AODE 4R75E ZIP

2016-12-23

: Sonnax Aode-4R75E-Zip AODE-4R75E-ZIP 2170 file instruction uploads

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PART NUMBER AODE-4R75E-ZIP QUICK GUIDE

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

ZIP KIT®

To ensure bypass/TCC system

has full control, drill "A" & "B"

holes out to .062".

Retainer

Sonnax

Retainer

Install Sonnax Retainer in

front of OE Retainer

as shown.

Eight checkballs to

install, see locations

on valve body.

See corresponding Technical booklet for installation of additional unit components.

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

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.

Step Replace OE Main Pressure

Regulator Valve

Packaging Pocket 1

• 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.

Packaging Pocket 2

• Valve • Sleeve

Step Replace OE Bypass Clutch

Control Sleeve, Plunger Valve

& Spring. Perform Separator

Plate Modications.

Reference page 2 in technical booklet for detailed instructions.

Packaging Pocket 3

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

Step Replace OE 2-3 Shift

Valve End Plug

Place O-Ring in shallow groove, lubricate with Sonnax Slippery Stick

O-LUBE and roll on bench to size. Install O-Ringed land inboard.

Packaging Pocket 4

• Plug • O-Rings (2) 1 extra

Step Install Solenoid Regulator

Valve Retainer

Reference page 2 in technical booklet for detailed instructions.

Packaging Pocket 5

• Retainer

Step Replace OE Overdrive Servo

Regulator Valve & Sleeve

NOTE: '01–Later applications only.

Reference page 2 in technical booklet for important inspection note.

Packaging Pocket 6

• Valve • Sleeve

Step Replace OE Checkballs

Packaging Pocket 7

• Checkballs (8)

Step Install Valve Body

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 8

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

Step Install Intermediate

Clutch Spiral Snap Ring

Reference page 3 in technical booklet for detailed instructions.

Packaging Pocket 9

• Spiral Retaining Ring • Locking Ring

Step

Replace Output Shaft Seals.

Inspect Direct Piston &

Direct Clutch Drum.

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

Packaging Pocket 10

• Output Shaft Seals (2)

Step Install Pump Cover &

Input Shaft Seals

NOTE: There are 2 types of seals for the stator

'02-earlier and '03-later.

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

Packaging Pocket 11

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

Step

Replace Overdrive Servo Pin

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

Packaging Pocket 12

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

Zip Kit Contents & Installation Steps

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

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

Component Application Chart

Gear Int.

Clutch

Int.

Sprag

Rev

Clutch

Fwd

Clutch

Over-

drive

Band

Low

Roller

Clutch

Low

Reverse

Band

Direct

Clutch

RON ON

OD–1st ON Holding

OD–2nd ON Holding ON

OD–3rd ON ON ON

OD–4th ON Holding ON ON

M2 ON Holding ON ON

M1 ON Holding ON

Solenoid Application Chart

Gear SS1/A SS2/B TCC

PON OFF

RON OFF

OD–1st ON OFF ON*

OD–2nd OFF OFF ON*

OD–3rd OFF ON ON*

OD–4th ON ON ON*

ON* = Based on PCM command.

Valve Body Identication

is kit ts ‘96–later units. It will not work on ‘91–’95 units. Rough forging must

begin with RF-F6 or 1L3P located below stiener plate (Figure 1).

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"

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

1Shift Solenoid 1/A Ground

212 Volt Power Supply for Shift Solenoids

3TCC Solenoid Ground

4Not Used

5Transmission Oil Temp Sensor Ground

6Shift Solenoid 2/B Ground

7EPC Power Supply

8TCC Power Supply

9Transmission Oil Temp Sensor Power

10 EPC Ground

8 Pin Terminal Location & Function

Pin Terminal Function

1Not used

2Transmission Oil Temp Sensor Ground

3TCC Solenoid Ground

412 Volt Power Supply for Solenoids

5Transmission Oil Temp Sensor Power

6EPC Ground

7Shift Solenoid 1/A Ground

8Shift Solenoid 2/B Ground

8 Pin Electronic Checks

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

Figure 1

Case Connector Pin Side Case Connector Pin Side Case Connector Pin Side

'97-Earlier 1998-2008 '09-Later

Figure 2

Solenoid Locations

NOTE:

EPC solenoid

located in case

SS2/B

TOT sensor in

harness or molded

lead frame

TCC

SS1/A

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

ZIP KIT®

PART NUMBER AODE-4R75E-ZIP INSTALLATION & TESTING BOOKLET

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

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Valve Body & Unit Rebuild

Tips & Techniques

Bore-by-bore tips for removal, installation, options and

checks of components. The detailed instructions below

correlate to the quick guide steps.

1. Replace OE Main Pressure Regulator Valve

Reuse OE spring.

2. Replace OE Boost Sleeve & Valve

Reference quick guide for details.

Replace OE Bypass Clutch Control Sleeve, Plunger

Valve & Spring. Perform Separator Plate Modications.

a. Remove plunger valve from Sonnax sleeve, set aside for reuse.

b. With enclosed sonnax drill bit, drill thru existing Sonnax sleeve cross orice

hole and out other side of sleeve. Remove debris and burrs. Reinstall Sonnax

plunger valve into sleeve.

c. Install Sonnax orange spring and plunger valve and sleeve assembly into bore

and retain with OE clip.

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.

6. Replace 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.

7. Replace OE Checkballs

Reference quick guide for details.

