E4OD 4R100 ZIP

2018-05-25

: Sonnax E4Od-4R100-Zip E4OD-4R100-ZIP 4406 instructions part uploads

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PART NUMBER E4OD-4R100-ZIP QUICK GUIDE

FORD E4OD, 4R100

ZIP KIT®

Stator Support

E4OD Shown

Pump Body

4R100 Shown

Accumulator Control Body

E4OD Shown

Reference pages 2-3 in Technical Booklet.

3-4 Location

2-3 Location 1-2 Location

Plug line-to-lube

hole if present.

See Note on

Installation

Steps (Pg 2).

See Note on

Installation

Steps (Pg 2).

See Note on

Installation

Steps (Pg 2).

See Note on

Installation

Steps (Pg 2).

(16)

5/16" Dia.

(3)

1/4" Dia.

Plastic Checkballs

Upper

Control

Body

E4OD Shown

Note I.D.

Groove

Note I.D.

Groove

No I.D.

Groove

See Note on

Installation

Steps (Pg 2).

See Note on

Installation

Steps (Pg 2).

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

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.

Step Replace OE TCC Control

Plunger Valve & Sleeve

CAUTION: Use in PWM units only. If core does NOT

have this, do not install this assembly. Go to step 2.

Packaging Pocket 1

• Valve • Sleeve

Step Replace OE Pressure

Regulator Valve

CAUTION: If a line-to-lube orice 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

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

Step Replace OE Front Lube/

Drainback Valve

Use common sheetrock screw to remove orice cup plug. Discard.

Remove and discard existing ball seat, spring and valve. Clean bore.

Place new assembly into bore, ball seat rst. Lightly stake orice cup

plug into bore, .030–.060" below ush.

Packaging Pocket 4

• Valve Assembly • Orifice Cup Plug

Step Replace OE Low/Reverse

Modulator Plunger

Assembly

CAUTION: Used in '96-later E4ODs, all 4R100s.

Packaging Pocket 5

• Valve • Sleeve

Step

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 6

• Valve • Sleeve • O-Rings (2) 1 Extra

Step

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 rmer than OE shifts are desired, add

shims as needed into appropriate accumulator control valve spring pocket.

• 1 shim = slightly rmer than OE

• 2 shims = sufcient 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

Packaging Pocket 8

• 2-3 Accumulator Valve • Shims (2) • Retainer

Packaging Pocket 9

• 3-4 Accumulator Valve • Shims (2) • Retainer

Step

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)

Step Replace OE Checkballs

Checkball locations vary by application. Reference OE material for

proper location.

Packaging Pocket 12

• Checkballs (16) 5/16" dia. • Checkballs (3) 1/4" dia.

Zip Kit Contents & Installation Steps

NOTE: The parts listed here may be protected by patent 6,826,908.

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

Ford E40D, 4R100 ZIP KIT® Quick Guide

Zip Kit Application Info

is Zip Kit services E4OD and 4R100 transmissions.

While there are many similarities and shared compo-

nents between the E4OD and 4R100, signicant

dierences pertain to some components in this kit.

Verify transmission type and production year prior to

installing components.

Solenoids

e E4OD and 4R100 use solenoid blocks that are

bolted to the case beside the valve body. ese are

prone to contamination and wear, and should be resis-

tance tested for electrical failures. OE replacements

and Sonnax remanufactured solenoid blocks are avail-

able 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 2

Component and Solenoid Application Chart

GEAR Park/

Neutral Reverse OD -

1st

OD -

2nd

OD -

3rd

OD -

4th

OD -

3rd**

M -

2nd

M -

1st

FWD Clutch On On On On On On On

Int. Clutch On On On On On

Direct Clutch On On On On

O.D. Clutch On

Coast Clutch On On On On

Intermediate

Band On

L/R Clutch On On

O.D. Roller Hold Hold Hold Hold Hold Hold Hold

Int. Sprag Hold Hold

Low Roller Hold Hold

Solenoids

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

Figure 1

Solenoid Connector Pin

Identification & Function

Pin No Description

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

7 Transmission Fluid Temp Sensor

8Transmission Fluid Temp Sensor (Signal Return)

9 Not Used

10 Not Used

11 Electronic Pressure Control (EPC)

12 Vehicle Power in for EPC Solenoid (VPWR)

Figure 4

Solenoid Resistance Chart

Solenoid Solenoid Body

Pin Numbers Resistance

Shift Solenoid “B” (2) 1 & 2 20 - 30 Ohms

Shift Solenoid “A” (1) 1 & 3 20 - 30 Ohms

TCC Solenoid (On-Off) 1 & 4 20 - 30 Ohms

TCC Solenoid (PWM) 1 & 4 10 - 20 Ohms

Coast Clutch Solenoid 1 & 5 20 - 30 Ohms

Electronic Pressure Control Solenoid 11 & 12 3 - 5 Ohms

Transmission Fluid Temp Sensor 7 & 8 Varies with Temperatures

Figure 5

Figure 3

54 36 2 1

71211 Solenoid Body

Connector

Pin Identification

910

*On = If the PCM determines that powertrain operat-

ing 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”.

