6R140 ZIP IN

2017-07-28

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FORD 6R140
ZIP KIT ®
PART NUMBER 6R140-ZIP

QUICK GUIDE

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

installation Diagram

WARNING: If ridge and sharp
edges are not eliminated, O-ring
will be damaged upon insertion
into bore.
Typical bore. Inspect all
bores at these locations.

Upper
Valve Body

2
2
2
2

a1. Ridge
Location

a2. S
harp edge here and
opposite side of bore.

Lower
Valve Body

3
3
3
3
6
4

3
3

*NOTE: Some late units may have an accumulator piston
at this location. Do NOT install Sonnax piston and spring
unless originally equipped.

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.
©2017 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

6R140-ZIP-Guide 07-28-17
Page 1

6R140 ZIP KIT®

Quick Guide

Zip Kit Contents & Installation Steps
Step 1 Replace OE TCC Apply
Boost Valve Assembly

Step 4 R
eplace OE LPC
End Plug

Packaging Pocket 1

Place O-ring into end plug groove. Lubricate with Sonnax Slippery
Stick O-LUBE and roll on bench to size.

• Boost Valve

• Sleeve

Packaging Pocket 4

Step 2 Replace OE Regulator
End Plugs
Place O-ring into end plug groove. Lubricate with Sonnax Slippery
Stick O-LUBE and roll on bench to size.
a. Inspect each bore that will receive an O-ringed end plug for sharp
edges. There are three locations where an O-ring may be damaged
during installation (Inset Page 1):

a1. Many valve bodies will have a small sharp ridge at bore
entry. The ridge is difficult to see but can be located by
carefully dragging a pick down the chamfer into the entry.

a2. The inboard edges of the two openings (top and bottom)
just inside the bores where the end plug retainers install
are often sharp.

b. Remove valve train to facilitate bore cleaning after ridge removal and
breaking of sharp edges.
c. Recommend using 3/8" diameter flap wheel chucked in miniature die
grinder, but any method that removes ridges and breaks sharp edges
without damaging bore is acceptable.

WARNING: If ridge and sharp edges are not eliminated,
O-ring will be damaged upon insertion into bore.

Packaging Pocket 2

• End Plugs (5)

• O-Rings (8)

• End Plug
• O-Rings (2)

1 extra

Step 5 R
eplace OE Converter
Limit Valve
a. Remove OE outboard retaining clip, plug, cooler bypass valve,
thermal valve, and spring. Set aside for reuse. Remove OE
inboard retaining clip and set aside for reuse. Remove and discard
OE inboard plug, spring, and converter limit valve.
b. Remove Sonnax valve from sleeve. Install Sonnax spring into valve
pocket then insert both components back into sleeve, spring end
first. Install complete sleeve assembly (valve end first) into bore.
Install inboard OE retaining clip into Sonnax sleeve groove.
c. Return OE spring, thermal bypass valve, cooler bypass valve, end
plug and retaining clip to bore.
Packaging Pocket 5

• Converter Limit Valve & Sleeve Assembly
• Spring

Step 6 R
eplace OE
Accumulator Pistons

3 extra

Packaging Pocket 6

Step 3 Replace OE Internal
End Plugs

• Accumulator Pistons (3)
• Matching Springs (3)

Place O-rings into end plug grooves. Lubricate with Sonnax Slippery
Stick O-LUBE and roll on bench to size.

NOTE: 2015–2016 models have three accumulator pistons.

