E4OD 4R100 ZIP
2018-05-25
: Sonnax E4Od-4R100-Zip E4OD-4R100-ZIP 4406 instructions part uploads
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FORD E4OD, 4R100 ZIP KIT ® PART NUMBER E4OD-4R100-ZIP QUICK GUIDE Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents. installation Diagram Pump Body 4R100 Shown 5 See Note on Installation Steps (Pg 2). See Note on Installation Steps (Pg 2). 1 3 2 Upper Control Body E4OD Shown Stator Support Plug line-to-lube hole if present. E4OD Shown See Note on Installation Steps (Pg 2). 16 4 See Note on Installation Steps (Pg 2). 9 8 Plastic Checkballs (16) 5/16" Dia. (3) 1/4" Dia. Accumulator Control Body No I.D. Groove E4OD Shown Note I.D. Groove See Note on Installation Steps (Pg 2). 3-4 Location 7 1-2 Location 2-3 Location 6 See Note on Note I.D. Installation Steps (Pg 2). Groove 10 11 12 13 14 15 Reference pages 2-3 in Technical Booklet. 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. ©2018 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com E4OD-4R100-ZIP_Guide_A 04-30-18 Page 1 Ford E40D, 4R100 ZIP KIT® Quick Guide Zip Kit Contents & Installation Steps Step 1 eplace OE TCC Control R Plunger Valve & Sleeve CAUTION: Use in PWM units only. If core does NOT have this, do not install this assembly. Go to step 2. Step 6 Replace OE Line Pressure Modulator Plunger Assembly Place O-ring into narrow groove. Lubricate with Sonnax Slippery Stick O-LUBE and roll on bench to size. Packaging Pocket 1 Packaging Pocket 6 • Valve • Sleeve • Valve • Sleeve Step 7 Step 2 eplace OE Pressure R Regulator Valve CAUTION: If a line-to-lube orifice has been drilled into pump casting wall, it must be plugged. FITS: E4OD and 4R100 with F1, F5, F8 and E9 stamped pump castings. Packaging Pocket 2 • Valve Step 3 Replace OE Boost Assembly Place O-rings into narrow sleeve grooves. Lubricate with Sonnax Slippery Stick O-LUBE and roll on bench to size. Packaging Pocket 3 • Valve • Sleeve • O-Rings (3) 1 extra • O-Rings (2) 1 Extra 9 Replace OE Accumulator - Control Valves CAUTION: Recommend doing one at a time to keep springs in correct bore. Remove components from bore. Discard accumulator control valve, keep all other components. Install replacement valve. If valve sticks in bore due to casting wear or ridges, bore sizing with Sonnax bore sizing tool 34948-12 (sold separately) is recommended. If firmer than OE shifts are desired, add shims as needed into appropriate accumulator control valve spring pocket. • 1 shim = slightly firmer than OE • 2 shims = sufficient for heavy-duty use Reinstall OE spring. Place included retainer into OE retainer, and install into casting while compressing spring. Packaging Pocket 7 • 1-2 Accumulator Valve • Shims (2) • Retainer • Shims (2) • Retainer • Shims (2) • Retainer Packaging Pocket 8 Step 4 eplace OE Front Lube/ R Drainback Valve Use common sheetrock screw to remove orifice cup plug. Discard. Remove and discard existing ball seat, spring and valve. Clean bore. Place new assembly into bore, ball seat first. Lightly stake orifice cup plug into bore, .030–.060" below flush. • 2-3 Accumulator Valve Packaging Pocket 9 • 3-4 Accumulator Valve Step 10 Packaging Pocket 4 • Valve Assembly Step 5 • Orifice Cup Plug eplace OE Low/Reverse R Modulator Plunger Assembly 15 Replace OE Case - Components Reference Technical Booklet pages 2-3 to install remaining Zip Kit components in Case. • Intermediate Clutch Feed Seal • Direct Clutch Feed Seal • EPC Stemmed Relief Valve • Rear Case Bushing • Center Support Gasket • Sure Lock Overdrive Spiral Snap Ring • Rear Planet Endplay Shims (2) CAUTION: Used in '96-later E4ODs, all 4R100s. Packaging Pocket 5 • Valve • Sleeve Step 16 Replace OE Checkballs Checkball locations vary by application. Reference OE material for proper location. Packaging Pocket 12 NOTE: The parts listed here may be protected by patent 6,826,908. ©2018 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com • Checkballs (16) 5/16" dia. • Checkballs (3) 