6T40 GEN2 ZIP Booklet

2017-02-03

: Sonnax 6T40-Gen2-Zip-Booklet 6T40-GEN2-ZIP-Booklet 2196 file instruction uploads

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GM 6T40 (GEN. 2), 6T45 (GEN. 2),
6T50 (GEN. 2) ZIP KIT ®
PART NUMBER 6T40-GEN2-ZIP
6T40 Generation 1, Transmission
Electro-Hydraulic Control Module
(TEHCM)

INSTALLATION & TESTING BOOKLET

Valve Body Identification

Figure 1

Confirm Generation

Upper section is Control
Solenoid (w/body & TCM)
Valve Assmebly.

This Zip Kit works in Generation 2 6T40 series valve bodies. To identify core as
Generation 1 versus Generation 2, check for presence of 4-5-6 clutch boost valve in
control valve body assembly (Figures 1 & 2).
Also check the Transmission Control Module (TCM) identifier (Figures 3 & 4). The
control valve body assembly and TCM must be of the same generation.

TCM

6T40 Generation 2
Control Valve Body Assembly

Figure 2

The 6T40, 6T45 and 6T50 are
equipped with several adaptive learning strategies. After
valve body service the existing
adaptive values will need to be
erased. Then, a “Fast Learn”
process should be performed.
Reference GM material for
proper “Fast Learn” process.

Lower section
is Control Valve
Body Assembly.

Generation 1 - No 4-5-6 clutch boost valve
Generation 2 - Has 4-5-6 clutch boost valve

Figure 3

Adaptive Learning

Solenoids
TCM Identifier

Figure 4

Generation 1

1 or 2 or 3

Generation 2

B or C or D

TCM Identifier is 8th digit from left.

Off

Reverse

Off

Neutral

Drive

1-2-3-4 Clutch

Off

Low & Rev.
Clutch

Low Rev. 4-5-6
CL PC Sol N.H.

Off

Low & Rev. CL
(OWC)

3-5 Rev. CL
PC Sol N.L.

2-6 Clutch

2-6 CL
PC Sol N.L.

3-5 Reverse
Clutch

1-2-3-4 CL
PC Sol N.H.

Park

Range/Gear

Figure 5
4-5-6
Clutch

Shift Solenoid

Solenoid & Clutch Apply Chart

The Generation 2 6T40, 6T45 and 6T50 solenoids
are a mix of normaly-high and normaly-low type.
These are calibrated at the factory and switching solenoids between locations in the control solenoid (w/
body and TCM) valve assembly should be avoided.

6T40 Generation 2
Solenoid Locations

Figure 6

Applied*
Applied

Applied

Off

Applied*

1st Braking

Off

Holding† Applied Applied

1st

Off

2nd

Off

3rd

Off

4th

Off

Applied

5th

Off

Applied Applied

6th

Off

Applied

Holding
Applied
Applied

Applied
Applied

Applied

NOTE: For shift solenoids, "ON" = solenoid energized (pressurized), "OFF" = solenoid de-energized (no
pressure). For pressure control (PC) solenoids, "ON" = pressurized, "OFF" = no pressure. *Applied with
no load. †Holding but ineffective.

1.
2.
3.
4.

Line PCS
2-6 PCS
3-5 Reverse PCS
Shift Solenoid

5. TCC PCS
6. 1-2-3-4 PCS
7. L/R 4-5-6 PCS

• Pressure Control Solenoid (PCS) 3-5 ohms at 70oF
• Shift Solenoid 16-20 ohms at 70oF

6T40-GEN2-ZIP_Booklet 02-03-17
Page 1

TIME TESTED • INDUSTRY TRUSTED

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT®

Installation & Testing Booklet

Additional Identification Information
Generation 1
Generation 2

Figure 7

Pump
casting
ID number

Figure 8

Number 12
in casting
circle ID-year.

Figure 10

Figure 9

Rib on pressure
regulator valve.

No rib on pressure
regulator valve.

Figure 11

Generation 1
Control Valve Body Assembly,
Case Side

Figure 12

Generation 2
Control Valve Body Assembly,
Case Side

Figure 13

Generation 1
Valve Channel Plate

02-03-17 6T40-GEN2-ZIP_Booklet
Page 2

Figure 14

Generation 2
Valve Channel Plate

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT®

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

Additional Identification Information
Generation 1
Generation 2
Figure 15

Figure 16

Generation 1, Control Solenoid (w/body and TCM) Valve Assembly

Generation 2, Control Solenoid (w/body and TCM) Valve Assembly,
Beaded gasket and screen changed. Solenoid caps changed color.

Figure 17

Figure 18

Generation 1, Control Solenoid (w/body and TCM) Valve Assembly:
4 Pressure Switches

Generation 2 Control Solenoid (w/body and TCM) Valve Assembly :
No Pressure Switches

Figure 19

Figure 20

Generation 1, TCM Identification Number:
Middle number under bar code starts with 1, 2 or 3.

Generation 2, TCM Identification Number:
Middle number under bar code starts with B, C or D.

6T40-GEN2-ZIP_Booklet 02-03-17
Page 3

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT®

TIME TESTED • INDUSTRY TRUSTED

OSS
Connection

Figure 21

Installation & Testing Booklet

Zip Kit Instructions
1. TEHCM Removal from Case

a. Disconnect the input speed sensor, output speed sensor and shift position
switch connectors from valve body.

Shift
Position
Switch
Connection

b. Remove the three control solenoid (w/body and TCM) valve assembly bolts,
40.5mm long (Figure 21 & 23).

ISS
Connection

c. Remove the 12 control solenoid (w/body and TCM) valve assembly bolts,
30mm long (Figure 21 & 23).
d. Remove the control solenoid (w/body and TCM) valve assembly from valve body.
e. Remove the nine control valve body assembly bolts, 60mm long (Figure 22 & 23).