Apply slight pressure and rotate end plug back and forth into bore
in small, incremental steps. This action allows a well-lubed O-ring
to compress into bore. Alternately, a small flat-bladed screwdriver
inserted through the retainer port cavity may be used to help
gently squeeze O-ring into bore.
Packaging Pocket 3

• Internal End Plugs (6)

• O-Rings (10)

4 extra

6R140-ZIP-Guide 07-28-17
Page 2

FORD 6R140
ZIP KIT ®
PART NUMBER 6R140-ZIP

INSTALLATION & TESTING BOOKLET

Torque Specifications

Valve Body ID & Tech Tips

Oil Pan to Case
9Nm/80 in-lb

Solenoid Strategy Tags

Note: Pan gasket is reusable

Valve Body Assembly
to Case
11Nm/97 in-lb

Valve Body Halves
11Nm/97 in-lb

Sump Filter to Case
11Nm/97 in-lb

Solenoid Retaining
Bracket 11Nm/97 in-lb

Feed Tube Bracket
to Case 11Nm/97 in-lb

Fluid
Ford Fluid Mercon LV

Check at 170-190o

Note: Various pan configurations between Gas/Diesel and
early/late configurations require different capacities.
Approximate Dry Fill 16-19 qts.

See service manual.

Drive-Cycle Relearn
• Using a capable scan tool, clear the TCM KAM
(Keep Alive Memory).
• Make certain transmission temperature is between
180oF and 200oF (82oC to 93oC).
• With engine running and brakes applied, move selector lever in the following sequence pausing between
each position for 4 seconds beginning in neutral as
follows: N-R-N-D-R-D-N. Repeat this sequence two
more times, for a total of three.
• Accelerate at moderate throttle so each shift occurs
around 2000 rpm for gas engines and 1500 rpm for
diesel engines up to 6 mph (105k/mh). Brake moderately to a stop, repeat this sequence two more times,
for a total of three.
• Accelerate at moderate throttle so each shift occurs
around 3000 rpm for gas engines and 2250 rpm for
diesel engines up to 65 mph (105 k/mh). Repeat this
sequence two more times, for a total of three.
• Come to a complete stop.
• With the engine running and the brakes applied, move
the selector lever in the following sequence pausing between each position for 4 seconds beginning
in neutral as follows: N-R-N-D-R-D-N. Repeat this
sequence two more times, for a total of three.

Both the valve body and the transmission case have a solenoid strategy number
on a tag. The numbers (Figures 1 & 2) should match on both interior and exterior
tags. It is possible to program the TCM with a new strategy number if components
have been changed.

Solenoid
Information
Solenoids are location
specific and have a band
number that is barely
legible (Figures 3 & 4). It
may be necessary to take
solenoid outside and look
at it at an angle in the
location shown. Solenoid
ohm value is approximately 5 to 5.5.

Figure 1

Figure 2

WARNING:

Band number on

solenoid (1–5)

corresponds to
solenoid calibration. Band
number of replacement
solenoid MUST match that
of OE solenoid, or shift calibration concerns will result.
In addition, solenoid calibration (Normally High or
Normally Low) must match.

Figure 4

Figure 3

Brown Snout
Green & Red O-Rings =
Normally Low Solenoids

Black Snout
Orange & Red O-Rings =
Normally High Solenoids

6R140-ZIP-Booklet 07-28-17
Page 1

6R140 ZIP KIT®

TIME TESTED • INDUSTRY TRUSTED

Figure 5

Installation & Testing Booklet

Zip Kit Instructions
1. Valve Body Removal from Case
a. Remove wiring harness connectors from the solenoids.
b. Remove three bolts securing the filter to valve body (yellow & orange), then
remove filter (Figure 5).
c. Remove three valve body-to-case bolts (blue) (Figure 5).
d. Remove four (green) valve body half retaining bolts (Figure 5).
d. Remove three tube bracket-to-case bolts (purple) (Figures 6).
e. Remove valve body from case. Keep track of case passage plugs, as these may
stick to valve body (Figure 7).

6R140 Disassembly & Reassembly Bolts
Bolt Color Code

Bolt Length

Purple

97mm

Red

48mm

Green

63mm

Blue

68mm

Yellow

68.5mm

Orange

90mm

f. Remove tube assemblies from valve body and tube assembly plugs from case
(Figure 6 & 7).
Figure 7

Torque

97 in-lb

Case Passage
Plugs
Figure 6

Figure 8
Seal Plate
#1

Case Seal
#1

Case Seal
#2

Seal Plate
#2

Once bracket-to-case bolts are removed.