1/4" dia. E4OD-4R100-ZIP_Guide_A 04-30-18 Page 2 FORD E4OD, 4R100 ZIP KIT ® PART NUMBER E4OD-4R100-ZIP Component and Solenoid Application Chart Park/ Neutral GEAR Reverse FWD Clutch OD 2nd OD 3rd OD 4th OD 3rd** M2nd M1st On On On On On On On On On On On On On On On On O.D. Clutch On Coast Clutch On On Intermediate Band On On O.D. Roller Hold Hold Hold Hold Hold Hold Low Roller Hold Hold Hold Hold Hold SS1 On On On On Off Off Off On On SS2 Off Off Off On On Off On On Off CCS Off Off Off* Off* Off* Off On On On TCC Off Off On* On* On* On* On* On* Off *On = If the PCM determines that powertrain operating conditions exist for TCC apply, the TCC solenoid may be On (Modulating with PWM TCC units) in any forward gear except Manual 1st. *Off = Will be “On”, if the TCS switch is pushed. **OD-3rd = TCS “On” with TCIL illuminated showing “Off”. This Zip Kit services E4OD and 4R100 transmissions. While there are many similarities and shared components between the E4OD and 4R100, significant differences pertain to some components in this kit. Verify transmission type and production year prior to installing components. Solenoids On Int. Sprag Zip Kit Application Info On On L/R Clutch Solenoids Figure 1 OD 1st Int. Clutch Direct Clutch INSTALLATION & TESTING BOOKLET Figure 2 The E4OD and 4R100 use solenoid blocks that are bolted to the case beside the valve body. These are prone to contamination and wear, and should be resistance tested for electrical failures. OE replacements and Sonnax remanufactured solenoid blocks are available thru your distributor (Figure 2). • 36424A: Sonnax Remanufactured Solenoid Block for E4OD 1989‐1994. • 36424B: Sonnax Remanufactured Solenoid Block for E4OD 1995‐1998 and 4R100 non‐PWM ’98‐later. • 36424D: Sonnax Remanufactured Solenoid Block for 4R100 PWM TCC, ’98‐later. Figure 3 7 8 9 10 11 12 Solenoid Connector Pin Identification & Function Pin No Solenoid Body Connector Pin Identification Figure 4 Description 6 5 4 3 2 1 1 Vehicle Power in for Solenoids (VPWR) 2 Shift Solenoid “B” (2) Ground from PCM 3 Shift Solenoid “A” (1) Ground from PCM 4 Converter Clutch Solenoid Ground from PCM 5 Coast Clutch Solenoid Ground from PCM 6 Not Used Shift Solenoid “B” (2) 1&2 20 - 30 Ohms 7 Transmission Fluid Temp Sensor Shift Solenoid “A” (1) 1&3 20 - 30 Ohms 8 Transmission Fluid Temp Sensor (Signal Return) TCC Solenoid (On-Off) 1&4 20 - 30 Ohms Solenoid Resistance Chart Solenoid Figure 5 Solenoid Body Pin Numbers Resistance 9 Not Used TCC Solenoid (PWM) 1&4 10 - 20 Ohms 10 Not Used Coast Clutch Solenoid 1&5 20 - 30 Ohms 11 Electronic Pressure Control (EPC) Electronic Pressure Control Solenoid 12 Vehicle Power in for EPC Solenoid (VPWR) Transmission Fluid Temp Sensor ©2018 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 11 & 12 7&8 3 - 5 Ohms Varies with Temperatures E4OD-4R100-ZIP_Booklet_A 04-30-18 Page 1 Ford E40D, 4R100 ZIP KIT® TIME TESTED • INDUSTRY TRUSTED Bolt Color Code Bolt Case Location 1 Pink Solenoid Assembly (Nut) 2 Yellow Lower-to-Upper Control Body Bolts 9 Blue Solenoid Assembly Bolts 13 Red Accumulator Control Body 16 Green Main Control Valve Body NOTE: Torque all bolts to 80-100 in-lb. 1 9 8 5 8 5 2 9 6 1 7 8 9 11 12 14 13 2 1 10 15 3 5 4 16 10 6 11 1 9 8 7 Zip Kit Instructions 11 12 4 5 3 13 10 6 7 6 12 2 7 Figure 6 2 3 1 4 Figure 7 1 2 Installation & Testing Booklet 1. Valve Body Removal from Case (Figure 6 & Color Chart) 3 a. Remove 13 (red) accumulator control body bolts. b. Remove the main control body assembly by removing 16 (green) bolts. 4 NOTE: Do not remove the two lower‐to‐upper control body bolts (yellow). Figure 8 c. Remove 9 bolts (blue), 1 nut (pink), and solenoid assembly. d. Remove the two lower‐to‐upper control body bolts (yellow). Center Support Gasket NOTE: Check ball locations vary significantly between applications and production year Reference OE manual for proper check ball sizes and locations for specific units. Center Support Hub Center Support e. Reference Quick Guide to install all valve body components. 