AODE 4R75E ZIP

2016-12-23

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4R70E, 4R70W, 4R75E, 4R75W, AODE
ZIP KIT ®
PART NUMBER AODE-4R75E-ZIP

QUICK GUIDE

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

installation Diagram

Eight checkballs to
install, see locations
on valve body.

3
6
A

B
To ensure bypass/TCC system
has full control, drill "A" & "B"
holes out to .062".

Install Sonnax Retainer in
front of OE Retainer
as shown.

5
OE
Retainer
Sonnax
Retainer

10
See corresponding Technical booklet for installation of additional unit components.

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.
©2016 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

AODE-4R75E-ZIP_Guide 12-22-16
Page 1

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT®

Quick Guide

Zip Kit Contents & Installation Steps
Step 1 R
eplace OE Main Pressure
Regulator Valve

Step 7 Replace OE Checkballs

Packaging Pocket 1

• Checkballs (8)

Packaging Pocket 7

• Valve

Step

Replace OE Boost Sleeve
& Valve

NOTE: Some early applications have a spring between the
boost valve and boost sleeve. It is ok to reuse this OE spring
if present, but not necessary.

8 Install Valve Body
Step
Retainer Plate

NOTE: Used on '01-later applications only. Installation requires
drilling of separator plate and drilling and threading of valve
body casting.

Reference pages 2 and 3 in technical booklet for detailed instructions.

Packaging Pocket 2

Packaging Pocket 8

• Valve • Sleeve

• Retainer Plate • Gasket • Bolts, 13/64" (2)

Step 3 R
eplace OE Bypass Clutch
Control Sleeve, Plunger Valve
& Spring. Perform Separator
Plate Modifications.

Step 9 Install Intermediate
Clutch Spiral Snap Ring

Reference page 2 in technical booklet for detailed instructions.
Packaging Pocket 3

• Valve • Sleeve • Spring • Drill bit, .062" (not shown)

Step 4 Replace OE 2-3 Shift
Valve End Plug

Reference page 3 in technical booklet for detailed instructions.
Packaging Pocket 9

• Spiral Retaining Ring • Locking Ring

Step 10 Replace Output Shaft Seals.
Inspect Direct Piston &
Direct Clutch Drum.

Place O-Ring in shallow groove, lubricate with Sonnax Slippery Stick
O-LUBE and roll on bench to size. Install O-Ringed land inboard.

Reference page 3 and 4 in technical booklet for detailed instructions.

Packaging Pocket 4

• Output Shaft Seals (2)

• Plug • O-Rings (2) 1 extra

Step

Install Solenoid Regulator
Valve Retainer

Packaging Pocket 10

Step 11 Install Pump Cover &
Input Shaft Seals

Reference page 2 in technical booklet for detailed instructions.

Packaging Pocket 5

Reference pages 4 and 5 in technical booklet for detailed instructions.

• Retainer

Packaging Pocket 11

Step

eplace OE Overdrive Servo
R
Regulator Valve & Sleeve

NOTE: '01–Later applications only.

NOTE: There are 2 types of seals for the stator
'02-earlier and '03-later.

• Pump Cover Seals; Early (2), Late (2) • Input Shaft Seals (2)

Step 12 Replace Overdrive Servo Pin
Reference page 4 and 5 in technical booklet for detailed instructions.

Reference page 2 in technical booklet for important inspection note.