Figure 3

Retainer plate,

gasket and bolts.

Figure 4

Underside of 4R70W Valve Body

2 Cast in-place

bolt holes

Figure 5

Underside of 4R70W Valve Body Partial Drill

Figure 6

Bolts

Retainer

Plate

Gasket

Proper position of

retainer plate sitting

on valve body.

Drill

& Tap

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

8. Install Valve Body Retainer Plate (Figure 3)

NOTE: Used on ‘01–later applications only. Installation requires drilling of separator

plate and drilling and threading of valve body casting.

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

bolts.

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).

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

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 under-

neath 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.

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.

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. Replace 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: Be careful not to nick the sealing ring lands

as this can cause ring damage.

WARNINGWARNING

CAUTIONCAUTION

Figure 7

Spiral Ring

Locking Ring

Drum

Figure 8

Figure 9

Proper

Staking

Technique

Proper

Staking

Sequence

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

b. Inspect checkball in direct piston (Figure 11), as it is prone to sticking.

Clean and ush with solvent or WD-40® and reseat with a small punch and

hammer.

Final Testing:

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

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 nger 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.

c. Install solid PTFE seals onto the input shaft. Resize with your ngers. Pre-lube

seals and install into the stator for nal 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 orice

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).

e 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.

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)

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 at surface to size O-rings into pin grooves.

TECH TIP: If a rmer 3-4 shift is desired, place Sonnax washer on pin against

shoulder to pre-load spring.

NOTE: Following step is easier if piston is compressed in bench vise to facilitate

retaining clip installation.

d. Install OE spring seat followed by springs, piston and retaining clip.

e. Set servo travel according to OE specications.

TECH

TIP!

TECH

TIP!

Figure 11

Checkball

Location

Direct

Piston

Figure 12

No Leaks

Here

Figure 10

Seals

Output Shaft

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Figure 14

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.

Figure 16

Verify correct forward piston return spring is used.

Clockwise Wind

2000–Earlier

Counter

Clockwise Wind

2001–Later

Figure 17

O-Rings

Washer

Overdrive

Servo Pin

Piston

Sleeve

Servo

Piston

Large

Spring

Small

Spring

Retainer

Plate

Figure 13

Pump Cover

Seals

Input shaft

removed from

the forward drum.

Selective Seals:

Early = .110" thick

Late = .083" thick

Input Shaft

Seals

Figure 15

Sand

Here

1st Checkball

2nd Checkball is located

inside drum under piston.

This orfice ends up full of

debris when run through parts

washer. Be sure to clean.

Forward

Clutch

Drum

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

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

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.

4R75E Valve Body

VACUUM

TEST

Boost Valve

• Delayed/No Reverse

• Burnt Reverse clutch

• Reverse slip

Replace with Sonnax Part No.

76948-02K*

NOTE: Fits all ‘91-later applications.

Main Pressure Regulator Valve

• Premature clutch/band failure

• Low line rise

• Poor shift quality

Replace with Sonnax Part No.

76948-09* & 76948-17K

76948-17K Requires F-76948-TL & VB-FIX

Bypass Clutch Control Valve

• Code 628, 741, 1741, 1744

• Low cooler ow • No lockup

• TCC slip

Replace with Sonnax Part No.

76948-31

3-4 Capacity

Modulator Valve

• 3-4 Flare

• Slips in manual low

3-4 Shift Valve

• No 4th

• Gear ratio codes

2-3 Capacity

Modulator Valve

• 2-3 Flare

• No 3rd & 4th NOTE: Not used

in ‘01–Later

Test

Together

2-3 Backout Valve

• No 2-3 • 2-3 Quality poor

• Gear ratio codes

Bypass Clutch Control

Plunger Valve & Sleeve

• TCC failure

• TCC slip codes

Replace with Sonnax Part No.

76948-04K*

Converter Pressure

Limit Valve

• Low converter pressure

• Lube failures

Center this valve land in

the passage as indicated.

Solenoid Regulator Valve

• Erratic shifts • 2-3 Neutral

• No 2nd • Neutral after 4th

Replace with Sonnax Part No.

76948-14K & 76948-47K

76948-47K Requires F-76948-TL & VB-FIX

Manual Valve

• Low line pressure

• Delayed engagements

Replace with Sonnax Part No.

76948-46

2-3 Shift Valve

• Delayed 3rd

• Gear ratio codes

• Wrong gear starts

Overdrive Servo

Regulator Valve

& Sleeve

• No 4th

• Burnt OD band

• 4-3 Neutral

Replace with Sonnax Part No.

76948-29K*

NOTE:

‘01–Later

Overdrive Servo

Regulator Valve

• No 4th

• Burnt OD band

• 4-3 Neutral

1-2 Shift Valve

• No 2nd

• Wrong gear starts

• Gear ratio codes

4R70E, 4R70W, 4R75E, 4R75W, AODE ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View

4R75E Valve Body

107

108

109

110

111

101

102

103

104

105

106

= 8 Checkball Locations

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)

TIME TESTED • INDUSTRY TRUSTED

Visit www.sonnax.com for details. • 800-843-2600 • 802-463-9722

Sonnax is an Employee-Owned Company

Problem...

...Solution

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.

• 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.

4R70W Smart-Tech®

Forward Clutch Drum

Part No. 76654-01K

Patent Pending

OE Drum

Smart-Tech Drum

AODE 4R75E ZIP

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