6R140 ZIP IN

2017-07-28

: Sonnax 6R140-Zip-In 6R140-ZIP-IN 4307 instructions part uploads

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PART NUMBER 6R140-ZIP QUICK GUIDE

Upper

Valve Body

Lower

Valve Body

a1. Ridge

Location

a2. Sharp edge here and

opposite side of bore.

Typical bore. Inspect all

bores at these locations.

WARNING: If ridge and sharp

edges are not eliminated, O-ring

will be damaged upon insertion

into bore.

* NOTE: Some late units may have an accumulator piston

at this location. Do NOT install Sonnax piston and spring

unless originally equipped.

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

FORD 6R140

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.

6R140 ZIP KIT® Quick Guide

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

Step Replace OE TCC Apply

Boost Valve Assembly

Packaging Pocket 1

• Boost Valve • Sleeve

Step 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 difcult 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 ap 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) 3 extra

Step Replace OE Internal

End Plugs

Place O-rings into end plug grooves. Lubricate with Sonnax Slippery

Stick O-LUBE and roll on bench to size.

Apply slight pressure and rotate end plug back and forth into bore

in small, incremental steps. is action allows a well-lubed O-ring

to compress into bore. Alternately, a small at-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

Step Replace OE LPC

End Plug

Place O-ring into end plug groove. Lubricate with Sonnax Slippery

Stick O-LUBE and roll on bench to size.

Packaging Pocket 4

• End Plug

• O-Rings (2) 1 extra

Step Replace 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

rst. Install complete sleeve assembly (valve end rst) 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 Replace OE

Accumulator Pistons

Packaging Pocket 6

• Accumulator Pistons (3)

• Matching Springs (3)

NOTE: 2015–2016 models have three accumulator pistons.

Zip Kit Contents & Installation Steps

Valve Body ID & Tech Tips

Solenoid Strategy Tags

Both the valve body and the transmission case have a solenoid strategy number

on a tag. e 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

specic 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 approximate-

ly 5 to 5.5.

WARNING:

Band number on

solenoid (1–5)

corresponds to

solenoid calibration. Band

number of replacement

solenoid MUST match that

of OE solenoid, or shift cali-

bration concerns will result.

In addition, solenoid cali-

bration (Normally High or

Normally Low) must match.

Figure 4

Figure 2

Figure 1

Figure 3

Brown Snout

Green & Red O-Rings =

Normally Low Solenoids

Black Snout

Orange & Red O-Rings =

Normally High Solenoids

FORD 6R140

ZIP KIT®

PART NUMBER 6R140-ZIP INSTALLATION & TESTING BOOKLET

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

Torque Specifications

Oil Pan to Case

9Nm/80 in-lb

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 170-190

Note: Various pan congurations between Gas/Diesel and

early/late congurations 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

180F and 200F (82C to 93C).

• With engine running and brakes applied, move selec-

tor 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 moder-

ately 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 paus-

ing 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.

6R140 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Zip Kit Instructions

1. Valve Body Removal from Case

a. Remove wiring harness connectors from the solenoids.

b. Remove three bolts securing the lter to valve body (yellow & orange), then

remove lter (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).

f. Remove tube assemblies from valve body and tube assembly plugs from case

(Figure 6 & 7).

6R140 Disassembly & Reassembly Bolts

Bolt Color Code Bolt Length Torque

Purple 97mm

97 in-lb

Red 48mm

Green 63mm

Blue 68mm

Yellow 68.5mm

Orange 90mm

Figure 5

Once bracket-to-case bolts are removed.

Figure 6

Blue

Plug

Black

Plug

Green

Plug

Figure 7

Case Passage

Plugs

Figure 8

Seal Plate

Case Seal

Seal Plate

6R140 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

2. Valve Body Disassembly

a. Remove valve body-to-case seals (Figure 8).

b. Remove 22 red valve body bolts (Figure 5). e

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).

NOTE: Pump inlet nozzle may stick to separa-

tor 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

a. Reverse order of above directions.

Figure 10

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.



Figure 9

Pry Point

Pry

Point

2 Accumulator Piston Locations

8 Retainer locations

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

Pump Inlet Nozzel

Check Valve

and Spring

Check Valve

and Spring

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

Figure 11

6R140 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.

Upper Valve Body

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

TCC Apply Regulator Valve

• TCC Codes, cycling, slip

• No lockup

Replace with Sonnax Part No.

126740-03K

TCC Apply Regulator Valve

• TCC Codes, cycling, slip

• No lockup

Replace with Sonnax Part No.

126740-15K Requires

F-126740-TL15 and VB-FIX

Low/Reverse Clutch

Regulator Valve

• Burnt Low/Reverse clutch

• Delayed Reverse

Direct 3-5-R Clutch

Regulator Valve

• Delayed Reverse

• Direct clutch burned

• 2-3, 4-5 Flare

• 3rd, 5th, Reverse slip

Replace with Sonnax Part No.

126740-11K Requires F-126740-TL11 & VB-FIX

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

• Burnt intermediate (2-6) clutch

• 1-2 Shift complaints

• 5-6 Shift complaints

TCC Charge Control Valve

• Low/High converter apply pressure

• TCC failure

Overdrive 4-5-6 Clutch

Regulator Valve

• Burnt overdrive (4-5-6) clutch

• 4th, 5th and/or 6th Gear complaints

End Plugs,

Multiple Locations

• Burnt clutches • Flare shifts

• Harsh/Soft shifts • Pressure loss

NOTE: Check visually for end plug

deterioration or bore wear.

Replace with Sonnax Part No.

126740-09K

NOTE: Several Locations =

   

6R140 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Lower Valve Body

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

VACUUM

TEST

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 =



 

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

Low/Reverse

Clutch Latch Valve

• Burnt Low/Reverse clutch

• Delayed Reverse

Direct 3-5-R

Clutch Latch Valve

• Burnt direct (3-5-R) clutch

• 3rd, 5th, Reverse shift complaints

Solenoid Feed Pressure

Regulator Valve

• Solenoid codes

• Ratio codes

• 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

Intermediate 2-6

Clutch Latch Valve

• Burnt intermediate (2-6) clutch

• 1-2, 5-6 Shift complaints

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

6R140 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Upper Valve Body Descriptions

I.D. No. 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

OE Exploded View

Upper Valve Body

NOTE: Depending upon vehicle application, the OE springs shown

may not be present.

101

102

103

104

105

106

107

6R140 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Lower Valve Body

205

206

207

208

209

210

201

202

203

204

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

Assembled view

of thermal valve.

6R140 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Band OE Part Number Sonnax Part Number

Normally Low Solenoids

Band Number 1 BC3Z-7G383-R 126421-NLR

Band Number 2 BC3Z-7G383-S

Band Number 3 BC3Z-7G383-T

Band Number 4 BC3Z-7G383-U

Band Number 5 BC3Z-7G383-V 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 126425-NHN

Solenoid Chart Figure 12

6R140 ZIP IN

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