AW60 40LE ZIP IN
Aw60-40Le-Zip-In AW60-40LE-ZIP-IN AW60-40LE-ZIP-IN 2769 instructions part uploads sonnax-dev
2015-02-11
: Sonnax Aw60-40Le-Zip-In AW60-40LE-ZIP-IN 1774 file instruction uploads
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AISIN AW 60-40LE (AF-13) ZIP KIT PART NUMBER AW60-40LE-ZIP Valve Body Identification QUICK GUIDE NOTE: This Zip Kit AW60-40LE-ZIP is designed for 60-40LE (AF-13) applications only. A separate Zip Kit AW60-41SN-ZIP is available for 60-41SN (AF-17) applications. No Number 2 Rear Control Body Has a Number 2 Rear Control Body 60-40LE (AF-13) Valve Body Has a Short TCC Solenoid Has a Long TCC Solenoid 60-41SN (AF-17) Valve Body Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents. installation Diagram 3 2 OE Assembly Shown 1 6 Shim Location Lowest of three OE sleeve steps. Check which step the retainer location sleeve is on, to determine how many shims (if any) are required for Sonnax replacement assembly. Front Control Valve Body 7 9 4 Checkballs 10 Small 1 Large 5 Rear Control Valve Body 8 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. ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com AW60-40LE-ZIP-Guide 02-11-15 Page 1 Aisin AW 60-40LE ZIP KIT Quick Guide Zip Kit Contents & Installation Steps Step 1 Replace OE Reverse Boost Assembly Step 6 R eplace OE Solenoid O-Rings Observe the step location of the retainer on OE sleeve prior to removal. If set at the lowest step, do not use the Sonnax shims. If set at middle step, use one Sonnax shim. If set at the highest step, use two Sonnax shims. Shims should be place on inboard sleeve diameter. Packaging Pocket 6 • O-Rings, Small (4) 1 extra Packaging Pocket 1 • Valve • Sleeve • Shims (3) Step 2 1 extra 7 Replace OE Lockup Control Step Plunger Valve Assembly Replace OE Accumulator Plunger Valve Assembly Packaging Pocket 7 • Valve • Sleeve Packaging Pocket 2 • Valve • Sleeve Step 3 Step 8 R eplace OE Secondary Regulator Valve End Plug Replace OE B1 Modulator Plunger Valve Assembly Packaging Pocket 8 • End Plug, Large • O-Rings, Large (2) 1 extra Discard OE retainer and use replacement pin to retain lineup. Step 9 Replace OE Checkballs Packaging Pocket 3 • Valve • Sleeve • Retaining Pin Checkballs Packaging Pocket 9 • Checkballs, Small .218" dia. (10) • Checkball, Large .250" dia. Step 4 Replace OE End Plugs Packaging Pocket 4 • End Plugs, Medium (2) • O-Rings, Medium (4) 2 extra Step 5 Replace OE End Plug Packaging Pocket 5 • End Plug, Large • O-Rings, Large (2) 1 extra ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com AW60-40LE-ZIP-Guide 02-11-15 Page 2 AISIN AW 60-40LE (AF-13) ZIP KIT PART NUMBER AW60-40LE-ZIP INSTALLATION & TESTING BOOKLET Torque Specifications NOTE: This Zip Kit AW60-40LE-ZIP is designed for 60-40LE (AF-13) applications only. A separate Zip Kit AW60-41SN-ZIP is available for 60-41SN (AF-17) applications. Transaxle Side Cover Bolt 18 ft-lb Manual Detent Spring Bolt 90 in-lb Valve Body Identification Manual Shift Lever Nut 60 in-lb Front Valve Body Cover Bolt 18 ft-lb Front-Valve-Body-toRear-Valve-Body Bolt 60 in-lb Rear Valve Body Cover Bolt 96 in-lb Solenoid-to-ValveBody Bolt 60 in-lb Valve-Body-toTransaxle Bolt 90 in-lb 60-40LE (AF-13) Valve Body: Use this kit. No Number 2 Rear Control Body Fluid Chart Has a Short TCC Solenoid Recommended Capacities: Dexron-III ATF Approximate Capacity, Complete Overhaul 6.0 qt (5.7L) - 1.6L 6.2 qt (5.9L) - 1.8L Approximate Capacity, Drain and Fill 2.9 qt (2.7L) - 1.6L 2.9 qt (2.7L) - 1.8L 60-40LE (AF-13) Valve Body 60-40LE (AF-13) Valve Body 60-41SN (AF-17) Valve Body: Use AW60-41SN-ZIP kit. Has a Number 2 Rear Control Body Has a Long TCC Solenoid 60-41SN (AF-17) Valve Body 60-41SN (AF-17) Valve Body Component Apply Chart Position Clutch Forward P Coast R X X 2 L OD 1st-Reverse 1-Way Clutch 2nd-4th No. 1 No. 0 X N D Brake Reverse 1 X X 2 X X X 3 X 4 X 1 X X X X X X X X X X 2 X X 1 X X ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com X X X X X X X X X AW60-40LE-ZIP-Booklet 02-11-15 Page 1 TIME TESTED • INDUSTRY TRUSTED Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet Solenoids Solenoid Apply Chart This 60-40LE unit uses four solenoids (Figure 1). • The S1 (shift solenoid no. 1) and S2 (shift solenoid no. 2) are an on/off style, operated by the TCM to control the various shifts. These two solenoids are interchangeable. • The TCC control solenoid is an on/off style controlled by the TCM to operate the converter clutch. • The throttle pressure control liner solenoid is modulated by the TCM to regulate line pressure. Solenoid Position No. 1 P X R X N Bolt Color Code D Bolt Length Yellow 10mm Red 16mm Orange 20mm Green 