Packaging Pocket 12

Packaging Pocket 6

• Servo Pin • O-Rings; Large (1), Medium (1) • Washer

• Valve • Sleeve
©2016 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

AODE-4R75E-ZIP_Guide 12-22-16
Page 2

4R70E, 4R70W, 4R75E, 4R75W, AODE
ZIP KIT ®
PART NUMBER AODE-4R75E-ZIP

INSTALLATION & TESTING BOOKLET

Valve Body Identification

Technical Specifications
Pump-to-Stator Bolts
15 ft-lb

Valve Body to Case Bolts
106 in-lb

Pump-to-Case Bolts
15 ft-lb

OE Endplay
.005–.020"

This kit fits ‘96–later units. It will not work on ‘91–’95 units. Rough forging must
begin with RF-F6 or 1L3P located below stiffener plate (Figure 1).
Figure 1

Valve Body Plate Bolts 106 in-lb

10 Pin Electronic Checks
Solenoid

Terminals

Ohm Value

Solenoid 1/A

1&2

20–30

Solenoid 2/B

6&2

20–30

TCC Solenoid

3&8

10–16

EPC Solenoid

7 & 10

2–5

10 Pin Terminal Location & Function
Pin

Terminal Function

12 Volt Power Supply for Shift Solenoids

TCC Solenoid Ground

Not Used

Gear

Int.
Clutch

Transmission Oil Temp Sensor Ground

Shift Solenoid 2/B Ground

OD–2nd

EPC Power Supply

OD–3rd

TCC Power Supply

OD–4

Transmission Oil Temp Sensor Power

EPC Ground

Solenoid

Terminals

Ohm Value

Solenoid 1/A

4&7

20–30

Solenoid 2/B

4&8

20–30

TCC Solenoid

4&3

10–16

EPC Solenoid

4&6

2–5

SS2/B

OFF

TCC

OFF

OD–1st

OFF

ON*

OD–2

OFF

ON*

OD–3rd

OFF

ON*

OD–4

ON*

Int.
Sprag

Rev
Clutch

Fwd
Clutch

Overdrive
Band

Low
Roller
Clutch

OD–1st

8 Pin Electronic Checks

SS1/A

Component Application Chart

Shift Solenoid 1/A Ground

Gear

ON* = Based on PCM command.

Solenoid Application Chart

Direct
Clutch

ON
ON

Holding

Low
Reverse
Band

Holding

ON
ON

Holding

Case Connector Pin Side
'97-Earlier

ON
ON

Holding

Case Connector Pin Side
1998-2008

Case Connector Pin Side
'09-Later

8 Pin Terminal Location & Function
Pin

Terminal Function

Not used

Transmission Oil Temp Sensor Ground

TCC Solenoid Ground

4
5
6

EPC Ground

Shift Solenoid 1/A Ground

Shift Solenoid 2/B Ground

Solenoid Locations

Figure 2
TCC

12 Volt Power Supply for Solenoids

NOTE:
EPC solenoid
located in case

Transmission Oil Temp Sensor Power

SS2/B

SS1/A

TOT sensor in
harness or molded
lead frame

AODE-4R75E-ZIP_Booklet 12-22-16
Page 1

TIME TESTED • INDUSTRY TRUSTED

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT®

Installation & Testing Booklet

Valve Body & Unit Rebuild
Tips & Techniques

Figure 3

Bore-by-bore tips for removal, installation, options and
checks of components. The detailed instructions below
correlate to the quick guide steps.

Retainer plate,
gasket and bolts.

1. Replace OE Main Pressure Regulator Valve

Figure 4

Reuse OE spring.

2. Replace OE Boost Sleeve & Valve
Reference quick guide for details.

3. R
eplace OE Bypass Clutch Control Sleeve, Plunger
Valve & Spring. Perform Separator Plate Modifications.
a. Remove plunger valve from Sonnax sleeve, set aside for reuse.
b. With enclosed sonnax drill bit, drill thru existing Sonnax sleeve cross orifice
hole and out other side of sleeve. Remove debris and burrs. Reinstall Sonnax
plunger valve into sleeve.

2 Cast in-place
bolt holes
Underside of 4R70W Valve Body

c. Install Sonnax orange spring and plunger valve and sleeve assembly into bore
and retain with OE clip.

Figure 5

d. Drill separator plate holes marked “A” and “B” out to .062" with enclosed
drill bit.

