A750E A761E ZIP IN C
2017-08-21
: Sonnax A750E-A761E-Zip-In C A750E-A761E-ZIP-IN_C 3477 instructions part uploads
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Toyota/Lexus A750E/F, A760E/F/H, A761E, A960E/F, AB60E/F ZIP KIT ® PART NUMBER A750E-A761E-ZIP QUICK GUIDE Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents. installation Diagram CAUTION! Step 5 must confirm OE application and sleeve size first. See notes on page 2. Upper Valve Body 4 Reuse OE Spring 5 2 3 ** 2 Note: A761 Valve Body Shown. A750E/F Valve Bodies Vary. * A760E/F/H, A761E, A960E/F AB60E/F ONLY ** A750E/F ONLY Upper Valve Body #2 2 2 * 7 * * CAUTION! Steps 8 & 9: Must note locations of adjustable steps prior to removal. See notes on page 2. 2 3 ** 6 8 * 6 ** 9 Reuse OE Spring * Lower Valve Body #2* 2 10 3 * Lower Valve Body * 9 * 3 ** 2 CAUTION! Note the location of OE checkballs during disassembly! Location and quantity of checkballs varies depending upon vehicle application! * 2 1 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 A750E-A761E-ZIP-Guide_C 08-03-17 Page 1 Toyota/Lexus A750E/F, A760E/F/H, A761E, A960E/F, AB60E/F ZIP KIT® Quick Guide Zip Kit Contents & Installation Steps FOR STEPS 1–4: Place O-ring in shallow groove. Install end plugs with O-ring outboard. Step 1 Replace OE 9mm End Plug Packaging Pocket 1 • End Plug, 9mm • O-Rings (2) • Piston Packaging Pocket 2 • O-Rings (15) 6 extra NOTE: Seven end plugs are used in A750E/F units, while ten end plugs are used in A760E/F/H & A761E, A960E/F. Step 3 NOTE: Save OE springs, cap and retainer for reuse. Install piston, O-ringed end first. Packaging Pocket 7 1 extra 2 Replace OE 11mm End Plugs Step • End Plugs, 11mm (9) Step 7 R eplace OE B1 Accumulator Piston Replace OE 12mm End Plug • O-Rings (2) 1 extra Step 8 R eplace OE Boost Valve Assembly NOTE: Prior to removal, note the position of the adjustable step on the OE boost sleeve. Reuse OE retainer and make sure it is set at the same step location on the Sonnax boost sleeve. Packaging Pocket 8 • Sleeve • Boost Valve • Reverse Boost Valve Packaging Pocket 3 • End Plugs, 12mm (3) • O-Rings (4) 1 extra • Bolt (1) NOTE: Bolt used as tool for installation of threaded end plug into bore in lower valve body. Step 4 Replace OE 14mm End Plug Packaging Pocket 4 • End Plug, 14mm • O-Rings (2) For AB60E/F applications, remove valve from .602" dia sleeve and install with .616" dia. sleeve. Reuse OE spring with all applications. Packaging Pocket 5 A750E/F, A761E, A960E/F A760E/F/H, AB60E/F Step 6 Replace OE Solenoid Modulator Valve Lineup NOTE: This lineup is in different locations based upon transmission type. Save OE retainer for reuse. Install Sonnax sleeve/valve assembly with sleeve end face notches inboard and long valve stem outboard. Install Sonnax spring over valve stem. Push the end plug in, stepped end first, fitting the spring into the spring pocket. Secure with OE retainer. Packaging Pocket 6 • Valve • Sleeve • Spring Packaging Pocket 9 • Plunger Valve • Shims (4) Selective • Sleeve installation and testing booklet. Step 5 Replace OE Lockup Control Plunger Valve & Sleeve NOTE: Verify OE application and sleeve OD per chart. • Sleeve (.616" dia.) NOTE: This lineup is in different locations based upon transmission type. NOTE: Detailed instructions and illustrations on page 8 of 1 extra • Valve/Sleeve Assembly (.602" dia. sleeve) Step 