Blue
Plug

Black
Plug

07-28-17 6R140-ZIP-Booklet
Page 2

Green
Plug

6R140 ZIP KIT®

Installation & Testing Booklet

2. Valve Body Disassembly

TIME TESTED • INDUSTRY TRUSTED

Figure 9

Pry Point
#1

a. Remove valve body-to-case seals (Figure 8).
b. Remove 22 red valve body bolts (Figure 5). The
valve body halves may now be separated, using
two pry points (Figures 9).
c. Remove two seperator plate bolts from upper
valve body casting (Figure 10).
d. Remove all valve body “small parts” (not valve
retainers) and set aside (Figures 10 & 11).

Pry
Point
#2

NOTE: Pump inlet nozzle may stick to separator plate. Ensure installation back into valve body
before reassembling the two valve body halves.

e. Remove solenoids (see page 1, Figures 3 & 4).
For more solenoid information see chart (page 8
Figure 12).

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 pages 4 & 5).

4. Valve Body Reassembly
a. Reverse order of above directions.

5. Valve Body Reinstall to Case

8 Retainer locations

a. Reverse order of above directions.

2 Accumulator Piston Locations

1 Alternate Accumulator Piston Location: 2015-16 models may have a NO 6

Pump Inlet Nozzel



Figure 10

Figure 11

Check Valve
and Spring
3




Check Valve
and Spring

1
2

2 Seperator plate retaining bolts: 77mm long, 97 in-lb.

Plate Part No.: BC3P-7Z490-EB (2016: BC3P-7Z490-EE).
 If there is NO hole in this location, checkball 3 is not used.

Check Ball Locations .375". Note: There can be variations in #3 location.

6R140-ZIP-Booklet 07-28-17
Page 3

TIME TESTED • INDUSTRY TRUSTED

6R140 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.

Upper Valve Body

Overdrive 4-5-6 Clutch
Regulator Valve
• Burnt overdrive (4-5-6) clutch
• 4th, 5th and/or 6th Gear complaints

TCC Charge Control Valve
• Low/High converter apply pressure
• TCC failure

• Burnt intermediate (2-6) clutch
• 1-2 Shift complaints
• 5-6 Shift complaints

Forward 1-2-3-4 Clutch
Regulator Valve
• Burnt Forward clutch
• Delayed Forward
• No Forward
• Slipping
Replace with Sonnax Part No.
126740-13K Requires F-126740-TL13 & VB-FIX

   

Intermediate 2-6 Clutch
Regulator Valve

Direct 3-5-R Clutch
Regulator Valve

Replace with Sonnax Part No.
126740-11K Requires F-126740-TL11 & VB-FIX



• Delayed Reverse
• Direct clutch burned
• 2-3, 4-5 Flare
• 3rd, 5th, Reverse slip

Low/Reverse Clutch
Regulator Valve
• Burnt Low/Reverse clutch
• Delayed Reverse

TCC Apply Regulator Valve
End Plugs,
Multiple Locations
• Burnt clutches
• Flare shifts
• Harsh/Soft shifts • Pressure loss
NOTE: Check visually for end plug
deterioration or bore wear.

• TCC Codes, cycling, slip
• No lockup
Replace with Sonnax Part No.
126740-15K Requires
F-126740-TL15 and VB-FIX

Replace with Sonnax Part No.
126740-09K
NOTE: Several Locations =

TCC Apply Regulator Valve
• TCC Codes, cycling, slip
• No lockup
Replace with Sonnax Part No.
126740-03K



*Part numbers with an asterisk (*) are included in this Zip Kit.
07-28-17 6R140-ZIP-Booklet
Page 4

6R140 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.