FORD E4OD, 4R100

ZIP KIT®

PART NUMBER E4OD-4R100-ZIP INSTALLATION & TESTING BOOKLET

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

Ford E40D, 4R100 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Zip Kit Instructions

1. Valve Body Removal from Case (Figure 6 & Color Chart)

a. Remove 13 (red) accumulator control body bolts.

b. Remove the main control body assembly by removing 16 (green) bolts.

NOTE: Do not remove the two lower‐to‐upper control body bolts (yellow).

c. Remove 9 bolts (blue), 1 nut (pink), and solenoid assembly.

d. Remove the two lower‐to‐upper control body bolts (yellow).

NOTE: Check ball locations vary signicantly between applications and

production year Reference OE manual for proper check ball sizes and

locations for specic units.

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

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. Conrm lubrication hole is properly lined up and correct clearance has been

maintained between bushing and output shaft.

Figure 9

Locking

Tabs

Cut-Out/

Recess

OE Intermediate

Overdrive Cylinder

Sure Lock Overdrive

Spiral Snap Ring

OE Return

Spring

Figure 7

14 15 16

123

12345

Figure 6

Figure 8

Center

Support

Hub

Center

Support

Gasket

Center

Support

Bolt Color Code Bolt Case Location

1 Pink Solenoid Assembly (Nut)

2 Yellow Lower-to-Upper Control

Body Bolts

9Blue Solenoid Assembly Bolts

13 Red Accumulator Control Body

16 Green Main Control Valve Body

NOTE: Torque all bolts to 80-100 in-lb.

Ford E40D, 4R100 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Figure 10

Rear Planet Endplay

Shim, 4 Slots

OE Thrust

Washer,

4 Tanged

OE Input Shell with

Sun Gear Assembly

OE Reverse

Planetary,

3 or 4 Pinion

Spring

Intermediate Seal

Adapter Tube

Intermediate

Clutch Seal

Direct Seal

Adapter Tube

Direct

Clutch Seal

4R100 Case

Figure 12

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. Replace OE Overdrive Piston Return Spring

Retaining Ring (Individually Packaged)

a. Remove and discard OE retaining ring.

b. Assemble overdrive piston assembly using Sure Lock retaining ring,

ensuring tabs on ring are locked as shown (Figure 9).

NOTE: Be sure snap ring is installed correctly.

Failure to install correctly may result in unit failure.

4. Install Endplay Shims (Individually Packaged)

a. Install Sonnax shims under the 4-tanged thrust washer, located between

the reverse planetary carrier and the input shell (Figure 10).

b. When nal assembly is completed, total endplay should be inspected

with a H gauge, depth mic., or dial caliper. e OE endplay is .075".

e recommended endplay is .040" or less.

NOTE: The Sonnax shim does not reduce output shaft free play and

will not t in late-model applications with six pinion carriers.

5. Install Intermediate & Direct Clutch Feed Seal

Kit (Packaging Pocket 10)

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 o 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 o seal (Figure 11)

b. Coat rubber seal with assembly lube.

c. Align 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).

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 specied pump banding tool for proper pump half align-

ment. Loosely install 11 bolts. Align pump halves. Tighten all bolts to 20 ft-lb.

Figure 14

Cut here if less

than .625" deep.

Direct Clutch

Intermediate Clutch

Figure 11

Figure 13

Intermediate Clutch

Location/Alignment

Direct Clutch

Location/Alignment

Measure

Direct Clutch Depth

Ford E40D, 4R100 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 and Sonnax parts noted for replacement.

Lower Control Body • 4R100 Non-PTO Shown

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.

* Part numbers with an asterisk (*)

are included in this Zip Kit.

Engagement Control Valve

• Delayed Forward & Reverse engagement

• Burnt Forward clutch

• Burnt Direct clutch

1-2 Manual

Transition Valve

• Burnt intermediate band

• Manual low gear bind-up

Drive 2 Valve

• Reverse concerns

Upper Control Body • 4R100 Non-PTO Shown

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.

4-3-2 Timing Valve & Control

Valve Shift Timing Plunger

• Manual low concerns

1-2 Shift Valve

• No 2nd

• 1-2 Shift concerns

Test: Flip casting over

and test at this orice.

Seal this side of casting

with foam mat.

3-4 Shift Valve &

4-3-2 Timing Valve

• 3-4 Shift concerns

• Burnt Direct clutch

• Manual low concerns

2-3 Shift Valve

• 2-3 Shift concerns

• Burnt Direct clutch

Solenoid Regulator

Valve

• 2nd or 3rd Gear starts

• TCC cycling or slip

• Reduced lube oil from the

center support

Replace with Sonnax Part No.