9 R eplace OE Accumulator Control Plunger Assembly • End Plug ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Prior to removal, note the position of the OE retaining pin on the step of the OE castellated plunger sleeve. Save the OE retaining pin and spring (between valve and sleeve bore) for reuse. Refer to chart for shim assembly details. After correct number of shims are installed over the long stem of Sonnax plunger valve, place OE spring over long stem of Sonnax plunger valve. Install this valve/shim/spring assembly into Sonnax sleeve, spring end first. Push assembly into bore and secure with OE retaining pin. OE Sleeve Notch Pin Location Install This Many Shims Deepest 0 2nd Deepest 1 Middle 2 2nd Shallowest 3 Shallowest 4 Step 10 Replace OE Checkballs NOTE: For best results, note location of OE checkballs prior to valve body disassembly. Checkball quantities and locations vary with specific valve body applications. Packaging Pocket 10 Checkballs, .218" dia. (20) A750E-A761E-ZIP-Guide_C 08-03-17 Page 2 Toyota/Lexus A750E/F, A760E/F/H, A761E, A960E/F, AB60E/F ZIP KIT ® PART NUMBER A750E-A761E-ZIP A750 Series 5-Speed, 7 Solenoids INSTALLATION & TESTING BOOKLET A760 Series 6-Speed, 9 Solenoids A750E Shown Upper Valve Body Casting # A761E Shown Upper Valve Body Cover Casting # Upper Valve Body Lower Valve Body Casting # Under Solenoid *Solenoid size, connector color and orientation can vary. SL1* S1 Lower Valve Body Casting # SLT* S2 S3 SLU* SR SL2* A750E Shown SLU** S2 S4 S1 SR SL1 SLT A761E Shown SL2 Lower Valve Body A761E, A960E, A760 & AB60E Valve Body ID All of the solenoid ID and locations are the same. The only easy way to tell these units apart is the casting numbers. Proper identification of this valve body is critical! **NOTE: For a quick identification the SLU connector is Blue on these models. Valve Body Type Large Lower Casting # Large Upper Casting # Small Lower Casting # Small Upper Casting # Small Lower Plate Code Small Upper Plate Code Large Plate Code A760** 89030 89060 89010 89020 F04 F09 F12 A761 8870 8870 8870 8870 F02 F03 F04 A960 8840 8840 8840 8840 S03 S02 S03 AB60** 89030 89060 89010 89020 F04 L01 L01 ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com A750E-A761E-ZIP-Booklet_C 08-03-17 Page 1 Toyota/Lexus A750E/F, A760E/F/H, A761E, A960E/F, AB60E/F ZIP KIT®Installation & Testing Booklet TIME TESTED • INDUSTRY TRUSTED Bolt Locations & Torque Specifications Valve Body Disassembly Bolts Bolt Color Code Valve Body to Case Bolts Bolt Length A Pink 20mm B Teal 25mm C Orange 32mm D White 40mm E Yellow 45/50mm F Black G H Reset Memory The Engine Control Module (ECM) in these transmissions adapts to the conditions of the engine and transmission assemblies. When replacing the engine, transmission, valve body or the ECM you must reset the memory so that the ECM can adapt to new conditions. Oil Filter Bolts Bolt Color Code Bolt Length Bolt Color Code Bolt Length 1 Red 25mm 7 Various 2 Green 36mm 3 Blue 45mm 4 Brown 50mm Purple Torque to 7 ft-lb Follow OE procedures to reset the memory. Afterwards, follow the OE road test procedures. Solenoid Bolts Flex Lockup Clutch Control Bolt Color Code Bolt Length 60mm 5 11.5mm Olive 64mm Torque above to 57 in-lb Gray 76mm 6 Torque to 8 ft-lb Lt. Blue Peach The ECM regulates the SLU solenoid to provide an intermediate mode between the On/Off