A340E LATE ZIP IN

2017-11-21

: Sonnax A340E-Late-Zip-In A340E-LATE-ZIP-IN 2764 instructions part uploads

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PART NUMBER A340-LATE-ZIP QUICK GUIDE

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

Toyota A340E/F

‘00-Later, V6 & V8 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.

NOTE: Type 4 EPC-style valve body

is shown. Parts will t in the same

locations in a throttle cable-style

and Type 3 EPC-style valve body

except where noted.

Upper Valve Body

Type 4 Shown

Lower

Valve Body

Type 4 Shown

* Not used on

Type 3 valve

bodies.

CAUTION: If replacing an OE

sleeve with NO dot or three

dots, use Sonnax EPC valve

with at on large spool diameter.

If replacing an OE sleeve with two

dots, use Sonnax EPC valve with

at on small spool diameter.

Discard the Sonnax EPC valve that

is not used.

Flat on

large spool

diameter.

Flat on

small spool

diameter.

• If replacing an OE sleeve

with two or three dots, do

NOT add shims.

• If replacing an OE sleeve

with no dots, add shims.

NOTE: Detailed instructions are included on page 8 of installation and testing booklet.

These

checkballs

may or

may not

belong!

CAUTION! Note the location

of OE checkballs during

disassembly! Usage of

checkballs vary greatly!

Toyota A340E/F, ‘00-Later, V6 & V8 ZIP KIT® Quick Guide

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

Step Replace OE End Plugs

Secondary Regulator Valve,

Reverse Control Valve*

*(Type 4 Valve Body Only)

Packaging Pocket 1

• End Plugs, Large (2) • O-Rings (4) 2 extra

Step Replace OE End Plugs

1-2, 2-3 & 3-4 Shift Valves

Packaging Pocket 2

• End Plugs, Medium (3) • O-Rings (5) 2 extra

Step Replace OE End Plug

2nd Coast Modulator Valve

Packaging Pocket 3

• End Plug, Small • O-Rings (2) 1 extra

Step Replace OE End Plug

Accumulator Control Valve

Packaging Pocket 4

• End Plug, Extra Large • O-Rings (2) 1 extra

Step Replace OE Lockup

Assembly

Packaging Pocket 5

• Valve • Sleeve

Step

Select Correct Replacement

EPC Boost Valve

Look at end of the OE boost sleeve for number of identication dots.

If replacing an OE sleeve with NO dots or three dots, use the Sonnax

EPC boost valve with at on large spool diameter. If replacing an OE

sleeve with two dots, use the Sonnax EPC boost valve with at on

small spool diameter. (See page 8 of Installation & Testing Booklet for

more details.)

Packaging Pocket 6

• EPC Boost Valve Flat on Large Spool Dia. (for no/three ID dots)

• EPC Boost Valve Flat on Small Spool Dia. (for two ID dots)

Step Assemble Boost Assembly

Place small reverse valve into sleeve. Place selected EPC boost

valve from step 6 into sleeve, smaller diameter rst. Place cutback

boost valve into sleeve with longer stem facing outboard.

Packaging Pocket 7

• Boost Sleeve

• Reverse Boost Valve

• Cutback Boost Valve

Step Pressure Regulator

Valve Shims

Look at the end of OE boost sleeve for the number of identication

dots. If replacing an OE sleeve with two or three dots, do NOT add

shim. If replacing an OE sleeve with no dots, add both shims. Shims

should be added, if used, between the OE washer and pressure regulator

valve. (See page 8 of installation and testing booklet for more details.)

Packaging Pocket 8

• Shim, .015" thick • Shim, .032" thick

Step Replace OE Large

Checkballs

See checkball caution notes on page 1.

Packaging Pocket 9

• Checkballs, Large .250" dia. (2)

Step Replace OE Small

Checkballs

See checkball caution notes on page 1.

Packaging Pocket 10

• Checkballs, Small .218" dia. (9)

NOTE: These items also are available separately;

Steps 1, 2, 3 & 4 Part No. 97741-19K

Steps 6, 7 & 8 Part No. 97741-01K

The parts listed here may be protected by patent number 8,955,533.

Zip Kit Contents & Installation Steps

Valve Body

Identication

This Zip Kit A340-LATE-ZIP is designed for 2000-later, V6 & V8 applications using Type 3 (valve body

casting identication #8935) or Type 4 (valve body casting identication #8938) style valve bodies.

Type 3 (Casting ID #8935) Valve Body

V8 applications, EPC style throttle control only.