4. Replace OE 2-3 Shift Valve End Plug
Reference quick guide for details.

5. Install Solenoid Regulator Valve Retainer
a. Check bore for wear, and repair with Sonnax oversized valve (76948-47K, not
included ) if required.
b. If not worn, check OE valve for sticking or hanging up.
c. Resize bore with bore sizing tool (76948-BST2, not included) if required.
d. Install Sonnax retainer outboard of OE retainer, as shown in quick guide inset
photo.

Underside of 4R70W Valve Body

6. R
eplace OE Overdrive Servo Regulator
Valve & Sleeve
Reference quick guide for details.

NOTE: Remove inboard overdrive servo regulator valve and insure
it is free in bore. The inboard valve is commonly stuck as overdrive
servo retaining ring often breaks and pieces of the retaining ring
lodge in this bore.

Partial Drill

Figure 6
Bolts
Retainer
Plate
Proper position of
retainer plate sitting
on valve body.

7. Replace OE Checkballs
Reference quick guide for details.
Gasket

12-22-16 AODE-4R75E-ZIP_Booklet
Page 2

Drill
& Tap

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT®

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

8. Install Valve Body Retainer Plate (Figure 3)

Figure 7

NOTE: Used on ‘01–later applications only. Installation requires drilling of separator
plate and drilling and threading of valve body casting.

Spiral Ring

a. Install separator plate onto valve body and align plate with OE alignment
bolts.

Locking Ring

b. Locate the two cast in-place bolt hole locations on underside of valve body
(Figure 4).
c. In a drill press use a 5/16" drill bit to clean up the cast in-place bolt hole
locations and establish a true center for drilling further with 13/64" or #9
drill (Figure 5).

Drum

WARNING: Do Not drill deeper than 1/16" with the 5/16" drill bit (Figure 5).
WARNING

d. After true center is established, use a 13/64" or #9 drill to drill all the way
through the valve body AND separator plate with a piece of wood underneath to prevent the plate from deforming as the drill bit cuts through.
e. Remove the separator plate and enlarge the two drilled holes with a 1/4" drill
bit. De-burr the new holes in the separator plate.

Figure 8

f. With a 6.0 x 1.0mm thread tap, cut new threads in the drilled holes in the
valve body. De-burr the gasket surface, making sure there are no high spots.
g. With Sonnax checkballs installed per quick guide, assemble valve body
gaskets and separator plate using OE procedures.
h. Install the Sonnax gasket, valve body retainer plate and two screws. Torque
to 80-100 in-lb (Figure 6).

9. Install Intermediate Clutch Spiral Snap Ring

a Remove and discard OE snap ring from the intermediate roller clutch or
mechanical diode assembly on reverse clutch drum.

Figure 9

Proper
Staking
Sequence

b. Install Sonnax locking ring, cup side facing up as shown (Figure 7 & 8).
c. Walk Sonnax spiral ring into retaining groove as pictured (Figure 8).

NOTE: The locking ring may need to be moved for correct spiral ring positioning.

d. Ensure Sonnax spiral ring is fully seated in groove all the way around
assembly.
e. Stake locking ring in six equally spaced places around outside as shown
(Figure 9).

10. R
eplace Output Shaft Seals.
Inspect Direct Piston & Direct Clutch Drum.
Installation:
a. Remove and discard OE output shaft sealing rings and replace with Sonnax
seals as shown (Figure 10).

CAUTION

Proper
Staking
Technique

CAUTION: Be careful not to nick the sealing ring lands
as this can cause ring damage.

AODE-4R75E-ZIP_Booklet 12-22-16
Page 3

TIME TESTED • INDUSTRY TRUSTED

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT®

Installation & Testing Booklet

b. Inspect checkball in direct piston (Figure 11), as it is prone to sticking.
Clean and flush with solvent or WD-40® and reseat with a small punch and
hammer.

Figure 10

Final Testing:
a. Assemble the direct clutch drum on to the output shaft (Figure 12).

