SC 01M 01N 01P IN

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APPLICATIONVW/Audi 01M, 01N, 01P

Sure Cure® Kit

Part No.

SC-01M/01N/01P

Valve Body Parts

Oversized Main Pressure

Regulator Valve Kit

119940-03K

Oversized TCC Apply

Valve Kit

119940-04K

Oversized Boost Regulator

Valve Kit

119940-05K

Oversized Solenoid

Regulator Valve

119940-06K

Shift Cup, Small (4)

119940-11

Shift Cup, Medium (2)

119940-10

The following tool kits are required

to install this Sure Cure Kit:

NOTE: Instructions are provided with this tool kit.

Part No.

F-119940-TL3

• Reamer

• Reamer Jig

• Guide Pin

NOTE: For installing oversized main

pressure regulator valve kit 119940-03K.

Part No.

119940-TL4

• Reamer

• Reamer Jig

• Bore Sizing Tool

NOTE: For installing oversized TCC

apply valve kit 119940-04K.

Part No.

F-119940-TL5

• Reamer * Reamer Jig

• Reamer Jig • Adjustment Tool

NOTE: For installing oversized boost

regulator valve kit 119940-05K.

Part No.

F-119940-TL6

• Reamer

• Reamer Jig

• Guide Pin

NOTE: For installing oversized solenoid

regulator valve 119940-06K.

NOTE: Sonnax “F-Tool” kits designed

to service a specic bore require the

VB-FIX, a self-aligning valve body

reaming xture. More information and

instructions can be found online at

www.sonnax.com.

©2016 Sonnax Industries, Inc. SC-01M_Pg1 10-07-16

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

TRANSMISSION PARTS

Instructions

Valve Body Preparation:

1. Remove the boost regulator valve ratcheting end plug as outlined below.

Ratcheting End Plug Removal:

Note: • Prior to removing the ratcheting end plug from the bore, measure and note how deeply it is

installed. The replacement plug should be installed to this same depth to ensure proper line

pressure control. The most accurate method is to insert a slide caliper rod through the hole in the

plastic plug until it bottoms against the control valve. Bring the caliper end toward the plug until

flush. This gives you the spring height adjustment from the plug to the valve. Record this measurement

before removing the plug and duplicate this distance during reassembly to most accurately

duplicate the spring compression setting. If your caliper will not pass through the hole, measure

from the valve body casting surface to the outer face of the OEM plug and duplicate later.

• The adjustment tool may be used during removal of either the OEM or Sonnax ratcheting end

plug at the boost regulator valve bore.

• Using the tool prevents breakage of the 2 anti-rotational tabs. The adjustment tool is provided

in the F-119940-TL5 tool kit.

To remove the ratcheting end plug from the bore, gently insert the cam end of the tool into the valve

body and over the end of the end plug.

2. Remove all other components from the valve body. Save all components at this time. Be sure to keep

individual components of the various line-ups together, to help ensure that matched valve and spring

combinations will be correctly installed together during reassembly. Clean the valve body after disassembly.

Note: Before reaming any bores, inspect the main pressure regulator valve. 01M, 01N, 01P valve inner

spools measure .5935" OD. If your valve inner spools measure .6095" OD, DO NOT CONTINUE. You have an

096, 097, 098 valve body and must order SC-096/097/098 and different tooling to continue with the repair.

Reaming Instructions – Tool Usage: 1. To align the valve body for reaming with all the

F-Series tool kits, follow the VB-FIX instructions.

2. Boost Regulator Bore: From tool kit

F-119940-TL5, use jig F-119940-RJ6 and

guide pin F-119940-GP2, then ream with

reamer F-119940-RM2.

3. Main Regulator Bore: From tool kit

F-119940-TL3, use jig F-119940-RJ5 and

guide pin F-119940-GP4, then ream with

reamer F-119940-RM.

4. Solenoid Regulator Bore: From tool kit

F-119940-TL6, use jig F-119940-RJ7 and

guide pin F-119940-GP3, then ream with

reamer F-119940-RM3.

Note: Extra attention should be paid to alignment

and securing the valve body to the fixture on this

bore. A very smooth action to insert and remove

the guide pin after final securing is a must to pro-

vide easy, on-center reaming.

5. TCC apply valve bore does not require use of

VB-FIX but the fixture may be used to mount

the valve body. From the tool kit 119940-TL4,

insert the reamer jig 119940-DJ4 directly into

the valve body bore, then ream with reamer

119940-RM4.

TORQUE SPECIFICATIONS:

Valve body to case bolts: 108 inch lbs.