Figure 22

f. Remove the two control valve body assembly bolts, 53mm long (Figure 22 & 23).

g. Remove the control valve body assembly from the case.

2. Installation
C

C
C

3. TEHCM Reinstall into Case

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).
a. Install control valve body assembly into case and secure with (2x) 53mm and
(9x) 60mm bolts until finger-tight (Figure 22).

Removal Bolts

Figure 23

b. Tighten to 97 in-lbs of torque in the indicated sequence (Figure 24).

Bolt Color
Code

Bolt
Length

Quantity

Torque
Specification

Red

40.5mm

71 in-lb

Green

30mm

106 in-lb

Blue

60mm

97 in-lb

d. Tighten (12x) 30mm bolts to 106 in-lb of torque in the indicated sequence
(Figure 25).

Yellow

53mm

97 in-lb

e. Tighten the (3x) 40.5mm bolts to 71 in-lb torque in the indicated sequence.

Figure 24
4

c. Install control solenoid (w/body and TCM) valve assembly to control valve
body assembly with (12x) 30mm and (3x) 40.5mm bolts until finger-tight
(Figure 21).

f. Reconnect the input speed sensor, output speed sensor and shift position
switch connectors (Figure 21).

Figure 26

9
2

Figure 25
11

9
14

6
2

3
13
15

02-03-17 6T40-GEN2-ZIP_Booklet
Page 4

NOTE: C
ontrol solenoid (w/body and TCM) valve assembly shown is a Gen. 2
(TCM identifier barcode, Figure 4).

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT®

Installation & Testing Booklet

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.

3-5 Reverse Clutch
Regulator Valve

Default Override
Valve

• Burnt 3-5 Reverse clutch
• Delayed Reverse
• 3rd & 5th Shift complaints
• 2-3 & 4-5 Shift flare



• Engagement concerns in
Reverse when in fail-safe
or default.

2-6 Clutch
Regulator Valve



Control Valve Body – Front • Gen. 2 6T40 Shown

TCC Regulator
Apply Valve
• No TCC/slip, soft apply
• Harsh TCC apply
Replace with Sonnax Part No.
144740-16K
Requires F-144740-TL16 & VB-FIX



• Burnt 2-6 clutch
• 2nd & 6th Shift complaints
• 1-2 & 5-6 Shift flare



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



1-2-3-4 Clutch
Boost Valve



• Burnt 1-2-3-4 clutch
• Delayed Forward
• 1-2-3-4 Shift complaints

Clutch Select Valve

Low Reverse
4-5-6 Clutch
Regulator Valve
• Burnt L/R & 4-5-6 clutch
• Delayed Reverse
• 4-5-6 Shift complaints
• 3-4 Shift flare

• Various shift complaints
• Shift related trouble codes

Actuator Feed
Limit Valve
• Harsh shifts
• No/Slipping shifts
• Low clutch pressure
Replace with Sonnax Part No.
144740-01 Requires 144740-TL

Low Reverse 4-5-6
Boost Valve

O-Ringed End Plugs

• Burnt Low/Reverse & 4-5-6 clutch
• Delayed Reverse
• 4-5-6 Shift complaints
• 3-4 Shift flare

NOTE: Vacuum test end plugs at outboard port
while sealing bore opening with thumb.

• Burnt clutches/brakes • Various shift complaints

Replace with Sonnax Part No.
144510-14K*
NOTE: Several Locations =



*Part numbers with an asterisk (*)
are included in this Zip Kit.
©2017 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

6T40-GEN2-ZIP_Booklet 02-03-17
Page 5

TIME TESTED • INDUSTRY TRUSTED

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT®

Installation & Testing Booklet

Pump Body • Gen. 2 6T40 Shown

Pressure
Regulator Valve
• Harsh/Soft shifts
• High/Low line pressure
• Burnt clutches
Replace with Sonnax Part No.
144510-01K
Requires F-144510-TLC & VB-FIX

TCC Control Valve
• Incorrect TCC apply/release
• Inadequate lube & cooling
• Transmission overheat
• Converter codes
Replace with Sonnax Part No.
144510-05K
Requires F-144510-TL5C & VB-FIX

02-03-17 6T40-GEN2-ZIP_Booklet
Page 6

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT®

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Control Valve Body Assembly • Gen. 2 6T40 Shown
NOTE: Depending upon vehicle application, the OE springs shown may not be present.

101

111

110
109
102

108
107

103
104
106
105

Control Valve Body Assembly Descriptions

I.D. No.

Description

101

Default Override Valve

102

TCC Regulator Apply Valve

103

Clutch Select Valve (inboard)
Shuttle Valve (outboard)

104

Actuator Feed Limit Valve

105

Manual Valve

106

Low/Reverse 4-5-6 Boost Valve

107

Reverse & 4-5-6 Clutch Regulator Valve

108

1-2-3-4 Clutch Boost Valve

109

1-2-3-4 Clutch Regulator Valve

110

2-6 Clutch Regulator Valve

111

3-5 Reverse Clutch Regulator Valve

6T40-GEN2-ZIP_Booklet 02-03-17
Page 7

TIME TESTED • INDUSTRY TRUSTED

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT®

Installation & Testing Booklet

OE Exploded View
Pump Body • Gen. 2 6T40 Shown
NOTE: Depending upon vehicle application, the OE springs shown may not be present.

201
202

Pump Body Descriptions

I.D. No.

204

Description

201

Line Pressure Relief Ball

202

Pressure Regulator Valve

203

TCC Control Valve

204

TCC Relief Ball

203

02-03-17 6T40-GEN2-ZIP_Booklet
Page 8

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