Seals

b. Squirt ATF into the direct clutch feed hole (Figure 12).
c. Apply 30-60 psi. of air pressure into the feed hole.
d. Verify that there are no leaks.
NOTE: If there are leaks, look for a worn bushing in the drum or leaks in the
ring grooves or the checkball seat.

11. Install Pump Cover & Input Shaft Sealing Rings
a. Install rings onto the pump cover (Figure 13).

NOTE: Two sets of seals are included. Select the correct size/style for the

application. The early style is a solid ring (.110" width), the late style is a butt-cut

ring (.083" width). Sizing of the early/solid style is required after installation. A

mixture of ATF and STP can be used to lubricate the solid sealing rings while
sizing with finger pressure.

b. Press input shaft out of the forward clutch drum. Sand forward drum ring
surface lightly with 320 grit sand paper, using a crosshatch pattern.

Output Shaft

Figure 11
Checkball
Location

c. Install solid PTFE seals onto the input shaft. Resize with your fingers. Pre-lube
seals and install into the stator for final sizing (Figure 13).
d. Inspect the checkballs in the forward clutch drum (Figure 15), as they are
prone to sticking. Flush with solvent or WD-40®. Also be sure that the orifice
shown, is free of debris that can come from parts washers.
e. An AOD forward drum can be used to size the early stator seals (Figure 14).
The seals can also be sized with the forward clutch drum, although it may take
a little longer. Carefully use the back of a pick to work the seals into the drum
and let sit for a while so the seals will stay conformed.

Direct
Piston

f. Verify correct forward piston return spring for the application you are working
on (Figure 16).

12. Replace Overdrive Servo Pin (Assembly illustration Figure 17)

Figure 12

a. Use bore brush to remove sharp edges of overdrive servo pin bore in case.
b. Install O-rings on Sonnax servo pin.
c. Lubricate O-rings and roll pin on clean flat surface to size O-rings into pin grooves.

TECH TIP: If a firmer 3-4 shift is desired, place Sonnax washer on pin against
TECH shoulder to pre-load spring.
TIP!
NOTE: Following step is easier if piston is compressed in bench vise to facilitate
retaining clip installation.

No Leaks
Here

d. Install OE spring seat followed by springs, piston and retaining clip.
e. Set servo travel according to OE specifications.

12-22-16 AODE-4R75E-ZIP_Booklet
Page 4

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT®

Pump Cover
Seals

Figure 13

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

Figure 15

Forward
Clutch
Drum

Sand
Here

Selective Seals:
Early = .110" thick
Late = .083" thick

Input shaft
removed from
the forward drum.
1st Checkball

Input Shaft
Seals

2nd Checkball is located
inside drum under piston.
Figure 14
This orfice ends up full of
debris when run through parts
washer. Be sure to clean.

Figure 17

Piston
Sleeve

Use an AOD forward drum to use as sizing tool, as it has
a larger bevel on it for the seals. You will need to remove
the input shaft (early seals only).
Set the stator down onto the AOD drum. Work the edges
of the seals with pick and ease the stator down into the
drum until you need it for assembly later.

Large
Spring

Servo
Piston

Figure 16
Verify correct forward piston return spring is used.
2000–Earlier

2001–Later
Small
Spring

Spring
Retainer
Washer
Overdrive
Servo Pin

Retainer
Plate
Clockwise Wind

Counter
Clockwise Wind

O-Rings

AODE-4R75E-ZIP_Booklet 12-22-16
Page 5

TIME TESTED • INDUSTRY TRUSTED

4R70E, 4R70W, 4R75E, 4R75W, AODE 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.

0
30
VACUUM
TEST

4R75E Valve Body
Boost Valve

Main Pressure Regulator Valve

Bypass Clutch Control Valve

• Delayed/No Reverse
• Burnt Reverse clutch
• Reverse slip

• Premature clutch/band failure
• Low line rise
• Poor shift quality

• Code 628, 741, 1741, 1744
• Low cooler flow • No lockup
• TCC slip

Replace with Sonnax Part No.
76948-02K*
NOTE: Fits all ‘91-later applications.