Type 4 (Casting ID #8938) Valve Body

V6 or V8 applications, EPC (shown) or throttle cable style throttle control.

Figure 1 Type 3, Upper Valve Body

Valve Body

Casting ID

Type 3

Contour ID

SLT Solenoid

Figure 3 Type 4, Upper Valve Body

Valve Body

Casting ID

Type 4

Contour ID

SLT Solenoid

Figure 2 Type 3, Lower Valve Body

Valve Body

Casting ID

Pressure Relief

Check Valve

Type 3

Contour ID

S1 Shift

Solenoid

Separator

Plate ID

Pressure Regulator

Valve (visible)

S2 Shift

Solenoid SL Shift

Solenoid

Accumulator

Piston Assembly

TC Control Valve

(visible here if used)

Figure 4 Type 4, Lower Valve Body

Valve Body

Casting ID

Pressure Relief

Check Valve

Type 4

Contour ID

S1 Shift

Solenoid

Separator

Plate ID

Pressure Regulator

Valve (visible)

S2 Shift

Solenoid

TC Control Valve

(visible here if used)

Alternate Configuration: May have

same lineup as Type 3, Figure 2

SL Shift

Solenoid

Accumulator

Piston Assembly

Toyota A340E/F

‘00-Later, V6 & V8 ZIP KIT®

PART NUMBER A340-LATE-ZIP INSTALLATION & TESTING BOOKLET

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

Toyota A34OE/F, ‘00-Later, V6 & V8 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Type 3 (Casting ID #8935) Valve Body

V8 applications, EPC style throttle control only.

Type 4 (Casting ID #8938) Valve Body

V6 or V8 applications, EPC (shown) or throttle cable style throttle control.

Torque

Specifications

Detent Spring Bolt

89 in-lbs (10 N.m)

Oil Pan Bolt

65 in-lbs (7.3 N.m)

Solenoid-to-Valve

Body Bolt

89 in-lbs (10 N.m)

Type 3 Valve

Body to Case Bolts

Bolt Color

Code

Bolt

Length

1Red 23mm

2Green 28mm

3Blue 36mm

Torque all to 8 ft-lbs

Type 4 Valve

Body to Case Bolts

Bolt Color

Code

Bolt

Length

1Purple 23mm

2White 28mm

3Yellow 36mm

Torque all to 8 ft-lbs

Type 3 & 4

Oil Pan Filter Bolts

Bolt Color

Code

Bolt

Length

APink 14mm

BBlack 20mm

COrange 23mm

Torque to 7 ft-lbs

Type 3 & 4 Valve Body

Disassembly Bolts

Bolt Color

Code

Bolt

Length

ALt. Purple 20mm

BTeal 28mm

CBrown 40mm

Torque to 57 in-lbs

Bolt Locations & Torque Specications

Type 3, Lower Valve Body, Case Removal - Bolt Locations

Figure 5

Type 4, Lower Valve Body, Case Removal - Bolt Locations

Figure 7

Type 3, Upper Valve Body, Valve Body Disassembly - Bolt Locations

Figure 6

Type 4, Upper Valve Body, Valve Body Disassembly - Bolt Locations

Figure 8

Toyota A34OE/F, ‘00-Later, V6 & V8 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Clutch & Band Application Chart

Selector

Position - Gear C0 C1 C2 B0 B1 B2 B3 F0 F1 F2

Park ON

Reverse ON ON ON ON

Neutral ON

D-1st Gear ON ON ON ON

D-2nd Gear ON ON ON ON ON

D-3rd Gear ON ON ON ON ON

D-Overdrive ON ON ON ON

2-1st Gear ON ON ON ON

2-2nd Gear ON ON ON ON ON ON

2-2nd Gear ON ON ON ON ON

Low-1st Gear ON ON ON ON ON

Low-2nd Gear ON ON ON ON ON ON

Figure 9 Shift Solenoid Chart

Selector

Position - Gear

Shift Solenoid

D - 1st Gear ON Off

D - 2nd Gear ON ON

D - 3rd Gear Off ON

D - Overdrive Off Off

2 - 1st Gear ON Off

2 - 2nd Gear ON ON

2 - 3rd Gear Off ON

Low - 1st Gear ON Off

Low - 2nd Gear ON ON

Figure 10

Solenoid Malfunctioning Shift Strategies

Selector

Position -

Normal Gear

Shift Solenoid S1 (A)

Malfunctioning

Shift Solenoid S2 (B)

Malfunctioning

Both Solenoids

Malfunctioning

(A)

(B) Gear S1

(A)

