & 5th Shift complaints
•	2-3 & 4-5 Shift flare
Replace with Sonnax Part No.
144740-23 Requires F-144740-TL22 & VB-FIX

Solenoid Pressure
Regulator Valve
•	Harsh shifts	
•	Low clutch pressure
•	No/Slipping shifts
•	Solenoid cores
Replace with Sonnax Part No.
124740-01 Requires
F-104740-TL12 & VB-FIX

L/R Overdrive Clutch
Latch Valve

Forward Clutch
Latch Valve
Plug port
on back.

•	Burnt forward clutch
•	Delayed forward
•	1-2-3-4 Shift complaints
Replace with Sonnax
Part No. 144740-23
Requires F-144740-TL22 & VB-FIX

Plug port
on back.

•	Burnt overdrive clutch
•	4-5-6 Shift complaints
•	3-4 Flare
Replace with Sonnax Part No.
144740-23 Requires
F-144740-TL22 & VB-FIX

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

04-24-15 6F50-ZIP-Booklet
Page 4

©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

FORD 6F50, 6F55 ZIP KIT®

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Upper Valve Body • 6F50 Shown

101

110
102

109
103
108
104
107
105
106

Upper Valve Body Descriptions

I.D. No.

6F50 Description

101

Pressure Regulator Valve

102

Isolator Valve

103

TCC Control Valve

104

Multiplex Manual Valve

105

Multiplex Shift Valve

106

Manual Valve

107

L/R Overdrive Clutch Regulator Valve

108

TCC Regulator Apply Valve

109

Intermediate Clutch Regulator & Gain Valve

110

Direct Clutch Regulator Valve

©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

6F50-ZIP-Booklet 04-24-15
Page 5

TIME TESTED • INDUSTRY TRUSTED

FORD 6F50, 6F55 ZIP KIT®

Installation & Testing Booklet

OE Exploded View
Lower Valve Body • 6F50 Shown

205

204
201

203
202

Lower Valve Body Descriptions

I.D. No.

04-24-15 6F50-ZIP-Booklet
Page 6

6F50 Description

201

Forward Clutch Latch Valve

202

Forward Clutch Regulator Valve

203

L/R Overdrive Clutch Latch Valve

204

Solenoid Pressure Regulator Valve

205

Direct Clutch Latch Valve

©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

start a rebuild right by

Nobody knows transmissions like

Vacuum Testing
Vacuum testing is...
Economical A vacuum testing station has
a low initial cost to set up and requires minimal
maintenance.

Quick & Easy Vacuum testing is easy to learn.
It doesn’t take long to become skilled at rapidly
testing multiple areas.

Quantitative Vacuum testing returns a specific
value (inches of mercury) which, with experience,
allows rebuilders to establish pass/fail standards for
proper valve body function.

Reliable Test results are accurate and repeatable
when routine calibration and basic test procedures
are performed.

the

TOOLS

The same tools and techniques used for years in
Sonnax engineering and tech labs are available
to shops seeking a fast, easy and reliable method
of evaluating bore wear and the effectiveness of
transmission repairs.

•	Brass needle valves and a built-in
test orifice for easy calibration.
Learn More

KNOWLEDGE

Sonnax’s growing collection of
guides for domestic and import
applications is a valuable
resource for any shop. In
addition to valve/pump body
diagnostics, these guides
contain complete OE exploded
views for handy reference.

Sonnax pioneered the use of vacuum testing by
recognizing that a worn valve or valve body bore
can result in incorrect hydraulic pressures, leading
to poor performance or failure of the transmission.

Proper equipment and calibration is essential
for accurate vacuum testing! The Sonnax vacuum
test stand kit is a great alternative to building a
custom testing rig.

NOTE: A vacuum pump is not included in this kit.
Sonnax recommends a 3cfm vacuum pump when
vacuum testing valve bodies.

the

A properly diagnosed valve body means no wasted
time and money on repairs which aren’t needed or
aren’t working.

Vacuum Test Stand Kit

Part No. VACTEST-01K
•	 Test Stand with Gauge
•	 Clear Test Plate
•	 Foam Mat
•	 Push-to-Connect Fitting
•	 Assorted Testing Tips (6)
•	 Testing Tip Adapter Tube
•	 Flexible Tubing & Flared Tubing
with Flared Nut

Better Diagnostics
= Better Rebuilds
& Fewer Comebacks

•	Clear test plate and various test tips for tackling
a variety of valve/pump body locations.
•	Comprehensive assembly and calibration
instructions included with each kit.

FREE Vacuum Test Guides
•	Learn Locations to Vacuum Test
•	Identify Common Transmission Problems
•	Select Recommended Parts for Repairs

All test guides are FREE to view,
print and download from
www.sonnax.com.
©2014 Sonnax Industries, Inc.

Make

Unit

Zip Kit Part No.

55-50SN, 55-51SN

AW55-50SN-ZIP

60-40LE

AW60-40LE-ZIP

60-41SN

AW60-41SN-ZIP

4R44E, 4R55E, 5R44E, 5R55E

4R44E-5R55E-ZIP

6F35

6F35-ZIP

6F50, 6F55

6F50-ZIP

6L45, 6L50, 6L80, 6L90

6L45-6L90-ZIP

6T40 (Gen. 1), 6T45 (Gen. 1),
6T50 (Gen. 1)

6T40-ZIP

6T70 (Gen. 1), 6T75 (Gen. 1)

6T70-ZIP

A340E/F V6 & V8 ‘00-Later

A340-LATE-ZIP

A750E/F, A760E/F/H, A761E & A960E/F

A750E-A761E-ZIP

U140E/F, U240E, U241E

U140E-U241E-ZIP

U151E/F, U250E

U151E-U250E-ZIP

U660E/F

U660E-ZIP

U760E/F

U760E-ZIP

ZF6HP19/26/32, Ford 6R60, 6R80

ZF6-6R60-ZIP

ZF6HP21/28/34

ZF6-GEN2-ZIP

Also fits AF 23/33 & RE5F22A units.

Aisin AW

These Aren’t Your
Average Shift Kits®

Ford

Installing gimmicky parts or tinkering
with shortcuts which ruin the integrity
of the valve body will never truly
repair a transmission. That means an
unhappy customer might be back,
asking you to fix something you’ve
already spent time and money on.
Fast, safe and effective shift
repairs are easy with Zip Kits.
Just like other Sonnax products,
these kits are soundly engineered
and extensively tested to ensure
they solve the root cause of valve
body problems.

GM

Toyota/
Lexus

It never pays to compromise a
rebuild when your shop’s reputation
is on the line. Trust Sonnax Zip Kits
for the easiest and most effective
repairs for common shift problems.

Which 				

ZF

kit is Right for a Rebuild?

All these kits are Transmission Digest Top 10 Shop Products!

Line Pressure Booster Kit

Zip Kit®

The Sure Cure®

Performance Pack

Affordable kit for big performance
without a big price tag.

The first step in correcting
common shift problems.

Comprehensive kit for big problems
you don’t want back.

The best parts for performance
& heavy duty recalibration.

• S
 imple, effective parts with
no special tools required

• No reaming or special tools
required to install simple parts

• Increases torque capacity

• Stops leaks so the valve body
works the way it’s supposed to

• Improves shift feel without
low-speed harshness

• In-depth tech booklet for
installation, plus diagnostics
& repair

• Restores OE shift quality
• R
 epairs biggest trouble areas
to reduce comebacks
• Step-by-step instructions for
comprehensive valve/pump
body restoration

• F
 irmer shifts under load
without low-speed harshness
• Consistent recalibration
results with tuning options
• Improved durability
• No special tools required
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