SC 48RE IN

2015-08-31

: Sonnax Sc-48Re-In SC-48RE-IN 1341 file instruction uploads

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©2015 Sonnax Industries, Inc. SC-48RE-GUIDE 08-27-15
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 Sure Cure kit contents.
See Sure Cure instruction booklet for detailed installation steps.
VALve Body install Diagram
Chrysler 48RE
SURE CURE® KIT
PART NUMBER SC-48RE INSTALLATION GUIDE
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION: This sheet is NOT intended to be
a quick install guide. Not ALL steps/parts are
shown here. See other side for details and
use in conjunction with instruction booklet.
8C
1
Remove Parking Sprag
(Rooster Comb)
OE Spring
8A
OE Spring
14D
14F
5
OE Spring
14B
8B
OE Plate
& Screws
OE Pin
OE
Spring
6
7
48RE Valve Body I.D. Locations
(These features are not present
on the 46/47RE units.)
48RE valve bodies
have this passage
in the
transfer plate.
Transfer
Plate
48RE valve
bodies have
these 3 holes
in the upper
separator plate.
Upper Separator Plate
Lower Separator Plate
48RE valve bodies
have these holes in
the lower separator
plate.
Chrysler 48RE SURE CURE® KIT Installation Guide
Step Disassemble Valve Body
& Manual Lever
Step Ream Lube Regulated PR Valve
& Line/TV Pressure Plug Bore
NOTE: Requires Sonnax tool kit F-22771A-TL7 and VB-FIX alignment
xture, not included in this kit.
Step Ream Throttle Valve Bore
NOTE: Requires Sonnax tool kit F-22771-TL and VB-FIX alignment
xture, not included in this kit.
Step Ream Switch Valve Bore
NOTE: Requires Sonnax tool kit 22771A-TL13.
Step
Ream Detent Bore & Install
Detent Sleeve & Pin
NOTE: Requires Sonnax tool kit 22771-TL12 not included in this kit.
Items provided for this step
Sleeve • Detent Ball (ball installed in Step 14)
Step
Install Oversized Throttle Valve Kit
Items provided for this step
Valve • Plunger • Sleeve
NOTE: Shims and spring from 22771-04K kit are not included in this
Sure Cure.
Step Install Oversized Four-Spool
Switch Valve
Item provided for this step
Oversized Valve
Step Install Oversized Lube Regulated
Pressure Regulator Valve &
Line/TV Pressure Plug Kit
Items provided for this step
Lube Regulated PR Valve Patent No. 6,712,726 22771A-16K
White Spring
Line/TV Pressure Plug Assembly
Step
Separator Plate Modication
1
2
3
4
5
Part No.
22771-12K
6
Part No.
22771-04K
7
Part No.
22771A-13
8
Part Nos.
9
Step Install 3-4 Accumulator Spring
& Seals
Items provided for this step
3-4 Accumulator Spring
4th Accumulator Seal • 4th Accumulator D-Ring
Step Vacuum Test Verication
Step Assemble Valve Body Sections
Item provided for this step
Checkball, .188" dia.
Step Install Adjusting Screw Bracket
& Adjust PR Spring
Step
Install Manual Valve with OE Manual
Lever (Rooster Comb), Boost Valve Spring
Retainer & Adjust TV Pressure Screw
Items provided for this step
Manual Valve Patent No. 6,689,007 22771-09
Shift Linkage E-Clip
Boost Valve Spring Retainer 22990-01
Detent Ball (included in Step 5 kit)
Step Install Intermediate Plug
& Pilot Kit
Items provided for this step
Shaft Pilot • Cup Plug
Step Install Output Pilot Bushing
Item provided for this step
Bushing
Step Install 6-Tab Thrust Washers
Items provided for this step
Thrust Washers (2)
Step Install Turbine Shaft Seals
Items provided for this step
Seals (2)
10
Part No.
12861-01
11
12
Part No.
10000-13
13
14
Part Nos.
15
Part No.
22171A-02K
16
Part No.
12510-01
17
Part No.
22700GT-01
18
Sure Cure® Contents & Installation Steps See instruction booklet for detailed instructions.
©2015 Sonnax Industries, Inc. SC-48RE-GUIDE 08-27-15
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2
Technical Specifications
Pump-to-Stator Bolts
15 ft-lb
Valve-Body-to-Case Bolts
106 in-lb
Pump-to-Case Bolts
15 ft-lb
OE Endplay
.034"–.084"
Valve Body Assembly Bolts
35 in-lb
We need to decide if we're going
to tell people to test before they
install parts, after, or both.