Valve body halves: 71 inch lbs.

Pump to stator: 71 inch lbs.

Pump to case: 71 inch lbs.

Oil cooler to case bolts: 26 ft. lbs.

ELECTRONICS:

Solenoids are prone to contamination failures.

Test on a solenoid tester or replace.

On-off solenoid resistance. 60 ohms

(triangular brass insert on the end)

PWM solenoid (TCC/EPC). 5 ohms

(round brass crimped onto end)

All On-Off solenoids are interchangeable –

Sonnax 119952-01.

EV6/ EPC & EV4/TCC are interchangeable –

Sonnax 119954-01

Wiring harnesses become brittle.

Connector issues and intermittent internal

breaks are common.

01M – Sonnax 119957A

01N – Sonnax 119957B

01P – Sonnax 119955C

BUSHINGS:

Inspect all bushings carefully.

Sonnax Bushing Kit 119905-01K

GENERAL NOTES / CAUTIONS

Do not forget to fill the differential on

01M/096 units. These have a separate

sump from the ATF.

Use 80-90 synthetic gear lube. Fill and

check location is the driven speedometer

gear. Gear lube should be visible on half

of the driven gear tooth.

Aftermarket fluid preference is partial

synthetic ATF. Dexron III with an additive may

be sufficient. VW/Audi fluid tends to varnish

easily at higher operating temperatures.

01M/01N/01P ATF level: Remove oil pan

plug, fill at the cap just above pan rail

until fluid comes out pan tube.

High transmission fluid temperatures:

Sonnax suggests the elimination of the OE

antifreeze to ATF cooler mounted on the

transmission.

All computer codes must be cleared

before rebuilt valve body or transmission

is test driven.

Boost

Regulator Valve

Ratcheting

End Plug

Boost

Regulator

Bore

Main

Regulator

Bore

Solenoid Regulator Bore

04-09-10 SC-01M-01N-01P-IN ©2010 Sonnax Industries, Inc.

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

TIME TESTED • INDUSTRY TRUSTED

Reaming Procedures – all bores:

1. Soak the bore and reamer with cutting fluid (Mobilmet S-122, Lubegard Bio-Tap, Tap Magic™, etc.). For best results, provide a con-

tinuous flow of water-soluble cutting fluid (i.e. Mobilmet S-122) during the reaming process.

2. Gently insert the reamer through the jig and into the bore until the cutting tip contacts the first bore to be reamed.

3. Select the correct sized socket to fit the square shank of the reamer, and attach it to a wobble/swivel socket drive.

Note: Once valve body alignment has been established on the VB-FIX, do not disturb or loosen the valve body setting or guide setting in any

way until the reaming process is complete. Be sure to use plenty of continuously supplied cutting fluid while reaming these bores. The large

amount of material being removed is more likely to cause reamer stalling than most operations.

4. The reamer should be turned by hand using a speed handle or by a low rpm, high torque air drill regulated to a maximum of 200 rpm.

5. The reaming action should be clockwise in a smooth and continuous motion, at 60-200 rpm. The reamer should actually pull itself

through the bore, so little or no forward force should be applied.

6. Continue reaming until the reamer stop is reached.

7. Using low air pressure, blow the chips free before removing the reamer.

8. To remove the reamer, turn clockwise while slowly pulling outward on the reamer.

9. Repeat the process until all bores have been reamed. ALL reamed bores should be deburred and polished with Scotchbrite™ on a

drill. Use a stiff wire bent back sharply to hold/ turn the Scotchbrite™. (This process is very important on this valve body, espe-

cially the oversized TCC valve.)

10. Thoroughly clean the valve body. Inspect all bores.

Cautions and Suggestions:

1. Turning the reamer backward will dull it prematurely.

2. Pushing on the reamer will result in poor surface finish and inadequate and sporadic material removal.

3. Never use a crescent wrench, ratchet or pliers to turn the reamer.

4. A dull reamer will cut a smaller hole.

Main Pressure Regulator Valve Installation

Install the Sonnax valve, Sonnax spring and the Sonnax o-ringed end plug and retainer as shown below. Lubricate the bore and o-ringed end

plug prior to assembly and insert into bore slowly to prevent seal damage. An extra o-ring is included in case of damage.

Note: Be sure to use the new end plug and o-ring provided in the kit. They are not the same size as the ones that were removed. Substituting

the original plug or original o-ring will negatively affect line rise.

Boost Regulator Valve Installation

Install the Sonnax valve, OEM spring

and the Sonnax ratcheting end plug

as shown at right.

1. To install the end plug, thread into

the bore until the premeasured

height is again achieved.