operation of the converter clutch in the low-to-mid-speed range. This is for improved fuel economy. Lockup control is prohibited if the brake is depressed, the accelerator pedal is released or engine coolant temperature is below 140°F. 12mm Torque above to 7 ft-lb Torque to 57 in-lb A750 Series Valve Bodies A760 & A960 Series Valve Bodies (A750E shown) (A761E shown) Figure 1 B E B BA E D D C D D B C C E E A B D D C B H B D B B G B C A D G B D D D E G G D E G G G D E D D D F B C B E B C E E Figure 3 B E B C NOTE: This bolt location varies • A760 Series = 25mm • A960 Series = 20mm Upper Valve Body, Valve Body Disassembly - Bolt Locations Upper Valve Body, Valve Body Disassembly - Bolt Locations Figure 4 Figure 2 1 2 1 1 5 1 1 1 1 1 1 1 1 5 7 2 7 1 2 2 2 6 4 6 2 6 2 2 6 3 2 2 2 7 5 7 2 2 1 5 5 1 4 2 1 7 5 5 2 7 1 Lower Valve Body, Case Removal - Bolt Locations 08-03-17 A750E-A761E-ZIP-Booklet_C Page 2 1 1 3 5 7 1 7 2 2 Lower Valve Body, Case Removal - Bolt Locations ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Toyota/Lexus A750E/F, A760E/F/H, A761E, A960E/F, AB60E/F ZIP KIT®Installation & Testing Booklet Selector Position Solenoid Valve S1 S2 SR SL1 Clutch SL2 SLU C1 P-Park ON ON R-Reverse* ON ON N-Neutral ON ON 1st ON ON 2nd ON ON ON ON ON Drive 3rd S5 4th* ON 5th* ON 1st ON Drive 2nd ON S4 3rd ON Drive ON ON ON ON S4 ON 1st ON 2nd ON 3rd* ON ON 4th* ON ON Drive S2 1st ON 2nd* ON ON S1 1st* ON C2 Brake C3 B1 B2 One-Way Clutch B3 B4 F1 F2 F3 A760 Series S1 11-15 11-15 S2 11-15 11-15 11-15 6 5.0-5.6 SL2 6 5.0-5.6 SLU 6 5.0-5.6 SLT 6 5.0-5.6 S3 – 11-15 S4 – 11-15 Test all at 68oF ON A750 Series 11-15 CHART KEY: = In operation. = Applied but ineffective. = Operates during engine braking. * = Engine braking occurs Resistance Ohms SR Figure 6 SL1 ON ON ON ON Solenoids Figure 5 Solenoid A750E/F Component & Solenoid Apply TIME TESTED • INDUSTRY TRUSTED Figure 7 A760, A960 & AB60 Series Component & Solenoid Apply Selector Position Solenoid Valve S1 S2 S3 ON ON ON R-Reverse* ON ON ON ON N-Neutral ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON Drive S6 ON 3rd ON 4th ON 5th ON 6th ON 1st Drive S5 2nd ON 3rd ON 4th ON 5th ON 1st 2nd ON S4 3rd ON 4th* ON Drive S3 1st 2nd ON ON 1st 2nd* S1 1st* ON ON SL2 ON ON ON ON SLU C1 ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com B1 B2 B3 B4 F1 F2 ON ON ON F3 F3 ON ON C4 ON ON C3 ON ON C2 ON ON 3rd* Drive S2 ON ON ON Drive SL1 One-Way Clutch ON 2nd SR Brake P-Park 1st S4 Clutch A750E-A761E-ZIP-Booklet_C 08-03-17 Page 3 Toyota/Lexus A750E/F, A760E/F/H, A761E, A960E/F, AB60E/F 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. A750 Series • Lower Valve Body 22 Block valve outboard with .218" dia. checkball. 1. Primary Regulator Valve 1 7 • Low/High line pressure • Clutch & band failures • Soft/Harsh shifts • Low converter pressure 10 Replace with Sonnax Part No. 147741-04K Requires F-147741-TL4 & VB-FIX 2. Boost Assembly • Insufficient line rise • Soft/Harsh shifts • High Reverse pressure • Clutch & band failures Replace with Sonnax Part No. 147741-01K* 3. Lockup Relay Valve •T CC apply & release concerns/codes 16 Replace with Sonnax Part No. 147741-07K Requires F-147741-TL7 & VB-FIX 4. Secondary Regulator Valve 15 11 • TCC apply & release concerns • Harsh lockup • Lube failures 2 Replace with Sonnax Part No. 147741-10K Requires F-147741-TL4 & VB-FIX 21 Upper Valve Body Block valve outboard with .218" dia. checkball. Seal port on back. 17 18 Seal port on back. 15 23 Test together. 