2. Pump Disassembly (Figure 7) a. Remove pump from transmission following OE instructions. b. Remove 12 bolts and separate the pump control body from the pump body. c. Reference Quick Guide to install all pump components. Install Case Components Figure 9 Sure Lock Overdrive Spiral Snap Ring OE Return Spring OE Intermediate Overdrive Cylinder OE Cut-Out/ Recess 04-30-18 Page 2 E4OD-4R100-ZIP_Booklet_A Locking Tabs 1. Install Rear Case Bushing (Individually Packaged) NOTE: Enclosed bushing services all 4R100s, ‘95-later E4ODs. a. Remove and discard OE bushing. b. Remove any ridge or case material with hone if bore inner diameter is irregular or not center machined. c. Apply Loctite® sealant to case bore. d. Align lube hole of Sonnax bushing with hole in case and three grooves to front of case. e. Press bushing to proper depth. Sonnax installation tool T36008A is available separately to aid in installation. f. Confirm lubrication hole is properly lined up and correct clearance has been maintained between bushing and output shaft. ©2018 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Ford E40D, 4R100 ZIP KIT® Installation & Testing Booklet 2. Install Center Support Gasket (Individually Packaged) a. Remove burrs and sharp edges on the aluminum center support contact surface. b. Using a medium grit oil stone, smooth the mating hub surface. c. Clean both parts including the tapped holes with solvent. d. Lightly coat gasket surface with TransJel and place it in the center support counter bore with beaded gasket surface against center support. e. Align gasket holes will center support and set hub in place (Figure 8). f. Apply Loctite® 242 thread locker on the three M6 mounting screws, following the Loctite® instructions. g. Install screws and progressively torque to 75-85 in-lbs initially, then torque to 100-120 in-lbs. 3. R eplace OE Overdrive Piston Return Spring Retaining Ring (Individually Packaged) a. Remove and discard OE retaining ring. b. A ssemble overdrive piston assembly using Sure Lock retaining ring, ensuring tabs on ring are locked as shown (Figure 9). TIME TESTED • INDUSTRY TRUSTED Figure 10 Rear Planet Endplay Shim, 4 Slots OE Reverse Planetary, 3 or 4 Pinion OE Thrust Washer, 4 Tanged OE Input Shell with Sun Gear Assembly Figure 11 Cut here if less than .625" deep. Intermediate Clutch Direct Clutch NOTE: Be sure snap ring is installed correctly. Failure to install correctly may result in unit failure. 4. Install Endplay Shims (Individually Packaged) a. I nstall Sonnax shims under the 4-tanged thrust washer, located between the reverse planetary carrier and the input shell (Figure 10). b. When final assembly is completed, total endplay should be inspected with a H gauge, depth mic., or dial caliper. The OE endplay is .075". The recommended endplay is .040" or less. 4R100 Case Spring Intermediate Seal Adapter Tube Intermediate Clutch Seal NOTE: The Sonnax shim does not reduce output shaft free play and will not fit in late-model applications with six pinion carriers. Spring 5. Install Intermediate & Direct Clutch Feed Seal Kit (Packaging Pocket 10) Direct Seal Adapter Tube Direct Clutch Seal NOTE: These intermediate and direct clutch feed seals are installed after internal parts are assembled and before valve body is installed. a. Due to casting variations on late 4R100 units, the alignment nub may need to be cut off the direct clutch seal. Measure distance from valve body gasket surface to the cast passage (Figure 13): • If more than .625", install Sonnax seal as-is • If more than .625", cut nub off seal (Figure 11) b. Coat rubber seal with assembly lube. c. A lign locator guide nub with slot in case and insert Sonnax rubber seal into feed port (Figure 12 & 13). d. Install Sonnax aluminum seal adapter tube followed by Sonnax spring. 