AW60 41SN ZIP IN

Aw60-41Sn-Zip-In AW60-41SN-ZIP-IN AW60-41SN-ZIP-IN 2770 instructions part uploads sonnax-dev

2015-02-11

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AISIN AW 60-41SN (AF-17)
ZIP KIT
PART NUMBER AW60-41SN-ZIP

Valve Body Identification

QUICK GUIDE

NOTE: This Zip Kit AW60-41SN-ZIP is designed for 60-41SN (AF-17) applications only.
A separate Zip Kit AW60-40LE-ZIP is available for 60-40LE (AF-13) applications.
No
Number 2
Rear Control
Body

Has a
Number 2
Rear Control
Body

Has a
Long TCC
Solenoid
60-40LE (AF-13) Valve Body

60-41SN (AF-17) Valve Body

Has a
Short TCC
Solenoid

Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents.

installation Diagram
3

Middle Control
Valve Body
2

1

6

Front Control
Valve Body

OE Assembly Shown

Shim
Location

9

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.

12

4

10

Checkballs
12 Small
1 Large

4

6

8
NOTE: Clocking
is important; see
details on next page.

5

7

No. 2 Rear Control
Valve Body

Rear Control Valve Body

11

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

AW60-41SN-ZIP-Guide 02-11-15
Page 1

Aisin AW 60-41SN ZIP KIT

Quick Guide

Zip Kit Contents & Installation Steps
Step	 1 Replace OE Reverse Boost

8 Replace OE Lockup Relay
Step	

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 placed on inboard sleeve diameter.

	
NOTE: Clocking is important; when properly installed, sleeve
ports face upward and endface protrusion to the left of the plate.

Packaging Pocket 1

•	Valve • Sleeve

Assembly

Plunger Valve Assembly

Packaging Pocket 8

•	Valve • Sleeve • Shims (3) 1 extra

Step	 2 Replace OE Accumulator

Control Plunger Valve Assembly

Packaging Pocket 2

•	Valve • Sleeve

3 Replace OE B1 Modulator
Step	

Plunger Valve Assembly

9 Replace OE C1 Damper Piston
Step	

Assembly

Place O-rings in the two sleeve grooves, lubricate with Sonnax Slippery Stick
O-LUBE and roll to size on bench. Push into bore, O-ring end outboard.
Place long, narrow spring into valve pocket. Push into installed sleeve,
spring end first. Larger diameter spring functions as sleeve retainer.
Packaging Pocket 9

•	Valve • Sleeve • Springs (2) • O-Rings, Large (3) 1 extra

Discard OE retainer and use replacement pin to retain lineup.
Packaging Pocket 3

•	Valve • Sleeve • Retaining Pin

4 Replace OE End Plugs
Step	

10 Rework OE C1 Control Assembly
Step	
Install Sonnax C1 control valve assembly into existing OE C1 control sleeve.
Remove and discard OE valve. Install replacement assembly into OE sleeve
tapered end (four notches) first. Ensure Sonnax valve has orificed spool at
the blind-bottom end of the OE sleeve.

Place O-rings in large groove, lubricate with Sonnax Slippery Stick
O-LUBE and roll to size on bench. Install end plugs with O-ring outboard.

Packaging Pocket 10

Packaging Pocket 4

NOTE: This sleeve is designed to be a slight/hand press fit-to-minimal slip
fit into the OE sleeve.

•	End Plugs, Medium (4) • O-Rings, Medium (6) 2 extra

5 Replace OE End Plugs
Step	
Place O-rings in large groove, lubricate with Sonnax Slippery Stick
O-LUBE and roll to size on bench. Install end plugs with O-ring outboard.

•	Valve • Sleeve

Step	 11 Replace OE Secondary

Regulator Valve End Plug

Packaging Pocket 5

Place O-rings in large groove, lubricate with Sonnax Slippery Stick O-LUBE
and roll to size on bench. Install end plugs with O-ring outboard.

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

Packaging Pocket 11

Step	 6 Replace OE Solenoid O-Rings
Packaging Pocket 6

•	O-Rings, Small (4) 1 extra

7 Replace OE TCC Control
Step	

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

Step	 12 Replace OE Checkballs
Packaging Pocket 12

•	Checkballs, Small .218" dia. (12) • Checkball, Large .250" dia.

Plunger Valve Assembly

Discard OE retainer and use replacement pin to retain sleeve.
Packaging Pocket 7

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

AW60-41SN-ZIP-Guide 02-11-15
Page 2

AISIN AW 60-41SN (AF-17)
ZIP KIT
PART NUMBER AW60-41SN-ZIP

INSTALLATION & TESTING BOOKLET

Torque Specifications

NOTE: This Zip Kit AW60-41SN-ZIP is designed for 60-41SN (AF-17) applications only.
A separate Zip Kit AW60-40LE-ZIP is available for 60-40LE (AF-13) applications.