5. B1 Accumulator Piston 5 • 4-5 Shift complaints (A750 Series) • 4-5, 5-6 Shift complaints (A760 Series) 12 Replace with Sonnax Part No. 57917E-19K* 6. Solenoid Modulator Valve • Solenoid codes • TCC slip cycling • Shift complaints • Low cooler flow 4 Replace with Sonnax Part No. 147741-05K Requires F-147741-TL5 & VB-FIX 7. Clutch Control Valve • Harsh up/down shifts • Flare shifts Replace with Sonnax Part No. 147741-22K A750 Series 147741-14K A760 & A960 Series Requires F-147741-TL22 or F-147741-TL14 & VB-FIX 24 Block valve outboard with .218" dia. checkball. 15 8 19 Seal port on back. Upper Valve Body No. 2 15 3 8. Lockup Control Valve • Harsh downshifts • RPM surge on coast Replace with Sonnax Part No. 147741-16K A750, A761 & A960 Series 157740-16K A760 & AB60 Series Requires F-147741-TL16 or F-157740-TL16 & VB-FIX 6 25 9 Inset: View of reverse side of upper valve body. Similar location on A760 series. 9. Lockup Control Plunger Valve & Sleeve • Harsh downshifts • RPM surge on coast Replace with Sonnax Part No. 147741-37K A750, A761 & A960 Series 157740-37K A760 & AB60 Series *Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately. 08-03-17 A750E-A761E-ZIP-Booklet_C Page 4 ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Toyota/Lexus A750E/F, A760E/F/H, A761E, A960E/F, AB60E/F ZIP KIT®Installation & Testing Booklet 20 15 TIME TESTED • INDUSTRY TRUSTED 10 25 5 0 30 VACUUM TEST For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com. A760, A960 & AB60 Series • Lower Valve Body 10. Accumulator Control Valve • Shift concerns • Shift codes • Harsh shifts Block valve inboard with .218" dia. checkball. 20 Replace with Sonnax Part No. 147741-24K Requires 147741-TL24 1 11. A ccumulator Control Plunger Valve & Sleeve • Shift concerns • Harsh shifts • Shift codes 16 Replace with Sonnax Part No. 147741-43K* 12. Brake Control Valve • Shift concerns • Harsh shifts • Flare shifts • Burnt bands 14 Replace with Sonnax Part No. 147741-28K Requires F-147741-TL28 & VB-FIX Upper Valve Body 13. B2 Accumulator Pistons Seal port on back. • Harsh/Slipping 5-6 shifts • Harsh 3-2 downshifts Replace with Sonnax Part No. 2 19 147741-13 22 18 17 21 14 14 Test together. 5 14. & 15. End Plugs Various complaints depending on locations of leaking end plug. 4 14. Replace with Sonnax Part No. 147741-30K 15. Replace with Sonnax Part No. 147741-31K 16. SLT Damper • Harsh/Soft shifts • Loss of pressure control 17. 18. 19. 20. 21. 22. 23. 24. 1-2 Shift Valve 2-3 Shift Valve 3-4 Shift Valve 4-5 Shift Valve Clutch Apply Control Valve Sequence Valve Clutch Lock Valve B1 Apply Control Valve & Assembly 25. Coast Brake Relay Valve 13 8 14 Seal port on back. 7 Seal port on back. Lower Valve Body No. 2 NOTE: May not have a valve in this locaiton if upper valve body #2 has a casting number of 89010. 