6F50 ZIP IN

2015-04-24

: Sonnax 6F50-Zip-In 6F50-ZIP-IN 1873 file instruction uploads

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PART NUMBER 6F50-ZIP QUICK GUIDE

6F50 Upper

Valve Body

6F50 Lower

Valve Body

6F50 Separator Plate

NOTE: Drill and

aluminum plugs for

this step not shown.

CAUTIONCAUTION

CAUTION: Ensure shuttle valve is

installed with blind bore facing

inboard and rounded, closed

end facing the end plug.

CAUTION: FORD TSB 11-12-10

recommends removing this check

ball in some applications, replac-

ing both separator plates and

reprogramming the PCM with

latest updates to prevent slip sensation or

sluggish acceleration from a stop.

CAUTIONCAUTION

Replace six

OE checkballs

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

FORD 6F50, 6F55

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.

FORD 6F50, 6F55 ZIP KIT® Quick Guide

Step 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 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

Step Replace OE TCC

Regulator Apply Valve

Bore Lineup

Remove and discard all OE components except the end clip. Save OE

end clip for reuse.

CAUTIONCAUTION

CAUTION: Ensure shuttle valve is installed with blind bore

facing inboard and rounded, closed end facing the end plug.

Packaging Pocket 3

• TCC Regulator Valve • Spring • Shuttle Valve

• End Plug • O-Rings (2) 1 extra

CAUTIONCAUTION

Step Replace 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

• Sleeve  Valve  Spring • Clip

Step Block Solenoid Pressure

Regulator Balance Port

Drill indicated separator plate orice 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

ush on both castings.

Packaging Pocket 5

• Drill (.062" dia.) • Aluminum Plugs (2) 1 extra

Step Replace OE Checkballs

CAUTIONCAUTION

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.

Packaging Pocket 6

• Checkballs (7) 1 extra

CAUTIONCAUTION

Zip Kit Contents & Installation Steps

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

Figure 2

1420710687754

SOL STRATEGY

06D598C

SOL BODY ID

6053001903

Identication: The original solenoid body tag on transmission

case will look like this.

Figure 4

7T4P-72369-AE

SOLENOID BODY SERVICE INFORMATION

1420710687754

SOLENOID BODY STRATEGY

06D598C

SOLENOID BODY STRATEGY

Clutch Apply Chart

Gear Direct

Clutch

Overdrive

Clutch

Forward

Clutch (Brakes)

Low/Reverse

Clutch (Brake)

Intermediate

Clutch (Brake) One-Way

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

Reverse X X

Figure 5

Solenoid Apply Chart

PCM

Commanded

Gear

Shift Solenoid

TCC

(VFS) NL

SSA

(VFS) NL

SSB

(VFS) NH

SSC

(VFS) NL

SSD

(VFS) NH

SSE

(on/off) NC

Park X X

Reverse X

Neutral X * X*

Drive

1st

X X * X*

2nd

XXXX

3rd

X X

4th

X X on/off

5th

on/off

6th

X X on/off

Low

X X * X*

Figure 6

KEY: X = On/Applied * = Modulating

6F50 Valve Body ID & Tech Tips

Reprogramming

Many transmission performance concerns both prior to and after an overhaul can

be addressed by reashing or reprogramming the PCM. Refer to OE reashing

procedures.

Part Updates

Ford has made numerous part updates to deal with drivability complaints, includ-

ing changes to the range sensor, TSS and OSS. Ensure the latest updates are made.

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 lead frame attached to the valve body (Figure 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 strategy is always 13 numeric digit. The solenoid body I.D. is a combi-

nation of numeric digits and any letters A–F.

Figure 1

6F50 Valve Body

Lead Frame

Figure 3

Solenoid Strategy on Lead Frame Solenoid Body I.D.

FORD 6F50, 6F55

ZIP KIT®

PART NUMBER 6F50-ZIP INSTALLATION & TESTING BOOKLET

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

FORD 6F50, 6F55 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

1. Valve Body Removal from Case

(Figure 7)

a. Disconnect 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.

2. Disassembly (Figures 9 & 10)

a. Remove the solenoid lter 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

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).

4. Separator Plate Update

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

a. Install valve body into transmission using 10 (blue)

62mm bolts. Hand tighten rst, then tighten in

indicated sequence to 106 lb-in (Figure 10).

b. Install a new solenoid lter 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).

Figure 9

6F50 Filter Plate

Figure 7

6F50 Solenoid Body

Turbine Shaft Speed

Sensor (TSS)

Output Speed

Sensor (OSS)

Transmission

Range Sensor

6F50 Disassembly & Reassembly Bolts

Bolt Color Code Bolt Length Torque

Purple 62mm

106 in-lb

Orange 35mm

Green 42mm

Blue 62mm

Red 95mm

Yellow 80mm

Figure 8

Figure 10

6F50 Solenoid Body

FORD 6F50, 6F55 ZIP KIT®

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

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.

Upper Valve Body • 6F50 Shown

VACUUM

TEST

Plug port

on back.