Manual Shaft Detent
Spring Bolt
89 in-lb

Manual Shift Shaft Detent
Lever Bolts
89 in-lb

Valve Body Identification

Manual Shift Shaft
Retaining Nut
61 in-lb

Park/Neutral Position
Switch Bolt
18 ft-lb

Transmission Speed
Sendor Bolt
48 in-lb

Torque Converter
Housing Bolts
22 ft-lb

Transmission Case
Cover Bolts
18 ft-lb

Transmission Fluid
Baffle Bolts
48 in-lb

Transmission Fluid
Drain Plug
29 ft-lb

Transmission Fluid Pump
Cover Bolt
89 in-lb

Transmission Fluid
Pump-to-Case Bolt
18 ft-lb

Valve-Body-to-Case
Bolts
18 ft-lb

60-41SN (AF-17) Valve Body: Use this kit.
Has a
Number 2
Rear Control
Body

60-41SN (AF-17) Valve Body

Fluid Chart

60-41SN (AF-17) Valve Body

60-40LE (AF-13) Valve Body: Use AW60-40LE-ZIP kit.

Recommended Capacities: Toyota / GM T-IV ATF
Approximate Capacity,
Complete Overhaul
7.6 qt (7.2L)

Has a
Long TCC
Solenoid

No
Number 2
Rear Control
Body

Approximate Capacity,
Drain and Fill
4.2 qt (4.0L)

Component Apply Chart
Clutch

Position
C0

C1

C2

P

Brake
C3

< = 7 mph

X

X

R

> 7 mph

X

X

N

2

F1

Has a
Short TCC
Solenoid

X
60-40LE (AF-13) Valve Body

1

X

X

2

X

X

X
X

N Cont.

X

X

3

X

X

X

4

X

X
X

2

60-40LE (AF-13) Valve Body

X

X
X

X

X

X

X

X

X

4

X

X

X
X

X

X
X

X

1

X

X

2

X

X

X

X
X

X

3

(3rd)
1

F0

X

1
3

B2

X

R

D

B1

1-Way
Clutch

X

X

1

X

X

(2nd)

X

X

X
X

X

X
X
X

X

X

X

X

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

AW60-41SN-ZIP-Booklet 02-11-15
Page 1

TIME TESTED • INDUSTRY TRUSTED

Aisin AW 60-41SN ZIP KIT

Installation & Testing Booklet

Electronic Cautions

Solenoid Apply Chart

Performance Modes
The transmission control module (TCM) programming allows the driver to select
among various modes for enhanced performance based upon driving conditions.
The TCM itself has the capability to change modes automatically when specific
conditions are met. These modes will alter shift feel, and could be confused with
shift problems by the driver if they are unaware of the TCM programming.
•	 Economy Mode/Power Mode The transmission is programmed to start
and operate in Economy Mode. This shift strategy sets the shift points to
occur at a lower speed than Power Mode to maximize fuel economy. The TCM
will automatically switch to Power Mode when the driver accelerates more
aggressively (higher engine load), or at higher speed, maximizing performance.

•	 Neutral Control is automatically activated by the TCM if the vehicle is in
Drive and comes to a stop for longer than 2 seconds with the brakes applied.
This condition allows the C1 (forward clutch) to be disengaged, placing the
vehicle in Neutral, for improved fuel economy. When the brake is released,
the C1 clutch is automatically applied and the vehicle will take off in 1st gear.
•	 Hill Hold The TCM monitors vehicle speed to determine if the driver is
coming to a stop on a hill. If so, the TCM will automatically apply the B1 (2/4
brake) to prevent vehicle rolling. Upon takeoff, the B1 brake is released, and
the vehicle moves forward in 1st gear. The TCM will disable Neutral Control
if Hill Hold is activated.

Solenoids
•	 The S1 solenoid is an on/off style, operated by
the TCM to control the 2-3 shift.

SLT Solenoid
3.3–3.7 ohm

S1

P
R

< = 7 mph

R

> 7 mph

N

D

S2

SN

SLU

X
X
X
X
1

X

2

X

X

N Cont.

X

X

•	 Winter Mode is activated by the driver by a switch on the shifter. This mode
starts the vehicle in 3rd gear to reduce tire slip on icy/slippery roads. Once the
vehicle is moving, the TCM will automatically shift to the appropriate gear.
Shifting into manual 1st or 2nd will cancel Winter Mode.