26. C3 Apply Relay Valve 12 14 3 14 Upper Valve Body No. 2 11 24 6 10 21 14 26 • Related shift complaints • Burnt clutches/brakes ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com A750E-A761E-ZIP-Booklet_C 08-03-17 Page 5 Toyota/Lexus A750E/F, A760E/F/H, A761E, A960E/F, AB60E/F ZIP KIT®Installation & Testing Booklet TIME TESTED • INDUSTRY TRUSTED OE Exploded View A750 Valve Body Filter Upper Valve Body No. 2 101 301 Lower Valve Body Check Valve 102 104 107 106 105 103 201 A750 Series Valve Body Descriptions I.D. No. Manual Valve 102 SLT Damper 103 Primary Regulator Valve (inboard) Boost Assembly (outboard) 104 Clutch Control Valve 105 Clutch Apply Control Valve 106 Accumulator Control Valve (inboard) Accumulator Control Plunger Valve & Sleeve (outboard) 107 Sequence Valve 201 Solenoid Modulator Valve 202 Clutch Lock Valve 203 B1 Accumulator Piston 204 Secondary Regulator Valve 205 Lockup Relay Valve 206 Lockup Control Valve (inboard) Lockup Control Plunger Valve & Sleeve (outboard) 207 C3 Check Valve 208 3-4 Shift Valve 209 Brake Control Valve 210 2-3 Shift Valve 211 1-2 Shift Valve 212 B1 Apply Control Valve (inboard) B1 Apply Control Plunger Valve & Sleeve (outboard) 202 Upper Valve Body 203 207 209 211 210 212 208 206 08-03-17 A750E-A761E-ZIP-Booklet_C Page 6 205 204 Description 101 301 Coast Brake Relay Valve Note: May not have a valve in this location if the upper cover or upper valve body #2 casting number is 89010. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Toyota/Lexus A750E/F, A760E/F/H, A761E, A960E/F, AB60E/F ZIP KIT®Installation & Testing Booklet A760, A960 & AB60 Series Valve Body NOTE: Checkballs are shown in proper location for A760 series valve bodies. Reference page 8 for proper checkball location in A960 series valve bodies. 304 302 301 Upper Valve Body 303 TIME TESTED • INDUSTRY TRUSTED Upper Valve Body No. 2 305 401 A760, A960 & AB60 Series Valve Body Descriptions I.D. No. 311 309 308 314 313 307 312 306 310 Filter 201 Lower Valve Body 102 Check Valve 103 202 104 101 Brake Control Valve 102 Accumulator Control Valve (inboard) Accumulator Control Plunger Valve & Sleeve (outboard) 103 SL1 Relay Valve 104 B1 Apply Relay Valve 105 Solenoid Modulator Valve 201 Manual Valve 202 SLT Damper 203 Primary Regulator Valve (inboard) Boost Valve Assembly (outboard) 204 4-5 Shift Valve 301 B2 Accumulator Piston 302 Reverse Sequence Valve 303 Clutch Control Valve 304 Clutch Apply Relay Valve 305 B1 Accumulator Piston 306 Secondary Regulator Valve 307 Lockup Relay Valve 308 Lockup Control Valve (inboard) Lockup Control Plunger Valve & Sleeve (outboard) 309 C3 Check Valve 310 1-2 Shift Valve 311 B4 Check Valve 312 2-3 Shift Valve 313 3-4 Shift Valve 314 B2 Accumulator Piston 401 C3 Apply Relay Valve 204 101 Lower Valve Body No. 2 105 ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 203 Description A750E-A761E-ZIP-Booklet_C 08-03-17 Page 7 TIME TESTED • INDUSTRY TRUSTED Toyota/Lexus A750E/F, A760E/F/H, A761E, A960E/F, AB60E/F ZIP KIT®Installation & Testing Booklet OE Exploded View A960 Series Valve Body • Proper Check Ball locations Upper Valve Body Small Upper Valve Body Detailed Instructions for Step eplace OE Accumulator Control R Plunger Valve & Sleeve Assembly 9 from Quick Guide OE Sleeve Notch Location Deepest Notch 0 2nd Deepest Notch 1 Middle Notch 2 2nd Shallowest Notch 3 Shallowest Step 4 Middle Notch 2nd Shallowest Notch Shallowest Notch Figure 8 Use This Many Sonnax Shims 2nd Deepest Notch Deepest Notch OE Castellated Plunger Sleeve Prior to removal, note the position of the OE retaining pin on the adjustable notch! See chart for number of Sonnax shims to add. 08-03-17 A750E-A761E-ZIP-Booklet_C Page 8 ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
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