AW60 40LE Vac

Aw60-40Le-Vac AW60-40LE-Vac AW60-40LE-Vac 437 file tech_resource uploads sonnax-dev

Aw60-40Le-Vac AW60-40LE-Vac AW60-40LE-Vac 102 pdf pdf uploads sonnax-dev

: Sonnax Aw60-40Le-Vac AW60-40LE-Vac 431 file tech_resource uploads

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Aisin AW 60-40LE

Zip Kit® AW60-40LE-ZIP Available for this unit.

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.

20

15

10

25

5

0
30
VACUUM
TEST

Front Control Valve Body - Separator Plate Side Shown

B1 Modulator Valve

1-2 Shift Valve

Shift complaints in 2nd & 4th

1-2 Shift complaints
NOTE: Seal port on opposite side of casting.

Pressure Regulator Valve
•	Low/High line pressure
•	Soft/Harsh shifts
•	Converter complaints
•	Loss of lube

B1 Modulator
Plunger Valve
Shift complaints in 2nd & 4th
Replace with Sonnax Part No.
19741-03K*

2-3 Shift Valve
2-3 Shift complaints
NOTE: Seal port on opposite side of
casting & solenoid port with thumb.

Click on Sonnax part numbers to see more information.

©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

AW60-40LE-Vac-Locations 03-02-15
Page 1

Aisin AW 60-40LE

Zip Kit® AW60-40LE-ZIP Available for this unit.

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.

20

15

10

25

5

0
30
VACUUM
TEST

Front Control Valve Body - Cover Side Shown
Click on Sonnax part
numbers to see more
information.

3-4 Shift Valve
3-4 Shift complaints
NOTE: Seal solenoid port with thumb.

TCC Modulator Valve
•	Converter slip/shudder/codes
•	No converter apply
NOTE: Test using non-orificed 2nd/4th
modulator brake control valve.

2-3 Shift Valve
2-3 Shift complaints
NOTE: Seal port on opposite side of casting and
seal solenoid port with thumb.

Seal

Seal

Reverse Boost Valve
•	Low reverse pressure
•	Delayed reverse
Replace with Sonnax Part No.
19741-07K*




End Plugs

Pressure Regulator Valve
•	Low/High line pressure
•	Soft/Harsh shifts
•	Converter complaints
•	Loss of lube

•	Burnt clutches/brakes
•	Various shift complaints
Replace with Sonnax Part No.
19741-13K*
NOTE: Several Locations =



1-2 Shift Valve
1-2 Shift complaints
NOTE: Seal port on
opposite side of casting.

©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

3-4 Shift Valve
3-4 Shift complaints
AW60-40LE-Vac-Locations 03-02-15
Page 2

Aisin AW 60-40LE

Zip Kit® AW60-40LE-ZIP Available for this unit.

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.

20

15

10

25

5

0
30
VACUUM
TEST

Rear Control Valve Body - Separator Plate Shown
Coast Clutch
Modulator Valve
Burned coast clutch
NOTE: Test using non-orificed 2nd/4th
brake modulator control valve.

Solenoid Modulator Valve
Low Coast
Modulator Valve
•	Burned 1st & reverse clutch
•	Delayed engagement reverse
or 1st in manual low
NOTE: Test both at the same time.

Lockup
Control Valve

Shift complaints
NOTE: Test using non-orificed 2nd/4th brake
modulator control valve

Reverse Clutch
Accumulator Piston
•	Burned reverse clutch
•	Delayed reverse
•	Bump in reverse



Lockup complaints/codes

Secondary
Regulator
Valve
•	TCC complaints
•	Loss of lube

End Plugs
•	Burnt clutches/brakes
•	Various shift complaints
Replace with Sonnax Part No.
19741-13K*
NOTE: Several Locations =



Lockup Control Plunger Valve Kit
•	Burnt converter • TCC codes
•	TCC apply & release concerns
Replace with Sonnax Part No.
59954-01K

*Part numbers with an asterisk (*)
are included in this Zip Kit.
©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

2nd/4th Brake
Modulator
Control Valve
•	Burned 2-4 brake
•	Shift complaints in
2nd & 4th

Click on Sonnax part
numbers to see more
information.

2nd/4th Brake & Foward
Clutch Accumulator Piston
•	Burned forward clutch • Delayed forward
•	Burned 2-4 brake • Bump 2nd & 4th gear

2-3 Timing Valve & Overdrive
Clutch Accumulator Piston
•	2-3 Shift complaints • Bump in 3rd gear
•	Burned overdrive clutch
•	NOTE: Test one port while sealing the other.

AW60-40LE-Vac-Locations 03-02-15
Page 3

Aisin AW 60-40LE

Zip Kit® AW60-40LE-ZIP Available for this unit.

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Front Control Valve Body - Cover Side (Separator Side Inset) Shown Here
106

Front Control Valve Body Descriptions

I.D. No.

105

Description

101

Reverse Boost Assembly
& Pressure Regulator Valve

102

Accumulator Control Valve
& Plunger Assembly

103

B1 Modulator Valve
& Plunger Assembly

104

1-2 Shift Valve

105

2-3 Shift Valve

106

3-4 Shift Valve

107

TCC Modulator Valve

104

107

Check
Valve

Front Valve Body
(Cover Side)

Check Valve

Filter
Filter
Front Control Valve Body
(Separator Side)

102
103

101
©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

104
AW60-40LE-Vac-Locations 03-02-15
Page 4

Aisin AW 60-40LE

Zip Kit® AW60-40LE-ZIP Available for this unit.

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Rear Control Valve Body

212

208

209
211
210

Check
Valve

Filter

Checkball, Large .250" dia.
(All 10 others, Small .218" dia.)

Rear Control Valve Body Descriptions

I.D. No.

Check
Valve

Description

201

Secondary Regulator Valve

202

2nd/4th Brake Modulator
Control Valve

203

Low Coast Modulator Valve

204

Solenoid Modulator Valve

205

Reverse Clutch
Accumulator Piston

206

2nd/4th Brake
Accumulator Piston

207

Manual Valve

208

Forward Clutch
Accumulator Piston

209

Overdrive Clutch
Accumulator Piston

210

2-3 Timing Valve

211

Coast Clutch Modulator Valve

212

Lockup Control Valve
& Plunger Assembly

©2015 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

Check
Valve

203
206
207

202

204
205
201

AW60-40LE-Vac-Locations 03-02-15
Page 5



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