This 60-41SN unit uses five solenoids (Figure 1).

Solenoid

Position

3

X

4

3

1

X

2

X

X

3

X

S1 Solenoid
11–15 ohm

•	 The S2 solenoid is an on/off style, operated by
the TCM to control the 1-2 and 3-4 shifts.

X
X

1

X

2

X

X

(3rd)
1

X
X

4

2

X

X

1

X

(2nd)

X

X

X

S2 Solenoid
11–15 ohm

Figure 1

SLU Solenoid
5.0–5.6 ohm

•	 The SN solenoid is an on/off style, operated by
the TCM to operate Neutral Control.
•	 The SLU linear solenoid is pulse width
modulated by the TCM to operate the converter
clutch.
•	 The SLT linear solenoid is modulated by the
TCM to regulate line pressure.

SN Solenoid
12–16 ohm

02-11-15 AW60-41SN-ZIP-Booklet
Page 2

Test all five solenoids at 20˚C/68˚F.

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

Aisin AW 60-41SN ZIP KIT

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

Zip Kit Instructions

Figure 2

1. Valve Body Disassembly
NOTE: See color charts for bolt lengths.

a. Remove the 13 bolts (Figure 2).
b. Remove the five solenoids (Figure 2).
c. Remove the eight bolts (Figure 3).
d. R
 emove the central (non-pink-coded) bolts
(Figure 4). The two rear valve body covers can be
removed to access bore components by removing
the 11 cover bolts (pink-coded).

Bolt Color
Code

2. Installation
Install Zip Kit parts as shown on diagram of
separate quick guide sheet included in this Zip Kit.

Bolt
Length

Yellow

10mm

Orange

12mm

Red

16mm

Green

40mm

Blue

75mm

Bolt installation torque specifications are 59 in-lb.

3. Valve Body Assembly

Figure 3

a. Loosely install the central (non-pink-coded) bolts
(Figure 4), then torque to 59 in-lb. The 11 cover
bolts (pink-coded) should be torqued to 89 in-lb.
b. L
 oosely install the eight bolts (Figure 3), then
torque to 59 in-lb.
c. Reinstall the five solenoids (Figure 2).
d. Loosely install the 13 bolts (Figure 2), then
torque to 59 in-lb.
Bolt Color
Code

Bolt
Length

Red

16mm

White

38mm

Lt Blue

54mm

Bolt installation torque specifications are 59 in-lb.

Figure 4

Bolt installation torque specifications are 59 in-lb for all
except for Pink code, 12mm bolts, which are 89 in-lb.

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

Bolt Color
Code

Bolt
Length

Pink

12mm

Red

16mm

White

38mm

Purple

50mm

AW60-41SN-ZIP-Booklet 02-11-15
Page 3

TIME TESTED • INDUSTRY TRUSTED

Aisin AW 60-41SN 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 - Top Side (Bottom Side Inset) Shown Here

Solenoid B-1 Modulator Valve No. 2
Shift complaints in 2nd & 4th
NOTE: Invert valve (as shown) to test.

Neutral Relay Valve
•	Delayed engagement
•	Loss of neutral control feature
NOTE: Prop valve in outboard position with checkball
and seal port on opposite side of casting.




Seal for neutral relay
valve vacuum test.

Front Control Valve Body
Top Side

End Plugs
Front Control Valve Body
Bottom Side

•	Burnt clutches/brakes
•	Various shift complaints
Replace with Sonnax Part No.
19741-15K*
NOTE: Several Locations =



*Part numbers with an asterisk (*)
are included in this Zip Kit.
02-11-15 AW60-41SN-ZIP-Booklet
Page 4

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

Aisin AW 60-41SN ZIP KIT

20

15

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

10

25

5

0
30
VACUUM
TEST

Middle Control Valve Body - Top & Bottom Sides Shown Here
Reverse Boost Assembly
•	Low reverse pressure
•	Delayed reverse
Replace with Sonnax Part No.
19741-07K*

Lockup Control Solenoid Valve
Middle Control Valve Body
Top Side

•	Converter slip/shudder/codes
•	No converter apply
NOTE: Test port by using 3-4 shift valve in bore instead.

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

3-4 Shift Valve
3-4 Shift complaints
NOTE: Seal solenoid port
when testing.

Middle Control Valve Body
Bottom Side

 


Tes
t
Seal

Seal

Seal for 2-3 shift
valve vacuum test.

Seal for 1-2 shift
valve vacuum test.

t

Tes

Solenoid B-1
Modulator
Valve No. 1
Shift complaints in
2nd & 4th

2-3 Shift Valve
2-3 Shift complaints
NOTE: Seal solenoid port as
well as port on opposite side
of casting.