6. Replace OE EPC Ball (Packaging Pocket 11) a. Replace OE EPC relief ball with Sonnax stemmed relief valve. Location in case is same for all units and production years (Figure 14). Intermediate Clutch Location/Alignment Figure 12 Figure 13 Direct Clutch Location/Alignment Measure Direct Clutch Depth Figure 14 Reassembly a. For valve body and solenoid block, reverse steps in disassembly section. Torque all bolts to 80–100 in-lbs. b. For pump body, use OE specified pump banding tool for proper pump half alignment. Loosely install 11 bolts. Align pump halves. Tighten all bolts to 20 ft-lb. ©2018 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com E4OD-4R100-ZIP_Booklet_A 04-30-18 Page 3 TIME TESTED • INDUSTRY TRUSTED Ford E40D, 4R100 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 and Sonnax parts noted for replacement. Lower Control Body • 4R100 Non-PTO Shown Engagement Control Valve NOTE: Worm tracks and test locations same for ‘96-’98 E40D. Worm tracks and test locations different for ‘89-’95 E40D. Worm tracks slightly different for PTO 4R100, test locations are the same. • Delayed Forward & Reverse engagement • Burnt Forward clutch • Burnt Direct clutch 1-2 Manual Transition Valve • Burnt intermediate band • Manual low gear bind-up Upper Control Body • 4R100 Non-PTO Shown Low/Reverse Modulator Valve Plunger & Sleeve NOTE: Worm tracks and test locations same for ‘96-’98 E40D. Worm tracks and test locations different for ‘89-’95 E40D. Worm tracks slightly different for PTO 4R100, test locations are the same. • No engine braking • Burnt Low/Reverse clutch • Low pressure at Low/Reverse clutch Replace with Sonnax Part No. 36947-06K* Note: Check for wear at inside diameter of sleeve. 2-3 Shift Valve • 2-3 Shift concerns • Burnt Direct clutch Note: Seal port on opposite side. Low/Reverse Modulator & Low/Reverse Modulator Valves 3-4 Shift Valve & 4-3-2 Timing Valve • No engine braking • Burnt Low/Reverse clutch • Low pressure at Low/Reverse clutch • 3-4 Shift concerns • Burnt Direct clutch • Manual low concerns Coast Clutch Shift Valve • Burnt coast clutch Drive 2 Valve • Reverse concerns Solenoid Regulator Valve 1-2 Shift Valve • 2nd or 3rd Gear starts • TCC cycling or slip • Reduced lube oil from the center support • No 2nd • 1-2 Shift concerns Test: Flip casting over and test at this orifice. Seal this side of casting with foam mat. *Part numbers with an asterisk (*) are included in this Zip Kit. 04-30-18 Page 4 E4OD-4R100-ZIP_Booklet_A 4-3-2 Timing Valve & Control Valve Shift Timing Plunger Replace with Sonnax Part No. 36947-14K Requires F-36947-TL14 & VB-FIX • Manual low concerns ©2018 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Ford E40D, 4R100 ZIP KIT® 20 15 Installation & Testing Booklet TIME TESTED • INDUSTRY TRUSTED 10 25 0 30 VACUUM TEST 5 For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com. Accumulator Control Body • 4R100 Non-PTO Shown Overdrive Clutch Accumulator Regulator Valve • No 4th • Soft shifts • Premature clutch failure Replace with Sonnax Part No. 36948-09K* Overdrive Clutch Accumulator Plunger Intermediate Clutch Accummulator Regulator Valve • Soft shifts • No 3rd • Premature clutch failure Replace with Sonnax Part No. 36948-13K* Intermediate Clutch Accumulator Plunger Note: Seal port on opposite side. • No 4th • Soft shifts • Premature clutch failure • No 3rd • Soft shifts • Premature clutch failure Direct Clutch Accumulator Plunger Line Pressure Modulator Valve • No 2nd • Soft shifts • Premature clutch failure • 1-2 Harsh • Harsh shifts • Soft shifts Direct Clutch Accumulator Regulator Valve • Soft shifts • No 2nd • Premature clutch failure Replace with Sonnax Part No. 36948-13K* Replace with Sonnax Part No. 36948-19 Requires 36948-TL Line Pressure Modulator Valve & Sleeve • Intermittent harsh shifts • 1-2 Soft • 2-3 Soft • Low EPC pressure • Low line rise Replace with Sonnax Part No. 36948-03K .331" dia. 36948-05K* .372" dia. 96948-01K .427" dia. 96948-05K .500" dia. *Part numbers with an asterisk (*) are included in this Zip Kit. ©2018 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com E4OD-4R100-ZIP_Booklet_A 04-30-18 Page 5 TIME TESTED • INDUSTRY TRUSTED Ford E40D, 4R100 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 and Sonnax parts noted for replacement. 