6T40 GEN2 ZIP Booklet

2017-02-03

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

Open the PDF directly: View PDF .
Page Count: 8

Figure 1

6T40 Generation 1, Transmission

Electro-Hydraulic Control Module

(TEHCM)

TCM

Upper section is Control

Solenoid (w/body & TCM)

Valve Assmebly.

Lower section

is Control Valve

Body Assembly.

Valve Body Identication

Conrm Generation

is 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) identier (Figures 3 & 4). e

control valve body assembly and TCM must be of the same generation.

Adaptive Learning

e 6T40, 6T45 and 6T50 are

equipped with several adap-

tive learning strategies. After

valve body service the existing

adaptive values will need to be

erased. en, a “Fast Learn”

process should be performed.

Reference GM material for

proper “Fast Learn” process.

Solenoids

e Generation 2 6T40, 6T45 and 6T50 solenoids

are a mix of normaly-high and normaly-low type.

ese are calibrated at the factory and switching sole-

noids between locations in the control solenoid (w/

body and TCM) valve assembly should be avoided.

Figure 6

6T40 Generation 2

Solenoid Locations

1. Line PCS

2. 2-6 PCS

3. 3-5 Reverse PCS

4. 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 70F

• Shift Solenoid 16-20 ohms at 70F

Solenoid & Clutch Apply Chart

Range/Gear

Shift Solenoid

1-2-3-4 CL

PC Sol N.H.

2-6 CL

PC Sol N.L.

3-5 Rev. CL

PC Sol N.L.

Low Rev. 4-5-6

CL PC Sol N.H.

4-5-6

Clutch

3-5 Reverse

Clutch

2-6 Clutch

Low & Rev. CL

(OWC)

Low & Rev.

Clutch

1-2-3-4 Clutch

Park On On Off Off Off Applied*

Reverse On On Off On Off Applied Applied

Neutral On On Off Off Off Applied*

Drive

1st Braking

On Off Off Off Off Holding†Applied Applied

1st

Off Off Off Off On Holding Applied

2nd

Off Off On Off On Applied Applied

3rd

Off Off Off On On Applied Applied

4th

Off Off Off Off Off Applied Applied

5th

Off On Off On Off Applied Applied

6th

Off On On Off Off Applied Applied

Figure 5

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.

TCM Identier Figure 4

Generation 1 1 or 2 or 3

Generation 2 B or C or D

Figure 3

TCM Identier is 8th digit from left.

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

Generation 2 - Has 4-5-6 clutch boost valve

Figure 2

6T40 Generation 2

Control Valve Body Assembly

GM 6T40 (GEN. 2), 6T45 (GEN. 2),

6T50 (GEN. 2) ZIP KIT®

PART NUMBER 6T40-GEN2-ZIP INSTALLATION & TESTING BOOKLET

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

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Additional Identification Information

Generation 1 Generation 2

Number 12

in casting

circle ID-year.

Pump

casting

ID number

No rib on pressure

regulator valve.

Rib on pressure

regulator valve.

Generation 2

Control Valve Body Assembly,

Case Side

Generation 1

Control Valve Body Assembly,

Case Side

Generation 1

Valve Channel Plate

Figure 7 Figure 8

Figure 9 Figure 10

Figure 11 Figure 12

Figure 13 Figure 14

Generation 2

Valve Channel Plate

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Additional Identification Information

Generation 1 Generation 2

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.

Generation 2 Control Solenoid (w/body and TCM) Valve Assembly :

No Pressure Switches

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

4 Pressure Switches

Generation 2, TCM Identication Number:

Middle number under bar code starts with B, C or D.

Generation 1, TCM Identication Number:

Middle number under bar code starts with 1, 2 or 3.

Figure 15 Figure 16

Figure 17 Figure 18

Figure 19 Figure 20

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT® Installation & Testing Booklet

Page 4 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

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.

b. Remove the three control solenoid (w/body and TCM) valve assembly bolts,

40.5mm long (Figure 21 & 23).

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).

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

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).

3. TEHCM Reinstall into Case

a. Install control valve body assembly into case and secure with (2x) 53mm and

(9x) 60mm bolts until nger-tight (Figure 22).

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

c. Install control solenoid (w/body and TCM) valve assembly to control valve

body assembly with (12x) 30mm and (3x) 40.5mm bolts until nger-tight

(Figure 21).

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

(Figure 25).

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

f. Reconnect the input speed sensor, output speed sensor and shift position

switch connectors (Figure 21).

B B

Figure 21 OSS

Connection

Shift

Position

Switch

Connection

ISS

Connection

Removal Bolts

Bolt Color

Code

Bolt

Length Quantity Torque

Specication

ARed 40.5mm 3 71 in-lb

BGreen 30mm 12 106 in-lb

CBlue 60mm 9 97 in-lb

DYellow 53mm 2 97 in-lb

Figure 23

Figure 24

12 3

8 6

Figure 25

NOTE: Control solenoid (w/body and TCM) valve assembly shown is a Gen. 2

(TCM identier barcode, Figure 4).

Figure 26

Figure 22

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT® Installation & Testing Booklet

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

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.

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

O-Ringed End Plugs

• 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.

144510-14K* NOTE: Several Locations =

* Part numbers with an asterisk (*)

are included in this Zip Kit.

3-5 Reverse Clutch

Regulator Valve

• Burnt 3-5 Reverse clutch

• Delayed Reverse

• 3rd & 5th Shift complaints

• 2-3 & 4-5 Shift are

2-6 Clutch

Regulator Valve

• Burnt 2-6 clutch

• 2nd & 6th Shift complaints

• 1-2 & 5-6 Shift are

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

• Various shift complaints

• Shift related trouble codes

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 are

Low Reverse 4-5-6

Boost Valve

• Burnt Low/Reverse & 4-5-6 clutch

• Delayed Reverse

• 4-5-6 Shift complaints

• 3-4 Shift are

Actuator Feed

Limit Valve

• Harsh shifts

• No/Slipping shifts

• Low clutch pressure

Replace with Sonnax Part No.

144740-01 Requires 144740-TL

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

Default Override

Valve

• Engagement concerns in

Reverse when in fail-safe

or default.

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT® Installation & Testing Booklet

Page 6 800-843-2600 • 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.

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

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT® Installation & Testing Booklet

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

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.

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

101

102

103

104

105

107

108

111

109

110

106

2nd GEN. 6T40, 6T45, 6T50 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Pump Body Descriptions

I.D. No. Description

201 Line Pressure Relief Ball

202 Pressure Regulator Valve

203 TCC Control Valve

204 TCC Relief Ball

201

202

203

204

OE Exploded View

Pump Body • Gen. 2 6T40 Shown

NOTE: Depending upon vehicle application, the OE springs shown may not be present.

6T40 GEN2 ZIP Booklet

Navigation menu

Versions of this User Manual:

Views

Navigation