Why are we wiggle/bore
inspecting?
Figure 1
Use
gouge
tool or
awl.
NOTE: This 48RE Sure Cure kit ts 2002-2004 TV lever-style transmissions as well as the
2005 and newer 48RE with the transmission throttle actuator (TTVA) motor.
PART INSTALLATION: To implement best practices and avoid chip contamination, wait
until all valve body reaming operations are nished before installing Sonnax products.
Detailed installation instructions steps are explained later in this booklet.
F-TOOL REAMING: See page 8 for general F-Tool reaming xture instructions, as well as
best practices for bore preparation, cautions and suggestions on bore reaming.
Step Disassemble Valve Body
& Manual Lever
a. Remove shouldered bolt retaining the solenoid wiring harness case connector
to the valve body.
b. Secure manual lever detent ball with Chrysler tool #6583 (Figure 1). An alter-
native method: use a dull wood workers gouge tool to compress the detent ball
while removing the manual lever.
C AUTION: The detent ball and spring will launch out of the detent bore by spring
tension if not retained during manual lever removal. Never reuse the OE detent
ball with the Sonnax sleeve. The Sonnax ball is specially toleranced to work with
the Sonnax sleeve, preventing binding of the ball in the bore.
c. Remove OE E-clip, washer and manual lever from valve body. Slide out throttle
lever. Discard detent ball. Save detent spring for reassembly.
d.
Disconnect governor pressure sensor and governor pressure solenoid connectors.
e. Remove governor body screws and then governor body.
f. Take out three screws holding overdrive/lockup solenoid from lower casting.
en, remove solenoids with wiring harness from valve body.
C AUTION: The pressure adjusting bracket is under spring tension by the pressure
regulator and switch valve springs.
g. Remove the center screw from the adjusting screw bracket. Temporarily remove
one of the long screws holding the three valve body castings together and install
it in place of the center screw (Figure 2). is will help to hold the bracket in
place when removing the upper and lower screws. Remove the upper and lower
bracket screws while holding the adjusting screw bracket. Remove the center
screw. Save the OE switch valve spring, line pressure screw and adjusting bracket
for reassembly. Discard the OE pressure regulator spring.
h. Remove two screws holding the throttle pressure plug retaining plate. Remove
the retaining plate, sleeve, plug, and spring from valve body. Discard the OE
plug and sleeve. Save OE spring for reassembly.
i. Bend tabs securing boost valve tube to valve body. en, remove OE boost
valve tube.
j. Remove the bolts from the lower housing which clamp the three valve body
castings together.
k. Remove and discard OE switch valve and pressure regulator valve. Remove
throttle valve assembly, discarding all parts except the TV and switch valve
springs which will be reused at assembly.
l. Remove all the remaining valves and springs from the upper casting. Reinstall
valves and springs after all reaming operations are completed.
m. Disassemble, clean and reassemble the lower casting.
NOTE: The only casting requiring reaming is the upper casting.
1
CAUTIONCAUTION
CAUTIONCAUTION
CAUTIONCAUTION
CAUTIONCAUTION
Figure 2
Adjust Screw Bracket
#1 Upper
Screw
#3
Lower Screw
Throttle
Lever
#2 Center
Screw
©2015 Sonnax Industries, Inc. SC-48RE-IN 08-27-15
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
Chrysler 48RE
SURE CURE® KIT
PART NUMBER SC-48RE INSTRUCTION BOOKLET
Chrysler 48RE SURE CURE® KIT Instruction Booklet
08-27-15 SC-48RE-IN ©2015 Sonnax Industries, Inc.
Page 2 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
TIME TESTED • INDUSTRY TRUSTED
Step Ream Lube Regulated
PR Valve & Throttle
Pressure Plug Bore
1. Valve Body Inspection
If a line-to-lube hole has been drilled in the PR valve circuit,
it should be plugged to reduce converter drainback.
