6T40 GEN2 ZIP IN

2017-05-25

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

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PART NUMBER 6T40-GEN2-ZIP QUICK GUIDE

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

GM 6T30, 6T40 (GEN. 2), 6T45 (GEN. 2),

6T50 (GEN. 2) 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.

6T40 (Gen. 2)

Control

Valve Body

Plastic Checkballs

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.

CAUTIONCAUTION

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).

CAUTION:

Failure to

block

orice

will result in no

movement of vehicle.

CAUTIONCAUTION

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

Step 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.

CAUTION: The small shuttle valve should be positioned with the

rounded end face outboard, and the blind bore inboard.

Packaging Pocket 2

• Spring

• Valve

• Shuttle Valve

• End Plug

• O-Rings (2) 1 extra

Step Block AFL Balance Port

Drill indicated separator plate orice 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 t ush on

both castings.

CAUTION: Failure to block orice will result in no movement of vehicle.

Packaging Pocket 3

• Drill Bit, .062" dia.

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

CAUTION: Use care when modifying the balance orice.

Gaskets are bonded to the plates and damage could occur.

CAUTIONCAUTION

Step Replace 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

sleeve groove after installation.

Packaging Pocket 4

• Sleeve

• Valve

• Spring

• Retainer Clip

Step Replace OE Checkballs

Packaging Pocket 5

Checkballs, .250" dia. (6)

CAUTIONCAUTION

Zip Kit Contents & Installation Steps

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

Figure 1

6T40 Generation 1 Transmission

Electro-Hydraulic Control Module

(TEHCM)

TCM

Upper section is control

solenoid (w/body & TCM)

valve assembly

Lower section

is control valve

body assembly

Valve Body Identication

Conrm Generation

is 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). e 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 identier 8th digit.

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 6T30, 6T40, 6T45 and

6T50 are equipped with sever-

al adaptive 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 the proper “Fast Learn” process.

Solenoids

e 6T30 and Generation 2 6T40, 6T45 and 6T50 sole-

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

ese are calibrated at the factory and switching solenoids

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.

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

Figure 3

TCM Identier is 8th digit from left.

TCM Identier Figure 4

Generation 1 1 or 2 or 3

Generation 2 B or C

or D

GM 6T30, 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

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

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

TIME TESTED • INDUSTRY TRUSTED

Installation &

Testing Booklet

Additional Identication Information

Generation 1 Generation 2

Number "12"

in casting circle

is the 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

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TIME TESTED • INDUSTRY TRUSTED

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

Installation &

Testing Booklet

Additional Identication 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

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

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

TIME TESTED • INDUSTRY TRUSTED

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.

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 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

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 (2) 53mm and

(9) 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 (12) 30mm and (3) 40.5mm bolts until nger-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).

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

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

TIME TESTED • INDUSTRY TRUSTED

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

Control Valve Body Assembly – 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 Low Reverse &

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 lockup

• TCC slip

• Harsh/Soft TCC apply

Replace with Sonnax Part No.

144740-16K

Requires F-144740-TL16 & VB-FIX

Default Override

Valve

• Engagement concerns in

Reverse when in failsafe

or default.

NOTE: Look in bore for

visual wear.

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

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

TIME TESTED • INDUSTRY TRUSTED

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.

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

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

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

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

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

TIME TESTED • INDUSTRY TRUSTED

Installation &

Testing Booklet

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 IN

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