38mm Blue 50mm No. 2 X 1 X 2 X 3 X X 4 2 L TCC X1 1 X 2 X 1 X 1 X1 X On only when TCC is operating. Zip Kit Instructions Figure 1 1. Valve Body Disassembly NOTE: See color charts for bolt lengths. a. Remove the 13 bolts (Figure 2). b. Remove the small cover, TCC control solenoid, throttle pressure control solenoid (Figure 1) and brackets. c. Remove the two bolts (Figure 3), two shift solenoids (Figure 1) and front valve body cover, separator plate and gasket. d. Remove the three checkballs, two oil filters, one check valve and spring, four bolts and one bracket (Figure 4). No. 1 TCC Solenoid 11–15 ohm No. 2 Test all four solenoids at 20˚C/68˚F. Throttle Pressure Control Solenoid 3–5 ohm Shift Solenoids (interchangeable) 11–15 ohm Figure 2 Bolt installation torque specifications are 60 in-lb. 02-11-15 AW60-40LE-ZIP-Booklet Page 2 Figure 3 Bolt installation torque specifications are 60 in-lb. ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet 1. V alve Body Disassembly (continued) TIME TESTED • INDUSTRY TRUSTED Figure 4 e. Flip valve body over and remove five bolts. Lift rear valve body and separator plate off of front valve body (Figure 5). f. Remove 11 bolts to access valves retained under the two rear valve body covers (Figure 6). 2. Installation Install Zip Kit parts as shown on diagram of separate quick guide sheet included in this Zip Kit. Bolt installation torque specifications are 60 in-lb. 3. Valve Body Assembly a. Reinstall the two rear valve body covers and loosely install the 11 bolts (Figure 6), then torque to 96 in-lb. b. Reinstall the separator plate, gasket and rear valve body onto the front valve body (first ensuring all checkballs, check valves and filters are in proper locations). Loosely install the five bolts (Figure 5), then torque to 60 in-lb. Figure 5 c. F lip the valve body over. d. Loosely install the four bolts (Figure 4), and torque the four bolts to 60 in-lb. e. Place the front valve body cover, gasket and separator plate onto the front valve body. Reinstall the two shift solenoids and loosely install the two bolts (Figure 3). Bolt installation torque specifications are 60 in-lb. f. Reinstall the brackets, throttle pressure control solenoid, TCC control solenoid (Figure 1) and small cover. g. Loosely install the 13 bolts (Figure 2) and then torque all 15 bolts to 60 in-lb. Figure 6 Bolt installation torque specifications are 96 in-lb. Bolt Color Code Bolt Length Yellow 10mm Red 16mm Orange 20mm Green 38mm Blue 50mm ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com AW60-40LE-ZIP-Booklet 02-11-15 Page 3 TIME TESTED • INDUSTRY TRUSTED Aisin AW 60-40LE 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. Front Control Valve Body - Separator Plate Side Shown Here 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. *Part numbers with an asterisk (*) are included in this Zip Kit. 02-11-15 AW60-40LE-ZIP-Booklet Page 4 ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Aisin AW 60-40LE ZIP KIT 20 15 Installation & Testing Booklet TIME TESTED • INDUSTRY TRUSTED 10 25 5 0 30 VACUUM TEST Front Control Valve Body - Cover Side Shown Here 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 Assembly • 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-ZIP-Booklet 02-11-15 Page 5 TIME TESTED • INDUSTRY TRUSTED Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet Critical Wear Areas & Vacuum Test Locations 20 15 10 25 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. 5 0 30 VACUUM TEST Rear Control Valve Body - Separator Plate Side Shown Here Coast Clutch Modulator Valve Burned coast clutch NOTE: Test using non-orificed 2nd/4th brake modulator control valve. Solenoid Modulator Valve Shift complaints NOTE: Test using non-orificed 2nd/4th brake modulator control 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 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 2nd/4th Brake Modulator Control Valve • Burned 2-4 brake • Shift complaints in 2nd & 4th 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. *Part numbers with an asterisk (*) are included in this Zip Kit. 02-11-15 AW60-40LE-ZIP-Booklet Page 6 ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet 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 AW60-40LE-ZIP-Booklet 02-11-15 Page 7 Aisin AW 60-40LE ZIP KIT TIME TESTED • INDUSTRY TRUSTED Installation & Testing Booklet 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. 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 02-11-15 AW60-40LE-ZIP-Booklet Page 8 Check Valve Description Check Valve 203 206 207 202 204 205 201 ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
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