2. Ream Bores
NOTE: These two bores require the use of tool kit F-22771A-TL7 and
the alignment xture VB-FIX (not included in this kit). See page 8 for
details on standard Sonnax bore preparation and reaming procedures.
a. Align VB-FIX to ream the pressure regulator bore using jig
F-22771A-RJ and guide pin F-22771A-GP.
b. Ream the pressure regulator bore using reamer
F-22771A-RM.
c. Align VB-FIX to ream the throttle pressure plug bore
using jig F-22771A-RJ2 and guide pin F-22771A-GP2.
d. Ream throttle pressure plug bore using reamer
F-22771A-RM2.
NOTE: Do not install valves at this time. Wait until all reaming
operations are nished.
Step
Ream Throttle Valve Bore
NOTE: This bore requires the use of tool kit F-22771-TL and the align-
ment xture VB-FIX (not included in this kit). See page 8 for details on
standard Sonnax bore preparation and reaming procedures.
a. Align VB-FIX to ream the throttle valve bore using jig and
guide pin provided in the tool kit.
b. Ream the bore using the reamer provided in kit.
NOTE: Do not install valves at this time. Wait until all reaming
operations are nished.
Step Ream Switch Valve Bore
NOTE: This bore requires the use of tool kit 22771A-TL13 (not included
in this kit). See page 8 for details on standard Sonnax bore preparation.
These piloted reamers do not require a reamer guide.
1. Ream bore with stepped reamer
22771A-RM13
a. Insert reamer into bore until chamfered cutting tip contacts
inner bore opening. Using a speed handle, ream bore clock-
wise at one to two turns per second. is reaming operation
should take approximately 1 minute.
b. With low air pressure and reamer still in bore, blow chips
out of bore.
c. Turning clockwise, remove the reamer from the bore.
Clean the remaining chips from the bore.
2
3
4
2. Ream bore with reamer 22771A-RM14
a. Insert Sonnax reamer 22771A-RM14 into bore until cham-
fered cutting tip contacts inner bore opening.
b.
Using same procedure as above, ream the same bore. is second
reaming operation should take approximately 1 minute as well.
NOTE: Do not install valves at this time. Wait until all reaming opera-
tions are nished.
Step Ream Detent Bore &
Install Detent Sleeve
& Pin
NOTE: This bore requires the use of tool kit 22771-TL12 (not included
in this kit). See page 8 for details on standard Sonnax bore preparation
procedures.
1. Disassembly
Remove and save the OE retaining pin.
NOTE: It is recommended to use a Dremel® #194 drill bit or .120" diam-
eter drill bit to remove some of the swaged aluminum over the top of
the retaining pin. Damage could occur to the enclosed .096" drill bit if
used for material removal.
2. Ream Bore
a. Securely clamp the valve body to the bench.
b. Soak the bore and reamer with cutting uid.
c. Insert the pilot on the self-guiding reamer into the retain-
ing pin end of the detent bore until the cutting chamfer
contacts the face of the bore (Figure 3).
d. Use a speed handle to turn the reamer in the bore. e ream-
ing action should be clockwise in a smooth and continuous
motion, 60-120 RPM.
e. Continue reaming until the reamer cutting chamfer passes
fully through the opposite end of the detent bore.
f. Using low air pressure, blow the chips free prior to removing
the reamer.
g. To remove the reamer, turn clockwise while slowly pulling
outward on the reamer.
3. Install Detent Sleeve & Pin (Figure 4)
NOTE: The Sonnax sleeve is designed as a slip t, and is secured by
drilling through the sleeve with the tool kit drill bit and reinstalling the
OE retaining pin. However, it is highly recommended that Loctite® (or
equivalent) be used with the sleeve.
a. Secure the Sonnax sleeve in the detent bore using Loctite®
retaining compound per the manufacturers directions.
b. e sleeve should be pushed in until the face is ush with
the face of the ball end of the detent bore.
NOTE: Before drilling, it helps to use the retaining pin as a center punch
and make a slight indentation in the sleeve to hold the drill bit on-center
and prevent the drill bit from walking off and making the pinhole in the
casting larger.
5
Chrysler 48RE SURE CURE® KIT Instruction Booklet
©2015 Sonnax Industries, Inc. SC-48RE-IN 08-27-15
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3
TIME TESTED • INDUSTRY TRUSTED
Figure 3
Figure 4
c. After the Loctite® has cured, use the existing retaining pinhole in the casting to
guide the drill bit through both sides of the sleeve.
CAUTION: Do not drill any deeper than the depth of the pin.
d. Reinstall the OE retaining pin and use a at blade screwdriver, center punch
or other tool to swage the aluminum casting over the top of the pin. Conrm
retaining pin is secured in place.