Direct Clutch Regulator Valve

• Burnt direct clutch

• 3rd & 5th Shift complaints

• Delayed Reverse

• 2-3 & 4-5 Shift are

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

Plug port

on back.

TCC Regulator

Apply Valve

• No TCC/slip, soft apply

• Harsh TCC apply

Replace with Sonnax Part No.

124740-24K Requires

F-124740-TL24 & VB-FIX

Intermediate

Clutch Regulator

& Gain Valve

• Burnt intermediate clutch

• 2nd & 6th Shift complaints

• 1-2 & 5-6 Shift are

Replace with Sonnax Part No.

124740-17K Requires

F-124740-TL17 & VB-FIX

Isolator Valve

• Low line pressure

• Slipping/Burnt clutches

• Soft shifts/apply

Replace with Sonnax Part Nos.

124740-16 (Spring Only)

124740-03K (Isolator Valve Kit)*

TCC Control Valve

• Incorrect TCC apply/release

• Transmission overheat

• Low/No cooler/lube ow

Replace with Sonnax Part No.

124740-14K Requires

F-124740-TL14 & VB-FIX

Multiplex Manual

Valve

• Various shift complaints

• Shift related trouble codes

Plug port

on back.

L/R Overdrive Clutch

Regulator Valve

• Burnt L/R and/or overdrive clutch

• 4-5-6 Shift complaints

• Delayed Reverse

• 3-4 Shift are

Plug port

on back.

Multiplex Shift Valve

• Various shift complaints

• Shift related trouble codes

Pressure Regulator

Valve

• High/Low line pressure

• Slipping/Burnt clutches

• Harsh/Soft shifts/apply

• Transmission overheat

• Low/No cooler/lube ow

Replace with Sonnax Part No.

124740-12K Requires F-124740-TL12 & VB-FIX





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

FORD 6F50, 6F55 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.

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

Lower Valve Body • 6F50 Shown

VACUUM

TEST

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

Plug port

on back.

L/R Overdrive Clutch

Latch Valve

• Burnt overdrive clutch

• 4-5-6 Shift complaints

• 3-4 Flare

Replace with Sonnax Part No.

144740-23 Requires

F-144740-TL22 & VB-FIX

Plug port

on back.

Forward Clutch

Latch Valve

• Burnt forward clutch

• Delayed forward

• 1-2-3-4 Shift complaints

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

Plug port

on back.

Direct Clutch Latch Valve

• Burnt Direct clutch

• Delayed Reverse

• 3rd & 5th Shift complaints

• 2-3 & 4-5 Shift are

Replace with Sonnax Part No.

144740-23 Requires F-144740-TL22 & VB-FIX

FORD 6F50, 6F55 ZIP KIT®

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

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View

Upper Valve Body • 6F50 Shown

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

110 101

109

102

108

107

106

105

104

103

FORD 6F50, 6F55 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View

Lower Valve Body • 6F50 Shown

201

202

205

204

203

Lower Valve Body Descriptions

I.D. No. 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

the tOOLS

the KNOWLeDGe

Better Diagnostics

= Better Rebuilds

& Fewer Comebacks

A properly diagnosed valve body means no wasted

time and money on repairs which aren’t needed or

aren’t working.

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.

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.

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 specic

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.

Vacuum Test Stand Kit

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.

• Brass needle valves and a built-in

test orice for easy calibration.

• 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.

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

Nobody knows transmissions like

Learn More

FREE Vacuum Test Guides

• Learn Locations to Vacuum Test

• Identify Common Transmission Problems

• Select Recommended Parts for Repairs

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.

All test guides are FREE to view,

print and download from

www.sonnax.com.

NOTE: A vacuum pump is not included in this kit.

Sonnax recommends a 3cfm vacuum pump when

vacuum testing valve bodies.

start a rebuild right by

Vacuum TesTing

Make Unit Zip Kit Part No.

Aisin AW

55-50SN, 55-51SN

Also fits AF 23/33 & RE5F22A units. AW55-50SN-ZIP

60-40LE AW60-40LE-ZIP

60-41SN AW60-41SN-ZIP

Ford

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

Toyota/

Lexus

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

These Aren’t Your

Average Shift Kits®

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 x 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.

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 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 rst step in correcting

common shift problems.

Comprehensive kit for big problems

you don’t want back.

The best parts for performance

& heavy duty recalibration.

• Simple, effective parts with

no special tools required

• Increases torque capacity

• Improves shift feel without

low-speed harshness

• No reaming or special tools

required to install simple parts

• Stops leaks so the valve body

works the way it’s supposed to

• In-depth tech booklet for

installation, plus diagnostics

& repair

• Restores OE shift quality

• Repairs biggest trouble areas

to reduce comebacks

• Step-by-step instructions for

comprehensive valve/pump

body restoration

• Firmer shifts under load

without low-speed harshness

• Consistent recalibration

results with tuning options

• Improved durability

• No special tools required

6F50 ZIP IN

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