1-2 Shift Valve

B1 Modulator
Plunger Valve

Accumulator Control
Plunger Valve

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

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

Shift complaints
Replace with Sonnax Part No.
19741-05K*

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

AW60-41SN-ZIP-Booklet 02-11-15
Page 5

TIME TESTED • INDUSTRY TRUSTED

Aisin AW 60-41SN 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 - Top Side (Bottom Side Inset) Shown Here
Secondary Regulator Valve

Rear Control Valve Body
Bottom Side

•	TCC complaints
•	Loss of lube
NOTE: Seal two ports on opposite side of casting when testing two middle ports.

Lockup Relay Plunger Valve



•	TCC apply & release concerns
•	Inadequate lubrication • Overheat
Replace with Sonnax Part No.
19741-09K*

Lockup Relay Control
Valve

C-3 Modulator Valve
•	Burned C3 clutch
•	Slips in 1st, 2nd & 3rd
NOTE: Test with 2-3 gear timing valve in
bore instead.

Lockup complaints/codes
NOTE: Seal port on opposite side of
casting when testing.

C-1 Damper Piston
B-1 Modulator Control
Valve

•	Burned C1 clutch
•	Delayed forward
Replace with Sonnax Part No.
19741-17K*

•	Shift complaints in 2nd & 4th
•	Burned B1 brake

2-3 Timing Valve
& C2 Accumulator

Low Modulator Valve

•	2-3 Shift complaints
NOTE: Test both ports at the same time.

Delayed forward in Manual 1
NOTE: Test both ports at the same time.

C-1 Control
Valve Assembly
•	Burned C1 clutch
•	Delayed forward

Solenoid Modulator Valve
Shift complaints
NOTE: Test with B-1 modulator valve
in bore instead.

C2 & B1 Accumulators
•	Burned C2 clutch
•	Bang/Delayed reverse
•	Burned B1 brake
•	Shift complaints in 2nd & 4th

No. 2 Rear Control Valve Body
Lockup Control Valve
•	Loss of lockup
•	Converter slips/shudder/codes
NOTE: Test with valve blocked inboard
(as shown).

02-11-15 AW60-41SN-ZIP-Booklet
Page 6

Rear Control Valve Body
Top Side

Lockup Control Plunger
Valve Assembly
•	Loss of lockup
•	Converter slips/shudder/codes
Replace with Sonnax Part No.
19741-01K*
*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

Aisin AW 60-41SN ZIP KIT

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Front & Middle Control Valve Bodies Shown Here
Filter

Front Control Valve Body Descriptions

I.D. No.

101

Description

101

Solenoid B-1 Modulator Valve
No. 2

102

Neutral Relay Valve

102
Front Control
Valve Body

Filter

Middle Control Valve Body Descriptions

I.D. No.

Description

201

Pressure Relief Valve

202

Lockup Control Solenoid Valve

203

3-4 Shift Valve

204

2-3 Shift Valve

205

1-2 Shift Valve

206

Solenoid B-1 Modulator
Valve No.1

207

Accumulator Regulator Valve and
Plunger Valve Assembly

208

Primary Regulator Valve
& Reverse Boost Assembly

209

Pressure Relief Valve

Middle Control
Valve Body
(Bottom Side)

209

201

208

202
203
204
205

207
206

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

Middle Control Valve Body
(Front Side)

AW60-41SN-ZIP-Booklet 02-11-15
Page 7

Aisin AW 60-41SN ZIP KIT

TIME TESTED • INDUSTRY TRUSTED

Installation & Testing Booklet

OE Exploded View
Rear & No. 2 Rear Control Valve Bodies Shown Here

Rear Control
Valve Body

316

301

315

314

302
Filter

313

303
312

304

311

305

310
306
309
307
308
Rear Control Valve Body Descriptions

I.D No.

Description

301

Secondary Regulator Valve

302

Check Valve

303

B-1 Modulator Control Valve

304

Low Modulator Valve

305

Solenoid Modulator Valve

306

C-2 Accumulator

307

B-1 Accumulator

308

Manual Valve

309

C-1 Control Valve Assembly

310

C-0 Accumulator

311

2-3 Timing Valve

312

C-1 Damper Piston

313

C-3 Modulator Valve

314

Lockup Relay Control Valve
& Plunger Assembly

315

Check Valve

316

Check Valve

No. 2 Rear Control
Valve Body

No. 2 Rear Control
Valve Body

401

No. 2 Rear Control Valve Body
Descriptions

I.D. No.
401

02-11-15 AW60-41SN-ZIP-Booklet
Page 8

Description
TCC Control Valve
& Plunger Valve Assembly

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