(B) Gear Gear

When selector position

in manually operated

D-1st Gear X ON 3rd ON X 1st Overdrive

D-2nd Gear X ON 3rd Off X O/D Overdrive

D-3rd Gear X ON 3rd Off X O/D Overdrive

D-Overdrive

XOff O/D Off X O/D Overdrive

2-1st Gear X ON 3rd ON X 1st 3rd

2-2nd Gear X ON 3rd Off X3rd 3rd

Low-1st Gear XOff 1st ON X 1st 1st

Low-2nd Gear X ON 2nd ON X 1st 1st

Figure 12

Solenoid Diagnostic Trouble Chart

DTC Description

P0750 Shift Solenoid S1 (A)/S2 (B) Malfunction

P0753 Shift Solenoid S1 (A)/S2 (B) Electrical Malfunction

P0755 Shift Solenoid S1 (A)/S2 (B) Malfunction

P0758 Shift Solenoid S1 (A)/S2 (B) Electrical Malfunction

P0770 Shift Solenoid SL (E) Malfunction

P0773 Shift Solenoid SL (E) Electrical Malfunction

Figure 11

Shift Strategies

e computer (ECM) controls the ON/O combina-

tion of the shift solenoids S1 (A) and S2 (B) to shift

between 1st gear and overdrive (O/D). If an electri-

cal failure occurs in one of these two solenoids, the

computer continues to control the other solenoid to

allow the vehicle to operate as smoothly as possible

while in Fail Safe mode. e ECM also turns o the

SL (E) solenoid during Fail Safe. Should both solenoids

S1 (A) and S2 (B) fail, shifting must be done manually.

Figures 11 and 12 give typical solenoid codes and sole-

noid malfunctioning shift strategies.

To test shift solenoids S1 (A), S2 (B) or SL (E) for

sticking, force 71 psi of compressed air into the snout

(Figure 13, arrow); it should not leak. Energizing the

solenoids should cause them to open and allow air

ow. Resistance on these three shift solenoids should be

11–15 ohm at 68˚F, and resistance on the SLT solenoid

should be 5.0–5.6 ohm at 68˚F.

Some valve bodies have an accumulator piston assem-

bly (Figure 14) that can be mistaken for a solenoid. is

is actually an accumulator for lockup and should be

checked to ensure the piston can move freely.

Figure 14

Figure 13

Toyota A34OE/F, ‘00-Later, V6 & V8 ZIP KIT® Installation & Testing Booklet

Page 4 800-843-2600 • 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.

*Part numbers with an asterisk (*) are included in this Zip Kit.

1. Primary Regulator Valve

• Delayed Shifts

• Poor Shift Quality

• Burnt clutches & brakes

• Delayed engagements

Replace with Sonnax Part No.

97741-06K EPC valve spool .426” dia.; replaces OE

2-dot boost sleeve

97741-10K EPC valve spool .353” dia.; replaces OE

3-dot or no-dot boost sleeve

97741-06K & 97741-10K: Requires F-97741-TL6 & VB-FIX

2. Boost Assembly

• Delayed Forward/Reverse engagement

• Soft shifts

• No kickdown

• Burnt clutches & brakes

Replace with Sonnax Part No.

97741-01K*

3. TCC Control Valve &

Plunger Assembly

• Loss of lockup

• Converter slips/shudder/codes

5. Lockup Relay Valve

& Plunger Assembly

Lockup complaints/codes

Replace with Sonnax Part No.

77741-02K* Lockup Relay Control Valve Kit

97741-20K Oversized Lockup Relay Valve Kit

97741-20K: Requires F-97741-TL20 & VB-FIX

6. Secondary Modulator Valve

• Shift complaints

• Solenoid codes

Lower Valve Body • Type 3, EPC Style Shown Here

4. Secondary Regulator Valve

• TCC complaints

• Lockup codes

• Loss of lube

• Burnt clutches & brakes

Replace with Sonnax Part No.

97741-18K Requires F-39741-TL18 & VB-FIX

Upper Valve Body • Type 3, EPC Style Shown Here





Toyota A34OE/F, ‘00-Later, V6 & V8 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

For specic vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

VACUUM

TEST

7. Accumulator Control Valve

• Shift complaints

• Solenoid codes

• Loss of throttle/line pressure

8. Cutback Valve

• No kickdown

• Loss of throttle pressure

9. Low Coast

Modulator Valve

• Burnt 1st/Reverse brake (B3)

• Loss of manual low

10. 2nd Coast Modulator

Valve

• Burnt 2nd brake (B2)

• Loss of manual second

11. 3–4 Shift Valve

3–4 Shift complaints

14. Reverse Control Valve

• Delayed Reverse

• No Reverse

15. End Plugs

• Slips & ared shifts

• Soft shifts

• Low line pressure

Replace with Sonnax Part No.