2. Adjustments to the base setting may

be required due to variations in the

plug, valve body or improvements

from either regulator bore. Initial

setting on average OEM parts is

.940" measured from the end of

the valve to the outer face of the

plastic adjuster. Turning the adjuster

clockwise will increase boost pressure,

line pressure and create firmer

engagements as well as upshifts

and downshifts. Counter clockwise

reduces line pressure at idle and

results in softer shifts. Each turn is

approximately an 8 psi alteration.

One turn is drastic and we suggest

you go by 1/2 to 1/4 turns. The

outcome of this adjustment is

monitored at line pressure tap.

3. A 5/16" socket may be used while threading the plug into the bore. However, the tool will be needed to turn the plug back out while

adjusting to the correct setting.

4. It is very important to verify line pressure when installation is complete. OEM line in Drive is generally 50-56 psi. Reverse is 95-110 at

idle. To obtain firm engagements or reduce flare, increase line in Drive to 60 (1/2 turn clockwise). Readjust if not within this range.

Boost Regulator

Valve Spring

Main Regulator Valve

Spring

End Plug

w/O-Ring

Ratcheting

Plug

119940-22

Adjustment

Tool

119940-TL9

is included in F-119940-TL5

©2010 Sonnax Industries, Inc. SC-01M-01N-01P-IN 04-09-10

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

TIME TESTED • INDUSTRY TRUSTED

Note: OE line pressure port is a straight 10 x 1.0mm thread with a flanged plug.

A line pressure adapter can be made from a common 1/8th NPT 45-degree

adapter. Chase male thread on the adapter with 10 x 1.0 thread die. Gently

screw adapter into the case and then screw pressure gauge into adapter.

Solenoid Regulator Valve Installation

Install the Sonnax valve with the OEM spring and end plug as shown. OEM end

plug is threaded but this is not an adjustment. Thread in until snug.

TCC Apply Valve, TCC Boost Valve & Sleeve

Installation

Note: Before valve installation, buff the entire bore with Scotchbrite™ on a wire.

1. Place the replacement spring over the stem of the oversized TCC apply valve

and install into the reamed

bore, spring end first.

2. Insert the replacement

TCC boost valve and

sleeve assembly into the

bore, using the photo as a

reference for correct ori-

entation. Stroke this

valve after the solenoid

is installed to ensure it

does not stick.

Note: The replacement TCC

boost valve and sleeve

assembly in this kit MUST be

used with the oversized TCC

apply valve to maintain proper

ratios and valve functions.

For identification purposes,

the replacement TCC boost

valve has a groove on the

outboard-facing end stem.

Reusing the OEM assembly

can result in TCC slippage,

burn-up and complaints.

Final Reassembly

Reassemble the remaining

line-ups using the photo at

right as a guide. Be sure to

replace the 4 small and 2

medium OEM end plugs

with the plugs provided in

this kit.

Note: Make sure the large

end plug in the main regula-

tor bore is the one that came

in this kit. The OEM plug and

o-ring and our standard

119940-12 large end plug

should not be substituted for

this plug that comes with the

oversized main PR valve.

Additionally, for '98-Up valve

bodies the OE K1 actuator

valve shift cup is solid and

not drilled through. DO NOT

USE the Sonnax small shift

cup (119940-11) in this valve

bore. Reuse the OE shift

cup. '97 and earlier units will

use the small Sonnax shift

cup at the K1 actuator bore.

Solenoid

Regulator Valve

Spring

End Plug

Oversized TCC

Apply Valve

TCC

Boost Valve

TCC Boost Sleeve

Also Available

119954-01 Converter

Clutch Solenoid

Spring

Identification

Groove

K3/Manual Low Valve

Main Pressure Regulator Valve

Boost Regulator Valve

K2 Actuator Valve

K1 Actuator Valve

Manual Valve

K3 Shift Valve

B1 Apply Valve

K1/B1 Shift Valve

B2 Shift Valve

2-3 Regulator Valve

B2 Actuator Valve

Converter Regulator Valve

119940-11 119940-11

TCC Apply Valve Kit

119940-10

119940-11

'97 & Earlier

119940-10 119940-11

K1 Cushion Valve

3-4 Regulator Valve

If working on a '98-Up valve body

DO NOT replace the OE K1 actuator

shift cup with the Sonnax small shift

cup (119940-11). Reinstall the OE

shift cup. See final reassembly note.

04-09-10 SC-01M-01N-01P-IN ©2010 Sonnax Industries, Inc.

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

TIME TESTED • INDUSTRY TRUSTED