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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PART NUMBER AW60-40LE-ZIP QUICK GUIDE

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

AISIN AW 60-40LE (AF-13)

ZIP KIT

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.

60-40LE (AF-13) Valve Body

Number 2

Rear Control

Body

Has a

Short TCC

Solenoid

Valve Body Identication 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.

Checkballs

10 Small

1 Large

Front Control

Valve Body

Rear Control Valve Body

Has a

Number 2

Rear Control

Body

60-41SN (AF-17) Valve Body

Has a

Long TCC

Solenoid

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.

OE Assembly Shown

Shim

Location

Aisin AW 60-40LE ZIP KIT Quick Guide

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

Step Replace OE Reverse

Boost Assembly

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 1

• Valve • Sleeve • Shims (3) 1 extra

Step Replace OE Accumulator

Plunger Valve Assembly

Packaging Pocket 2

• Valve • Sleeve

Step Replace OE B1 Modulator

Plunger Valve Assembly

Discard OE retainer and use replacement pin to retain lineup.

Packaging Pocket 3

• Valve • Sleeve • Retaining Pin

Step Replace OE End Plugs

Packaging Pocket 4

• End Plugs, Medium (2) • O-Rings, Medium (4) 2 extra

Step Replace OE End Plug

Packaging Pocket 5

• End Plug, Large • O-Rings, Large (2) 1 extra

Step Replace OE Solenoid

O-Rings

Packaging Pocket 6

• O-Rings, Small (4) 1 extra

Step Replace OE Lockup Control

Plunger Valve Assembly

Packaging Pocket 7

• Valve • Sleeve

Step Replace OE Secondary

Regulator Valve End Plug

Packaging Pocket 8

• End Plug, Large • O-Rings, Large (2) 1 extra

Step Replace OE Checkballs

Checkballs

Packaging Pocket 9

• Checkballs, Small .218" dia. (10) • Checkball, Large .250" dia.

Zip Kit Contents & Installation Steps

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.

Valve Body Identication

60-40LE (AF-13) Valve Body: Use this kit.

60-41SN (AF-17) Valve Body: Use AW60-41SN-ZIP kit.

Torque Specifications

Transaxle Side

Cover Bolt

18 ft-lb

Manual Detent

Spring Bolt

90 in-lb

Manual Shift Lever Nut

60 in-lb

Front Valve Body

Cover Bolt

18 ft-lb

Front-Valve-Body-to-

Rear-Valve-Body Bolt

60 in-lb

Rear Valve Body

Cover Bolt

96 in-lb

Solenoid-to-Valve-

Body Bolt

60 in-lb

Valve-Body-to-

Transaxle Bolt

90 in-lb

Fluid Chart

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

Has a

Number 2

Rear Control

Body

60-41SN (AF-17) Valve Body 60-41SN (AF-17) Valve Body

Has a

Long TCC

Solenoid

60-40LE (AF-13) Valve Body

Has a

Short TCC

Solenoid

60-40LE (AF-13) Valve Body

Number 2

Rear Control

Body

Component Apply Chart

Position Clutch Brake 1-Way Clutch

Forward Coast Reverse OD 1st-Reverse 2nd-4th No. 1 No. 0

RX X X

1X X X X

2X X X X

3X X X X

4X X X

21X X X X

2X X X X

L 1 X X X X X

AISIN AW 60-40LE (AF-13)

ZIP KIT

PART NUMBER AW60-40LE-ZIP INSTALLATION & TESTING BOOKLET

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

Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Solenoids

is 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.

Zip Kit Instructions

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 sole-

noids (Figure 1) and front valve body cover,

separator plate and gasket.

d. Remove the three checkballs, two oil lters, one

check valve and spring, four bolts and one brack-

et (Figure 4).

Figure 1

TCC Solenoid

11–15 ohm

Test all four solenoids at

20˚C/68˚F.

Throttle Pressure

Control Solenoid

3–5 ohm

Shift Solenoids

(interchangeable)

11–15 ohm

No. 1

No. 2

Figure 2

Bolt installation torque specications are 60 in-lb.

Figure 3

Bolt installation torque specications are 60 in-lb.

Bolt Color

Code

Bolt

Length

Yellow 10mm

Red 16mm

Orange 20mm

Green 38mm

Blue 50mm

Solenoid Apply Chart

Position Solenoid

No. 1 No. 2 TCC

2X X

3X X1

4X1

21X

2X X

L 1 X

1On only when TCC is operating.

Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

1. Valve Body Disassembly

(continued)

e. Flip valve body over and remove ve bolts. Lift

rear valve body and separator plate o 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.

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 (rst ensuring all

checkballs, check valves and lters are in proper

locations). Loosely install the ve bolts (Figure 5),

then torque to 60 in-lb.

c. Flip 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).

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 4

Bolt installation

torque specications

are 60 in-lb.

Figure 5

Bolt installation

torque specications

are 60 in-lb.

Figure 6

Bolt installation

torque specications

are 96 in-lb.

Bolt Color

Code

Bolt

Length

Yellow 10mm

Red 16mm

Orange 20mm

Green 38mm

Blue 50mm

Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet

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

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.

Front Control Valve Body - Separator Plate Side Shown Here

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

* Part numbers with an asterisk (*)

are included in this Zip Kit.

Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Front Control Valve Body - Cover Side Shown Here

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

Assembly

• 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

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 =





Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet

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

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.

Rear Control Valve Body - Separator Plate Side Shown Here

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

Aisin AW 60-40LE 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

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

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

Front Valve Body

(Cover Side)

107

102

101

103

Filter

106

105 104

Check

Valve

Front Control Valve Body

(Separator Side)

Check Valve

Filter

Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet

Page 8 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

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

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

AW60 40LE ZIP IN

Aw60-40Le-Zip-In AW60-40LE-ZIP-IN AW60-40LE-ZIP-IN 2769 instructions part uploads sonnax-dev

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