5 0 30 VACUUM TEST For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com. Pump Body • E4OD Shown NOTE: Test ports on 4R100 slighlty different. Main Regulator Valve • Code 62, 628, 1744 • Engine stall on engagement in Reverse • Engine stumble on engagement in Reverse • High line pressure • Overheated converter Main Regulator Valve & Sleeve • Soft shifts • Delayed Reverse • Low line rise Replace with Sonnax Part Nos. 36424-01K* Boost Valve Kit (with O-rings) 36424-03K Boost Valve Kit (without O-rings) Replace with Sonnax Part Nos. 36424-04K* Line-to-Lube Pressure Regulator Valve 36424-16K Oversized Line-to-Lube Pressure Regulator Valve Kit Requires F-36424-TL16C & VB-FIX Note: Test ports on opposite side while sealing this side against foam pad. Note: 4R100 has air bleed here that will need to be sealed. NOTE: 4R100 Port is different. Must seal indicated air bleed when testing these ports. *Part numbers with an asterisk (*) are included in this Zip Kit. Converter Regulator Valve • Internal converter damage • Excess converter pressure • Low converter & converter clutch apply pressure Note: Seal holes on opposite side. Converter Clutch Control Valve • Lockup shudder • TCC cycling Replace with Sonnax Part Nos. Replace with Sonnax Part Nos. 36424-11K Oversized Converter Regulator Valve Kit Requires F-36424-TL11C & VB-FIX 36424-08K* TCC Control Plunger Valve Kit (4R100 PWM Only) 36424-15K Oversized TCC Control Valve (4R100 PWM Only) Requires F-36424-TL15C & VB-FIX 04-30-18 Page 6 E4OD-4R100-ZIP_Booklet_A ©2018 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Ford E40D, 4R100 ZIP KIT® Installation & Testing Booklet TIME TESTED • INDUSTRY TRUSTED OE Exploded View Lower Control Body 4R100 Non - PTO Shown Upper Control Body 4R100 Non - PTO Shown NOTE: E4OD is the same. NOTE: E4OD Worm tracks and valves vary slightly. 101 201 202 203* 204 < Lower Control Valve Body Descriptions I.D. No. Description 101 Engagement Control Valve 102 1-2 Manual Transition Valve 102 Upper Control Valve Body Descriptions > I.D. No. Description 201 2-3 Shift Valve 202 3-4 Shift Valve Low/Reverse Modulator Valve (Inboard) 203* Low/Reverse Modulator Valve (Center) Low/Reverse Modulator Valve Plunger & Sleeve (Outboard) 204 Manual Control Valve 205* Solenoid Regulator Valve 206 Coast Clutch Shift Valve 205* 206 4-3-2 Timing Valve (Inboard) 207* 208* Control Valve Shift Timing Plunger (Outboard) 208* * E4OD Different Drive 2 Valve (Inboard) 1-2 Shift Valve (Outboard) 207* ©2018 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com E4OD-4R100-ZIP_Booklet_A 04-30-18 Page 7 TIME TESTED • INDUSTRY TRUSTED Ford E40D, 4R100 ZIP KIT® Installation & Testing Booklet OE Exploded View Accumulator Control Body 4R100 Non - PTO Shown 301 Pump Body E4OD Pump Body Shown 302 < Accumulator Control Body Descriptions I.D. No. 301 302 303 304 Description Direct Clutch Accumulator Regulator Valve (Inboard) Direct Clutch Accumulator Plunger (Outboard) Overdrive Clutch Accumulator Regulator Valve (Inboard) Overdrive Clutch Accumulator Plunger (Outboard) Intermediate Clutch Accumulator Regulator Valve (Inboard) Intermediate Clutch Accumulator Plunger (Outboard) Line Pressure Modulator Valve (Inboard) Line Pressure Modulator Plunger Valve & Sleeve (Outboard) 403A 402 Pump Body Descriptions > I.D. No. Description Main Regulator Valve (Inboard) 304 401 Main Regulator Valve & Sleeve (Outboard) 402 Converter Regulator Valve 403A E4OD Converter Clutch Control Valve 403B 4R100 Non-PWM Converter Clutch Control Valve 403C 303 04-30-18 Page 8 E4OD-4R100-ZIP_Booklet_A 401 403B 403C 4R100 PWM Converter Clutch Control Valve (Inboard) Converter Clutch Control Plunger Valve & Sleeve (Outboard) ©2018 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
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