77754 03K IN
77754-03K-In 77754-03K-IN 77754-03K-IN 2457 instructions part uploads sonnax-dev
2015-07-02
: Sonnax 77754-03K-In 77754-03K-IN 874 file instruction uploads
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T R A N S M IS S ION PART S Instructions Part No. 77754-03K R TOOL EQ D TCC Regulator & Isolator Valve Kit GM 4L60-E, 4L65-E, 4L70-E UIRE Isolator Valve • Isolator Valve • Spring • Regulator Valve • Regulator Sleeve Spring 4L60-E Valve Body Regulator Sleeve Regulator Valve Patent Nos. 6,990,996 & 7,104,273 NOTE: See "Part Selection" on this page and "Reaming Options" on page 2 for usage & tooling requirements. 77754-SERV F-77754-TL4 77754-R2 77754-RM5 Required for 77754-ISO 1. Part Selection a. T here are two TCC regulator valve kit options. Selection is based on the application year and TCC apply strategy. • 77754-04K matches the OE apply rate. It can be used in any application and is required in ‘98-later vehicles using EC3 apply strategy. • 77754-03K has an increased apply rate and should only be used in ‘97-earlier vehicles which do not use EC3 apply strategy, though it can be used in PWM applications. b. Measure OE Isolator Valve Diameter & Evaluate Isolator Section of Bore for Wear. OE Isolator Valve Diameter Isolator Bore Worn? Use Reaming Option Install Sonnax Part Number .441" No Reaming Option A 77754-03K or 77754-04K .441" Yes Reaming Option B 77754-03K or 77754-04K and 77754-ISO .473" N/A Reaming Option C 77754-03K or 77754-04K and 77754-ISO ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 77754-03K-IN 06-26-15 Page 1 T R A N S M IS S ION PART S Instructions TCC REGULATOR & ISOLATOR VALVE KIT 77754-03K, 77754-R2, 77754-SERV, 77754-RM5, F-77754-TL4 Tool Kits 2. Reaming Options Part No. 77754-R2 Reamer 77754-SERV Reamer • Bench Tool option – use 77754-R2 • F-tool option – use F-77754-TL4 and VB-FIX For Non-Serviced VB Part No. b. Isolator valve was .441" dia. but isolator bore is worn: For GM-Serviced VB Part No. 77754-RM5 Reamer Use with 77754-ISO Part No. F-77754-TL4 • Reamers (2) • Reamer Jigs (2) • Guide Pin • Stop Pin NOTE: Sonnax “F-Tool” kits designed to service a specific bore require the VB-FIX, a self-aligning valve body reaming fixture. More information and instructions can be found online at www.sonnax.com. Figure 1 a. Isolator valve was .441" dia. and isolator bore is not worn: • Bench Tool option – use 77754-R2 followed by 77754-RM5 • F-tool option – use F-77754-TL4 and VB-FIX NOTE: If casting has "SERV" stamped here, follow reaming option C. c. Isolator valve was .473" dia. – GM Service valve body (Figure 1): • Bench Tool option – use 77754-SERV followed by 77754-RM5 • F-tool option – use F-77754-SERV followed by F-77754-TL4, each using VB-FIX NOTE: Tool kit F-77754-SERV is no longer in production but may be available from distributor inventory. 3. Disassembly Remove and discard OE valve train. Save OE retainer for reuse. 4. Reaming Instructions NOTE: The following reaming instructions are for Bench Tool reaming only (see reaming options A, B or C above). Reaming directions for F-tool kits that utilize the VB-FIX can be found on those individual tool kit instructions. CAUTIONS & SUGGESTIONS: • Turning the reamer backward will dull it prematurely. • Pushing on the reamer will result in poor surface finish and inadequate and sporadic material removal. • Never use a crescent wrench, ratchet or pliers to turn the reamer. • A dull reamer will cut a smaller hole. Reamers can be sharpened, but should only be done by a professional tool sharpener. Actual life of a Sonnax reamer before resharpening or replacing averages 50-70 bores. a. Clean bore thoroughly in a solvent tank. b. Generously lubricate the bore and reamer with cutting fluid (i.e. Mobilmet S-122, Lubegard® Bio-Tap, Tap Magic™, etc.). For best results, provide a continuous flow of cutting fluid during the reaming process. c. Gently insert the proper reamer into the bore until the cutting tip contacts the first land to be reamed. For Bench Tool options A or B, use 77754-R2 for this step. For Bench Tool option C, use 77754-SERV for this step. d. Use a loose-fitting reamer socket and a wobble adapter to ream the bore. The reamer can be turned by using a speed handle or with a low-RPM, high-torque drill regulated to a maximum of 200 RPM. The reaming actions must be clockwise in smooth and continuous motion at 60-200 RPM. Continue reaming until the reamer stop is reached. ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 77754-03K-IN 06-26-15 Page 2 T R A N S M IS S ION PART S TCC REGULATOR & ISOLATOR VALVE KIT 77754-03K, 77754-R2, 77754-SERV, 77754-RM5, F-77754-TL4 Instructions 4. Reaming Instructions (continued) e. Using low air pressure, blow the chips free before removing reamer. f. To remove the reamer, turn clockwise while slowly pulling outward. g. If performing bench reaming option A, proceed to step 5, "Installation & Assembly". If performing bench reaming option B or C, repeat steps "a" through "f" with reamer 77754-RM5. 5. Installation & Assembly a. Ensure valve bore and body is clean and cleared of dirt and debris. b. Refer to Figures 2 and 3 for correct Sonnax valve train installation lineup. Consult Figures 4, 5 and 6 to determine whether your original lineup was PWM or non-PWM. c. F or PWM applications: Install Sonnax valve lineup as pictured in Figure 2. Use transjel to retain spring in the isolator valve during installation. For non-PWM applications: Install Sonnax valve lineup as pictured in Figure 3. d. I nsert valve/sleeve assembly into the valve body, just deep enough to reinstall OE retaining clip around sleeve. Sonnax Installed Non-PWM Sonnax Installed PWM Regulator Valve Isolator Valve Isolator valve installs with no spring. Figure 2 Regulator Sleeve Spring Figure 3 Isolator Valve Install Spring Pocket First Regulator Valve Regulator Sleeve PWM Valve Lineup OE ‘98–Later PWM OE ‘93–‘97 PWM Common to EC3 controls. Two solenoids at front of body and 13-pin case connector. Figure 5 Figure 4 Wear Isolator Valve Regulator Valve ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Wear Isolator Valve Regulator Valve 77754-03K-IN 06-26-15 Page 3 T R A N S M IS S ION PART S TCC REGULATOR & ISOLATOR VALVE KIT 77754-03K, 77754-R2, 77754-SERV, 77754-RM5, F-77754-TL4 Instructions Figure 7 Non-PWM Valve Lineup OE ‘91–‘94 Non-PWM One solenoid at front of body and 12-pin case connector. Figure 6 A Wear B One-Piece Regulator Valve NOTE: Since the castings for PWM and non-PWM valve bodies are identical, this kit can be used when updating a non-PWM valve body for use in a PWM unit or retrofitting a PWM valve body for use in a non-PWM unit. The separator plate must also be changed when this is done (Figure 7). PWM plates have “A” & “B” holes (Figure 7). Non-PWM plates do not have holes “A” & “B” (Figure 7). ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 77754-03K-IN 06-26-15 Page 4
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