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

: Sonnax Aw60-41Sn-Zip-In AW60-41SN-ZIP-IN 1775 file instruction uploads

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PART NUMBER AW60-41SN-ZIP QUICK GUIDE

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

AISIN AW 60-41SN (AF-17)

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 AW60-41SN-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.

Front Control

Valve Body

Rear Control Valve Body

No. 2 Rear Control

Valve Body

Middle Control

Valve Body

Checkballs

12 Small

1 Large

Shim

Location

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

Lowest of three OE

sleeve steps.

Has a

Number 2

Rear Control

Body

60-41SN (AF-17) Valve Body

Has a

Long TCC

Solenoid

NOTE: Clocking

is important; see

details on next page.

Aisin AW 60-41SN 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 placed on inboard sleeve diameter.

Packaging Pocket 1

• Valve • Sleeve • Shims (3) 1 extra

Step Replace OE Accumulator

Control 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

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 4

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

Step Replace OE End Plugs

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 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 TCC Control

Plunger Valve Assembly

Discard OE retainer and use replacement pin to retain sleeve.

Packaging Pocket 7

• Valve • Sleeve • Retaining Pin

Step Replace OE Lockup Relay

Plunger Valve Assembly

NOTE: Clocking is important; when properly installed, sleeve

ports face upward and endface protrusion to the left of the plate.

Packaging Pocket 8

• Valve • Sleeve

Step Replace OE C1 Damper Piston

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 rst. Larger diameter spring functions as sleeve retainer.

Packaging Pocket 9

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

Step Rework OE C1 Control Assembly

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) rst. Ensure Sonnax valve has oriced spool at

the blind-bottom end of the OE sleeve.

Packaging Pocket 10

• Valve • Sleeve

NOTE: This sleeve is designed to be a slight/hand press t-to-minimal slip

t into the OE sleeve.

Step Replace OE Secondary

Regulator Valve End Plug

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 11

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

Step Replace OE Checkballs

Packaging Pocket 12

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

Zip Kit Contents & Installation Steps

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.

Valve Body Identication

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

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

Component Apply Chart

Position Clutch Brake 1-Way

Clutch

C0 C1 C2 C3 B1 B2 F0 F1

R < = 7 mph X X X

R > 7 mph X X

1X X X X

2X X X X

N Cont. X X X X

3X X X X

4X X X

1X X X X

2X X X X

3X X X X

4X X X

1X X X X

2X X X X

(3rd) X X X X

11X X X X X

(2nd) X X X X

Torque Specifications

Manual Shaft Detent

Spring Bolt

89 in-lb

Manual Shift Shaft Detent

Lever Bolts

89 in-lb

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

Bafe 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

Fluid Chart

Recommended Capacities: Toyota / GM T-IV ATF

Approximate Capacity,

Complete Overhaul

7.6 qt (7.2L)

Approximate Capacity,

Drain and Fill

4.2 qt (4.0L)

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

AISIN AW 60-41SN (AF-17)

ZIP KIT

PART NUMBER AW60-41SN-ZIP INSTALLATION & TESTING BOOKLET

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

Aisin AW 60-41SN ZIP KIT Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Solenoid Apply Chart

Position

Solenoid

S1 S2 SN SLU

R< = 7 mph X

R> 7 mph X

2X X

N Cont. XXX

3X X

2X X

3X X

2X X

(3rd) X X

(2nd) X X

Electronic Cautions

Performance Modes

e transmission control module (TCM) programming allows the driver to select

among various modes for enhanced performance based upon driving conditions.

e TCM itself has the capability to change modes automatically when specic

conditions are met. ese 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.

• 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.

• 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

is 60-41SN unit uses ve solenoids (Figure 1).

• The S1 solenoid is an on/off style, operated by

the TCM to control the 2-3 shift.

• The S2 solenoid is an on/off style, operated by

the TCM to control the 1-2 and 3-4 shifts.

• 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.

Figure 1

SLT Solenoid

3.3–3.7 ohm

SN Solenoid

12–16 ohm

SLU Solenoid

5.0–5.6 ohm

S2 Solenoid

11–15 ohm

S1 Solenoid

11–15 ohm

Test all ve solenoids at 20˚C/68˚F.

Aisin AW 60-41SN ZIP KIT Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Zip Kit Instructions

1. Valve Body Disassembly

NOTE: See color charts for bolt lengths.

a. Remove the 13 bolts (Figure 2).

b. Remove the ve solenoids (Figure 2).

c. Remove the eight bolts (Figure 3).

d. Remove the central (non-pink-coded) bolts

(Figure 4). e two rear valve body covers can be

removed to access bore components by removing

the 11 cover bolts (pink-coded).

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. Loosely install the central (non-pink-coded) bolts

(Figure 4), then torque to 59 in-lb. e 11 cover

bolts (pink-coded) should be torqued to 89 in-lb.

b. Loosely install the eight bolts (Figure 3), then

torque to 59 in-lb.

c. Reinstall the ve solenoids (Figure 2).

d. Loosely install the 13 bolts (Figure 2), then

torque to 59 in-lb.