36947-14K

Requires F-36947-TL14 & VB-FIX

Coast Clutch Shift Valve

• Burnt coast clutch

Low/Reverse Modulator Valve

Plunger & Sleeve

• 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.

Low/Reverse Modulator &

Low/Reverse Modulator Valves

• No engine braking • Burnt Low/Reverse clutch

• Low pressure at Low/Reverse clutch

Note: Seal port

on opposite side.

Ford E40D, 4R100 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

Accumulator Control Body • 4R100 Non-PTO Shown

For specic vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

VACUUM

TEST

Direct Clutch

Accumulator

Regulator Valve

• Soft shifts • No 2nd

• Premature clutch failure

Replace with Sonnax Part No.

36948-13K*

Direct Clutch

Accumulator Plunger

• No 2nd • Soft shifts

• Premature clutch failure

Overdrive Clutch

Accumulator Plunger

• No 4th • Soft shifts

• Premature clutch failure

Line Pressure

Modulator Valve

• 1-2 Harsh

• Harsh shifts

• Soft shifts

Replace with

Sonnax Part No.

36948-19 Requires 36948-TL

Intermediate Clutch

Accumulator Plunger

• No 3rd • Soft shifts

• Premature clutch failure

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.

Intermediate Clutch

Accummulator Regulator Valve

• Soft shifts • No 3rd • Premature clutch failure

Replace with Sonnax Part No.

36948-13K*

Overdrive Clutch

Accumulator Regulator Valve

• No 4th • Soft shifts • Premature clutch failure

Replace with Sonnax Part No.

36948-09K*

Note: Seal port

on opposite side.

* Part numbers with an asterisk (*)

are included in this Zip Kit.

Ford E40D, 4R100 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 and Sonnax parts noted for replacement.

For specic 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.

VACUUM

TEST

Main Regulator Valve

• Code 62, 628, 1744

• Engine stall on engagement in Reverse

• Engine stumble on engagement in Reverse

• High line pressure

• Overheated converter

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.

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)

Converter Clutch Control Valve

• Lockup shudder • TCC cycling

Replace with Sonnax Part Nos.

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

Note: Seal holes

on opposite side.

NOTE:

4R100 Port is

different. Must seal

indicated air bleed

when testing

these ports.

Converter Regulator Valve

• Internal converter damage

• Excess converter pressure

• Low converter & converter clutch apply pressure

Replace with Sonnax Part Nos.

36424-11K Oversized Converter Regulator Valve Kit

Requires F-36424-TL11C & VB-FIX

* Part numbers with an asterisk (*)

are included in this Zip Kit.

Ford E40D, 4R100 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

Lower Control Body

4R100 Non - PTO Shown

NOTE: E4OD is the same.

201

202 203*

208*

207*

204

206

205*

* E4OD Different

Upper Control Body

4R100 Non - PTO Shown

NOTE: E4OD Worm tracks and valves vary slightly.

Upper Control Valve Body Descriptions >

I.D. No. Description

201 2-3 Shift Valve

202 3-4 Shift Valve

203*

Low/Reverse Modulator Valve (Inboard)

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

207*

4-3-2 Timing Valve (Inboard)

Control Valve Shift Timing Plunger

(Outboard)

208* Drive 2 Valve (Inboard)

1-2 Shift Valve (Outboard)

< Lower Control Valve Body Descriptions

I.D. No. Description

101 Engagement Control Valve

102 1-2 Manual Transition Valve

102

101

Ford E40D, 4R100 ZIP KIT® Installation & Testing Booklet

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

TIME TESTED • INDUSTRY TRUSTED

402

403A

403B

403C

401

OE Exploded View

Accumulator Control

Body Descriptions

I.D. No. Description

301

Direct Clutch Accumulator

Regulator Valve (Inboard)

Direct Clutch Accumulator

Plunger (Outboard)

302

Overdrive Clutch Accumulator

Regulator Valve (Inboard)

Overdrive Clutch Accumulator

Plunger (Outboard)

303

Intermediate Clutch Accumulator

Regulator Valve (Inboard)

Intermediate Clutch Accumulator

Plunger (Outboard)

304

Line Pressure Modulator Valve

(Inboard)

Line Pressure Modulator Plunger

Valve & Sleeve (Outboard)

304

303

302301

Pump Body Descriptions >

I.D. No. Description

401

Main Regulator Valve (Inboard)

Main Regulator Valve & Sleeve

(Outboard)

402 Converter Regulator Valve

403A E4OD Converter Clutch Control

Valve

403B 4R100 Non-PWM Converter

Clutch Control Valve

403C

4R100 PWM Converter Clutch

Control Valve (Inboard)

Converter Clutch Control Plunger

Valve & Sleeve (Outboard)

Accumulator Control Body

4R100 Non - PTO Shown

Pump Body

E4OD Pump Body Shown

E4OD 4R100 ZIP

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