Lower Valve Body
Converter Limit (Inboard) Valve
• Excess TCC slip • TCC Codes • Reduced clutch life
• TCC apply & release concerns
Replace with Sonnax Part No.
126740-19K Requires F-126740-TL19 & VB-FIX

TCC Charge Limit Valve
• Excessive converter pressure
• Ballooning converter
Replace with Sonnax Part No.
126740-01K Requires
F-126740-TL & VB-FIX

   
 



Overdrive 4-5-6
Clutch Latch Valve
• Burnt overdrive (4-5-6) clutch
• 4th, 5th, 6th Gear complaints

Intermediate 2-6
Clutch Latch Valve
• Burnt intermediate (2-6) clutch
• 1-2, 5-6 Shift complaints

Forward 1-2-3-4 Clutch
Latch Valve
• Burnt Forward clutch
• Delayed engagement
• Harsh shifts
• Gear ratio & solenoid codes
Replace with Sonnax Part No.
126740-06K Requires F-126740-TL6 & VB-FIX

Direct 3-5-R
Clutch Latch Valve
• Burnt direct (3-5-R) clutch
• 3rd, 5th, Reverse shift complaints

Solenoid Feed Pressure
Regulator Valve
Low/Reverse
Clutch Latch Valve
Line Pressure Control
(LPC) Valve
• Burnt clutches
• Poor shift quality
• Erratic line pressure
• TCC apply & release concerns
Replace with Sonnax Part No.
126740-08K Requires F-126740-TL8 & VB-FIX

• Solenoid codes
• Ratio codes
• Shift complaints

• Burnt Low/Reverse clutch
• Delayed Reverse

Internal O-Ringed
End Plug Kit
• Burnt clutches
• Flare shifts
• Harsh/Soft shifts • Pressure loss
NOTE: Check visually for end plug
deterioration or bore wear.
Replace with Sonnax Part No.
126740-05K
NOTE: Several Locations =



6R140-ZIP-Booklet 07-28-17
Page 5

TIME TESTED • INDUSTRY TRUSTED

6R140 ZIP KIT®

Installation & Testing Booklet

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

107
106
101

105
104

103

102

Upper Valve Body Descriptions

I.D. No.

07-28-17 6R140-ZIP-Booklet
Page 6

Description

101

TCC Charge Control Valve

102

TCC Apply Regulator Valve

103

Low/Reverse Clutch Regulator Valve

104

Direct 3-5-R Clutch Regulator Valve

105

Forward 1-2-3-4 Clutch Regulator Valve

106

Intermediate 2-6 Clutch Regulator Valve

107

Overdrive 4-5-6 Clutch Regulator Valve

6R140 ZIP KIT®

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

Lower Valve Body

Assembled view
of thermal valve.

204
205
206
207

203

208
202

209
210
201

Lower Valve Body Descriptions

I.D. No.

Description

201

Manual Valve

202

Line Pressure Control (LPC) Valve

203

TCC Charge Limit Valve

204

Converter Limit Valve (Inboard)
Cooler Bypass and Thermal Valve (Outboard)

205

Overdrive 4-5-6 Clutch Latch Valve

206

Intermediate 2-6 Clutch Latch Valve

207

Forward 1-2-3-4 Clutch Latch Valve

208

Direct 3-5-R Clutch Latch Valve

209

Solenoid Feed Pressure Regulator Valve

210

Low/Reverse Clutch Latch Valve

6R140-ZIP-Booklet 07-28-17
Page 7

TIME TESTED • INDUSTRY TRUSTED

6R140 ZIP KIT®

Solenoid Chart
Band

OE Part Number

Installation & Testing Booklet

Figure 12
Sonnax Part Number

Normally Low Solenoids
Band Number 1

BC3Z-7G383-R

Band Number 2

BC3Z-7G383-S

Band Number 3

BC3Z-7G383-T

Band Number 4

BC3Z-7G383-U

Band Number 5

BC3Z-7G383-V

126421-NLR

126425-NLV

Normally High Solenoids
Band Number 1

BC3Z-7G383-J

126421-NHJ

Band Number 2

BC3Z-7G383-K

126422-NHK

Band Number 3

BC3Z-7G383-L

Band Number 4

BC3Z-7G383-M

Band Number 5

BC3Z-7G383-N

07-28-17 6R140-ZIP-Booklet
Page 8

126425-NHN

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