6T40 GEN2 ZIP IN

2017-05-25

: Sonnax 6T40-Gen2-Zip-In 6T40-GEN2-ZIP-IN 4515 instructions part uploads

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GM 6T30, 6T40 (GEN. 2), 6T45 (GEN. 2),
6T50 (GEN. 2) ZIP KIT ®
PART NUMBER 6T40-GEN2-ZIP

QUICK GUIDE

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

installation Diagram
6T40 (Gen. 2)
Control
Valve Body

NOTE: All components of this kit

install into the mechatronic unit,

and not the pump. Removal of

the pump is not required for
this kit, unless vacuum testing is to
be performed.

1
1

1
2

CAUTION

5
Plastic Checkballs

1
4
CAUTION:

Failure to

block
CAUTION
orifice
will result in no
movement of vehicle.

Separator Plate on Valve Body

Block AFL balance
port by drilling and
plugging separator
plate where indicated
using drill bit and
aluminum plug
provided (not shown).

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

6T40-GEN2-ZIP_Guide 05-11-17
Page 1

GM 6T30, 6T40 (Gen. 2), 6T45 (Gen. 2), 6T50 (Gen. 2) ZIP KIT®

Quick Guide

Zip Kit Contents & Installation Steps
Step 1 Replace 5 OE End Plugs
Place O-ring in groove, lubricate with Sonnax Slippery Stick O-LUBE
and roll on bench to size.
Packaging Pocket 1

• End Plugs (5)
• O-Rings (7) 2 extra

Step

Replace TCC Regulator
Apply Valve Bore Lineup

Remove and discard all OE components except the retainer clip. Save
retainer clip for reuse.

Step 4 R
eplace OE Actuator Feed
Limit (AFL) Valve Lineup
Remove and discard OE valve and spring. Save outboard retainer clip
for reuse. Install Sonnax sleeve and valve as illustrated. Secure sleeve
into bore by installing included clip into sleeve groove at inboard port.
Install included spring and secure all into bore with OE retainer.

CAUTION: Ensure supplied retainer clip is fully seated in AFL
CAUTION sleeve groove after installation.
Packaging Pocket 4

• Sleeve
• Valve
• Spring
• Retainer Clip

CAUTION: The small shuttle valve should be positioned with the
CAUTION rounded end face outboard, and the blind bore inboard.
Packaging Pocket 2

• Spring
• Valve
• Shuttle Valve
• End Plug
• O-Rings (2) 1 extra

Step 5 Replace OE Checkballs
Packaging Pocket 5

Checkballs, .250" dia. (6)

Step 3 Block AFL Balance Port
Drill indicated separator plate orifice with included .062" dia. drill bit.
Remove any burrs. Insert .062" dia. aluminum plug into drilled hole and
peen in place on both sides of plate. Ensure plate will still fit flush on
both castings.
CAUTION: Failure to block orifice will result in no movement of vehicle.

CAUTION

Packaging Pocket 3

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

CAUTION: Use care when modifying the balance orifice.
CAUTION Gaskets are bonded to the plates and damage could occur.

6T40-GEN2-ZIP_Guide 05-11-17
Page 2

GM 6T30, 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 assembly

This Zip Kit works in 6T30 and 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 the control valve body assembly (Figures 1 & 2). The 6T30 is similar to the
Generation 2 6T40 series valve bodies, in that it has a 4-5-6 clutch boost valve, no
pressure switches, and has a letter as the TCM identifier 8th digit.

TCM

6T40 Generation 2
Control Valve Body Assembly

Lower section
is control valve
body assembly

Figure 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.

Adaptive Learning
The 6T30, 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 the proper “Fast Learn” process.

Generation 1 - No 4-5-6 clutch boost valve
Generation 2 - Has 4-5-6 clutch boost valve
Figure 3

TCM Identifier

Figure 4

Generation 1

1 or 2 or 3

Generation 2

B or C
or D

Solenoids
The 6T30 and 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.

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

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 05-11-17
Page 1

TIME TESTED • INDUSTRY TRUSTED

GM 6T30, 6T40 (Gen. 2), 6T45 (Gen. 2), 6T50 (Gen. 2) 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
is the 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

05-11-17 6T40-GEN2-ZIP_Booklet
Page 2

Figure 14

Generation 2
Valve Channel Plate

GM 6T30, 6T40 (Gen. 2), 6T45 (Gen. 2), 6T50 (Gen. 2) 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 05-11-17
Page 3

GM 6T30, 6T40 (Gen. 2), 6T45 (Gen. 2), 6T50 (Gen. 2) 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

Figure 22
D

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 control
valve body assembly.
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
C

C
C

3. TEHCM Reinstall into Case

Removal Bolts

Figure 23

Bolt Color
Code

Bolt
Length

Quantity

Torque
Specification

Red

40.5mm

71 in-lb

Green

30mm

106 in-lb

Blue

60mm

97 in-lb

Yellow

53mm

97 in-lb
Figure 24

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 (2) 53mm and
(9) 60mm bolts until finger-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 (12) 30mm and (3) 40.5mm bolts until finger-tight
(Figure 21).
d. Tighten (12) 30mm bolts to 106 in-lb of torque in the indicated sequence
(Figure 25).
e. Tighten the (3) 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).
Figure 26

9
2

Figure 25
11

9
14

6
2

3
13
15

05-11-17 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).

GM 6T30, 6T40 (Gen. 2), 6T45 (Gen. 2), 6T50 (Gen. 2) 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.

Control Valve Body Assembly – Front • Gen. 2 6T40 Shown
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 failsafe
or default.
NOTE: Look in bore for
visual wear.



2-6 Clutch
Regulator Valve



3-5 Reverse Clutch
Regulator Valve

TCC Regulator
Apply Valve

• 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



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

1-2-3-4 Clutch
Boost Valve

• No lockup
• TCC slip
• Harsh/Soft TCC apply
Replace with Sonnax Part No.
144740-16K
Requires F-144740-TL16 & VB-FIX

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

Clutch Select Valve
• 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 05-11-17
Page 5

TIME TESTED • INDUSTRY TRUSTED

GM 6T30, 6T40 (Gen. 2), 6T45 (Gen. 2), 6T50 (Gen. 2) ZIP KIT®

Installation &
Testing Booklet

Pump Body • Gen. 2 6T40 Shown

Pressure
Regulator Valve
• Harsh/Soft shifts
• High/Low line pressure
• Burnt clutches

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

05-11-17 6T40-GEN2-ZIP_Booklet
Page 6

GM 6T30, 6T40 (Gen. 2), 6T45 (Gen. 2), 6T50 (Gen. 2) 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 05-11-17
Page 7

TIME TESTED • INDUSTRY TRUSTED

GM 6T30, 6T40 (Gen. 2), 6T45 (Gen. 2), 6T50 (Gen. 2) 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

05-11-17 6T40-GEN2-ZIP_Booklet
Page 8

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