97741-19K* NOTE: Several Locations =

12. 2–3 Shift Valve

2–3 Shift complaints

13. 1–2 Shift Valve

1–2 Shift complaints

Lower Valve Body • Type 4, EPC Style Shown Here

Upper Valve Body • Type 4, EPC Style Shown Here

  





Toyota A34OE/F, ‘00-Later, V6 & V8 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

206 205

204

201

202

203

207

NOTE: Filters should be installed into the separator

plate during assembly. The open end of the lter

snaps into the plate opening.

OE Exploded View

Upper & Lower Valve Body • Type 3, EPC Style Shown Here

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

Lower Valve Body Descriptions

I.D. No. Description

201 Accumulator Control Valve

202 Secondary Modulator Valve

203 Cutback Valve

204 Primary Regulator Valve

& Boost Assembly

205 Converter Limit Valve

206 Manual Valve

207 1–2 Shift Valve

Lower Valve Body - Type 3

Upper Valve Body - Type 3

106

105

104

101

102

103

.250" dia.

.090" dia.

Orice

.150" dia.

Orice

Separator

Plate

Upper Valve Body Descriptions

I.D. No. Description

101 Lockup Relay Valve

& Plunger Assembly

102 3–4 Shift Valve

103 2nd Coast Modulator Valve

104 Low Coast Modulator Valve

105 2–3 Shift Valve

106 Secondary Regulator Valve

Checkball Cautions

& Notes

• Care should be taken

during disassembly. Note location of

checkballs as usage varies greatly!

• When determining when a

checkball is required, the circuit

orice in the separator plate over

that location will be about .090"

dia. When no ball is required, the

orice will be about .150" dia.

• All checkballs are .218" dia. except

where noted (.250" dia.).

Toyota A34OE/F, ‘00-Later, V6 & V8 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Upper & Lower Valve Body • Type 4, EPC Style Shown Here

NOTES: Depending upon vehicle application, the OE springs shown may not be present. Slight wormtrack difference and valve components will vary in

throttle cable style valve bodies.

206

205

204**

201

202

203

209

208

207

Large Filter

Teardrop

Filter

Small Filter

Lower Valve Body Descriptions

I.D. No. Description

201 Accumulator Control Valve

202 Secondary Modulator Valve

203 Cutback Valve

204** TCC Control Valve

& Plunger Assembly

205 Primary Regulator Valve

& Boost Assembly

206 Converter Limit Valve

207 Manual Valve

208 1–2 Shift Valve

209 Low Coast Modulator Valve

**Not in all applications

108

106

101

103

102

104*

105*

107

.250" dia.

.090" dia.

Orice

.150" dia.

Orice

Separator

Plate

Upper Valve Body Descriptions

I.D. No. Description

101 Lockup Relay Valve

& Plunger Assembly

102 3–4 Shift Valve

103 2nd Coast Modulator Valve

104* Check Valve

105* Check Valve

106 Reverse Control Valve

107 2–3 Shift Valve

108 Secondary Regulator Valve

*Not in throttle cable style.

Lower Valve Body - Type 4

Upper Valve Body - Type 4

Please review

Checkball

Cautions & Notes as well

as Filter Note on page 6 as

they apply to both Type 3

& Type 4 valve bodies.

Toyota A34OE/F, ‘00-Later, V6 & V8 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Detailed Instructions for Steps to from Quick Guide

For Replacing a No–Dot OE Boost Valve Assembly

Add 2 Sonnax

Shims Under OE

Washer Choose Sonnax

EPC Boost Valve

with Flat on Large

Diameter

Primary Regulator

Valve & Boost

Assembly Bore

Figure 15

For Replacing a 2–Dot OE Boost Valve Assembly

Do NOT add

Sonnax Shims

Here

Choose Sonnax

EPC Boost Valve

with Flat on Small

Diameter

Primary Regulator

Valve & Boost

Assembly Bore

Figure 16

For Replacing a 3–Dot OE Boost Valve Assembly

Do NOT add

Sonnax Shims

Here Choose Sonnax

EPC Boost Valve

with Flat on Large

Diameter

Primary Regulator

Valve & Boost

Assembly Bore

Figure 17

A340E LATE ZIP IN

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