Replace with Sonnax Part No.
76948-09* & 76948-17K
76948-17K Requires F-76948-TL & VB-FIX

Replace with Sonnax Part No.
76948-31

Overdrive Servo
Regulator Valve
• No 4th
• Burnt OD band
• 4-3 Neutral

Bypass Clutch Control
Plunger Valve & Sleeve
• TCC failure
• TCC slip codes

Overdrive Servo
Regulator Valve
& Sleeve

Replace with Sonnax Part No.
76948-04K*

NOTE:
‘01–Later

Converter Pressure
Limit Valve

• No 4th
• Burnt OD band
• 4-3 Neutral

• Low converter pressure
• Lube failures

Replace with Sonnax Part No.
76948-29K*

2-3 Shift Valve

3-4 Capacity
Modulator Valve

• Delayed 3rd
• Gear ratio codes
• Wrong gear starts

• 3-4 Flare
• Slips in manual low

Manual Valve

1-2 Shift Valve

• Low line pressure
• Delayed engagements

• No 2nd
• Wrong gear starts
• Gear ratio codes

Replace with Sonnax Part No.
76948-46
Test
Together
Center this valve land in
the passage as indicated.

3-4 Shift Valve
• No 4th
• Gear ratio codes

Solenoid Regulator Valve
• Erratic shifts
• No 2nd

• 2-3 Neutral
• Neutral after 4th

Replace with Sonnax Part No.
76948-14K & 76948-47K
76948-47K Requires F-76948-TL & VB-FIX

2-3 Backout Valve
• No 2-3 • 2-3 Quality poor
• Gear ratio codes

2-3 Capacity
Modulator Valve
• 2-3 Flare
• No 3rd & 4th

NOTE: Not used
in ‘01–Later

*Part numbers with an asterisk (*) are included in this Zip Kit.
12-22-16 AODE-4R75E-ZIP_Booklet
Page 6

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT®

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
4R75E Valve Body
111
110

109
108

101

102

103
= 8 Checkball Locations

104

106
107

105
Valve Body Descriptions

I.D. No.

Description

101

Overdrive Servo Regulator Valve (Inboard), Overdrive Servo Regulator Valve & Sleeve (Outboard)

102

3-4 Capacity Modulator Valve (Inboard), 2-1 Capacity Modulator Valve (Outboard)

103

3-4 Shift Valve

104

2-3 Capacity Modulator Valve

105

2-3 Backout Valve

106

Solenoid Regulator Valve

107

Manual Valve

108

1-2 Shift Valve (Inboard), 2-3 Shift Valve (Outboard)

109

Converter Pressure Limit Valve

110

Bypass Clutch Control Valve (Inboard), Bypass Clutch Control Plunger Valve & Sleeve (Outboard)

111

Main Pressure Regulator Valve (Inboard), Boost Valve & Sleeve (Outboard)

AODE-4R75E-ZIP_Booklet 12-22-16
Page 7

Problem...

A common failure of the Ford 4R70W series transmission
is breakage of the forward drum at the snap ring groove.
Pressure on the forward clutch piston creates a high
stress load at the snap ring groove, causing the upper
portion of the drum to split and break away.

...Solution

OE Drum

Part No. 76654-01K
Patent Pending

Smart-Tech Drum

4R70W Smart-Tech

Forward Clutch Drum
• One-piece forged material for more strength and durability.
• Increased groove depth for additional ring support.
The NEW Sonnax forged forward clutch drum design provides increased
strength in all areas, most importantly at the ring groove, preventing
the breakage and subsequent transmission damage associated with
OE stamped steel drums.

TIME TESTED • INDUSTRY TRUSTED
Visit www.sonnax.com for details. • 800-843-2600 • 802-463-9722

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