Bolt Color

Code

Bolt

Length

Yellow 10mm

Orange 12mm

Red 16mm

Green 40mm

Blue 75mm

Figure 2

Bolt installation torque specications are 59 in-lb.

Bolt Color

Code

Bolt

Length

Red 16mm

White 38mm

Lt Blue 54mm

Figure 3

Bolt installation torque specications are 59 in-lb.

Bolt Color

Code

Bolt

Length

Pink 12mm

Red 16mm

White 38mm

Purple 50mm

Figure 4

Bolt installation torque specications are 59 in-lb for all

except for Pink code, 12mm bolts, which are 89 in-lb.

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

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.

Solenoid B-1 Modulator Valve No. 2

Shift complaints in 2nd & 4th

NOTE: Invert valve (as shown) to test.

Front Control Valve Body

Bottom Side

Front Control Valve Body

Top Side

End Plugs

• 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.

Aisin AW 60-41SN ZIP KIT Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Middle Control Valve Body - Top & Bottom Sides Shown Here

VACUUM

TEST

B1 Modulator

Plunger Valve

Shift complaints in 2nd & 4th

Replace with Sonnax Part No.

19741-03K*

1-2 Shift Valve

1-2 Shift complaints

NOTE: Seal port on opposite

side of casting.

Reverse Boost Assembly

• Low reverse pressure

• Delayed reverse

Replace with Sonnax Part No.

19741-07K*

Lockup Control Solenoid Valve

• 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

Seal for 2-3 shift

valve vacuum test.

Seal for 1-2 shift

valve vacuum test.

Test

Seal

Test

2-3 Shift Valve

2-3 Shift complaints

NOTE: Seal solenoid port as

well as port on opposite side

of casting.

3-4 Shift Valve

3-4 Shift complaints

NOTE: Seal solenoid port

when testing.

Middle Control Valve Body

Top Side

Middle Control Valve Body

Bottom Side



Solenoid B-1

Modulator

Valve No. 1

Shift complaints in

2nd & 4th

Accumulator Control

Plunger Valve

Shift complaints

Replace with Sonnax Part No.

19741-05K*

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

VACUUM

TEST

No. 2 Rear Control Valve Body

Lockup Relay Control

Valve

Lockup complaints/codes

NOTE: Seal port on opposite side of

casting when testing.

Secondary Regulator Valve

• TCC complaints

• Loss of lube

NOTE: Seal two ports on opposite side of casting when testing two middle ports.

B-1 Modulator Control

Valve

• Shift complaints in 2nd & 4th

• Burned B1 brake

Low Modulator Valve

Delayed forward in Manual 1

NOTE: Test both ports at the same time.

Solenoid Modulator Valve

Shift complaints

NOTE: Test with B-1 modulator valve

in bore instead.

C-1 Damper Piston

• Burned C1 clutch

• Delayed forward

Replace with Sonnax Part No.

19741-17K*

2-3 Timing Valve

& C2 Accumulator

• 2-3 Shift complaints

NOTE: Test both ports at the same time.

C-1 Control

Valve Assembly

• Burned C1 clutch

• Delayed forward

C2 & B1 Accumulators

• Burned C2 clutch

• Bang/Delayed reverse

• Burned B1 brake

• Shift complaints in 2nd & 4th

Lockup Control Valve

• Loss of lockup

• Converter slips/shudder/codes

NOTE: Test with valve blocked inboard

(as shown).

Lockup Control Plunger

Valve Assembly

• Loss of lockup

• Converter slips/shudder/codes

Replace with Sonnax Part No.

19741-01K*

Rear Control Valve Body

Bottom Side

Rear Control Valve Body

Top Side

* Part numbers with an asterisk (*)

are included in this Zip Kit.



C-3 Modulator Valve

• Burned C3 clutch

• Slips in 1st, 2nd & 3rd

NOTE: Test with 2-3 gear timing valve in

bore instead.

Lockup Relay Plunger Valve

• TCC apply & release concerns

• Inadequate lubrication • Overheat

Replace with Sonnax Part No.

19741-09K*

Aisin AW 60-41SN ZIP KIT Installation & Testing Booklet

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 7

TIME TESTED • INDUSTRY TRUSTED

101

102

Front Control

Valve Body

Filter

208

Middle Control Valve Body

(Front Side)

207

206

201

202

203

204

205

Front Control Valve Body Descriptions

I.D. No. Description

101 Solenoid B-1 Modulator Valve

No. 2

102 Neutral Relay Valve

OE Exploded View

Front & Middle Control Valve Bodies Shown Here

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

Aisin AW 60-41SN ZIP KIT Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

316

315

314

313

312

311

310

309

308

307

306

305

303

304

302

301

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

Descriptions

I.D. No. Description

401 TCC Control Valve

& Plunger Valve Assembly

Rear Control

Valve Body

OE Exploded View

Rear & No. 2 Rear Control Valve Bodies Shown Here

No. 2 Rear Control

Valve Body

401

Filter

No. 2 Rear Control

Valve Body

AW60 41SN ZIP IN

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

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