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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©2015 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 03-02-15

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

Aisin AW 60-40LE

TIME TESTED • INDUSTRY TRUSTED

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

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.

Front Control Valve Body - Separator Plate Side Shown

20

25

15

0

10

5

30

VACUUM

TEST

20

25

15

0

10

5

30

VACUUM

TEST

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.

B1 Modulator Valve

Shift complaints in 2nd & 4th

1-2 Shift Valve

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

Click on Sonnax part numbers to see more information.

©2015 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 03-02-15

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

Aisin AW 60-40LE

TIME TESTED • INDUSTRY TRUSTED

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

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.

Front Control Valve Body - Cover Side Shown

20

25

15

0

10

5

30

VACUUM

TEST

20

25

15

0

10

5

30

VACUUM

TEST

1-2 Shift Valve

1-2 Shift complaints

NOTE: Seal port on

opposite side of casting.

3-4 Shift Valve

3-4 Shift complaints

Pressure Regulator Valve

• Low/High line pressure

• Soft/Harsh shifts

• Converter complaints

• Loss of lube

Reverse Boost Valve

• Low reverse pressure

• Delayed reverse

Replace with Sonnax Part No.

19741-07K*

TCC Modulator Valve

• Converter slip/shudder/codes

• No converter apply

NOTE: Test using non-oriced 2nd/4th

modulator brake control valve.

Seal

Seal

2-3 Shift Valve

2-3 Shift complaints

NOTE: Seal port on opposite side of casting and

seal solenoid port with thumb.

3-4 Shift Valve

3-4 Shift complaints

NOTE: Seal solenoid port with thumb.

End Plugs

• Burnt clutches/brakes

• Various shift complaints

Replace with Sonnax Part No.

19741-13K*

NOTE: Several Locations =





Click on Sonnax part

numbers to see more

information.

©2015 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 03-02-15

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

Aisin AW 60-40LE

TIME TESTED • INDUSTRY TRUSTED

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

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.

Rear Control Valve Body - Separator Plate Shown

20

25

15

0

10

5

30

VACUUM

TEST

Secondary

Regulator

Valve

• TCC complaints

• Loss of lube

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.

2nd/4th Brake & Foward

Clutch Accumulator Piston

• Burned forward clutch • Delayed forward

• Burned 2-4 brake • Bump 2nd & 4th gear

Reverse Clutch

Accumulator Piston

• Burned reverse clutch

• Delayed reverse

• Bump in reverse

Solenoid Modulator Valve

Shift complaints

NOTE: Test using non-oriced 2nd/4th brake

modulator control valve

Coast Clutch

Modulator Valve

Burned coast clutch

NOTE: Test using non-oriced 2nd/4th

brake modulator control valve.

Lockup

Control Valve

Lockup complaints/codes

Low Coast

Modulator Valve

• Burned 1st & reverse clutch

• Delayed engagement reverse

or 1st in manual low

NOTE: Test both at the same time.



End Plugs

• Burnt clutches/brakes

• Various shift complaints

Replace with Sonnax Part No.

19741-13K*

NOTE: Several Locations =

2nd/4th Brake

Modulator

Control Valve

• Burned 2-4 brake

• Shift complaints in

2nd & 4th

* Part numbers with an asterisk (*)

are included in this Zip Kit.

Lockup Control Plunger Valve Kit

• Burnt converter • TCC codes

• TCC apply & release concerns

Replace with Sonnax Part No.

59954-01K Click on Sonnax part

numbers to see more

information.

©2015 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 03-02-15

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

Aisin AW 60-40LE

TIME TESTED • INDUSTRY TRUSTED

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

104

OE Exploded View

Front Control Valve Body - Cover Side (Separator Side Inset) Shown Here

Front Valve Body

(Cover Side)

107

102

101

103

Filter

106

105 104

Check

Valve

Front Control Valve Body

(Separator Side)

Check Valve

Filter

Front Control Valve Body Descriptions

I.D. No. 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

©2015 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 03-02-15

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

Aisin AW 60-40LE

TIME TESTED • INDUSTRY TRUSTED

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

207

Filter

212

208 209

210

211

206

205

204

203 202

201

Check

Valve

Check

Valve

Check

Valve

Checkball, Large .250" dia.

(All 10 others, Small .218" dia.)

OE Exploded View

Rear Control Valve Body

Rear Control Valve Body Descriptions

I.D. No. 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