Step Install Throttle Valve Kit (Figure 5)
a. Install Sonnax oversized throttle valve.
b. Reinstall OE throttle valve spring.
c. Install Sonnax throttle plunger and
sleeve, with cupped side of sleeve
facing inboard.
Step Install Oversized Four-Spool
Switch Valve (Figure 6)
Install Sonnax oversized
switch valve. e OE
switch valve spring will be
installed while installing the
pressure adjusting bracket
in Step 13 (Figure 18).
Step Install Lube Regulated PR Valve
& Line/TV Pressure Plug Kit
a. At the opposite end of the pressure regula-
tor bore, reinstall the OE throttle spring,
followed by the Sonnax oversized line/TV
pressure plug assembly (Figure 7).
b. Install the OE end plate with the two screws.
NOTE: Check to be sure the end cap (plate) sits ush
against the valve body and seals the bore. If the plate
is not ush, remove material from the castellated side
of the O-ringed sleeve. Remove the minimum material necessary to allow the plate to seal
the bore. Do not remove more than .015" [0.38 mm] total from the sleeve.
CAUTION: Pressure leaking at the plate will result in increased line pressure.
c. Install Sonnax pressure regulator valve. e Sonnax white-striped spring will
be installed later in Step 13.
CAUTIONCAUTION
CAUTIONCAUTION
6
7
8
CAUTIONCAUTION
CAUTIONCAUTION
Figure 5
Plunger Sleeve
Valve OE Spring
OE TV Spring Specs
Free Length 1.275"
Wire Diameter .048"
Number of Coils Approx. 12
NOTE: Chart for reference only.
Existing retaining
pinhole.
OE
Retaining
Pin Sleeve
Line/TV Pressure
Plug Assembly
Figure 7
White-Striped Spring
OE
Screws
OE End Plate
Pressure Regulator Valve
OE Throttle
Pressure
Spring
Figure 6
Four-Spool Switch ValveOE Spring
OE Throttle Pressure
Spring Specs
Free Length 1.460"
Wire Diameter .035"
Number of Coils 6
NOTE: Chart for reference only.
O-Ring
Chrysler 48RE SURE CURE® KIT Instruction Booklet
08-27-15 SC-48RE-IN ©2015 Sonnax Industries, Inc.
Page 4 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
TIME TESTED • INDUSTRY TRUSTED
Step Separator Plate Modication
Enlarge TRE orice in OE separator plate from original size .045" to .062" (Figure 8).
CAUTION: Drilling larger than .062" will create a bump on TCC apply.
a. Drill with 1/16" (.062") drill bit.
b. Remove burrs with a large drill bit.
Step Install 3-4 Accumulator Spring
& Seals (Figure 9)
1. Disassembly
a. Remove cover plate and screws.
b. Remove and discard OE piston spring.
c. Remove OE piston and save for reuse.
d. Remove and discard the OE seals from the
OE piston.
2. Installation (Figure 10)
a. Use red-colored Scotch-Brite™ to remove
glaze from bore. Clean bore until spotless.
b. Install Sonnax seal by the open end of the
piston.
c. Install Sonnax D-ring by the closed end of the piston.
d. Install OE piston, then Sonnax spring.
CAUTION! The 4th accumulator D-ring can be easily cut on hole edge in
accumulator bore during installation.
Step Vacuum Test Verication
NOTE: To verify reaming operations use Sonnax vacuum test stand kit VACTEST-01K
(not included with this kit).
A vacuum test at the ports indicated should hold the recommended in-Hg of
vacuum or more (Figure 11).
9
CAUTIONCAUTION
CAUTIONCAUTION
10
CAUTIONCAUTION
CAUTIONCAUTION
11
Figure 10 Spring
Seal
3-4
Accumulator
Bore
D-Ring
CAUTION! D-Ring
can be cut on the
edges of this hole.
CAUTIONCAUTION
CAUTIONCAUTION
3-4
Accumulator
Piston
Figure 8
Drill 1/16" hole
Figure 11
20
25
15
0
10
5
30
VACUUM
TEST
15"-Hg
20
25
15
0
10
5
30
VACUUM
TEST
18"-Hg
20
25
15
0
10
5
30
VACUUM
TEST
18"-Hg
20
25
15
0
10
5
30
VACUUM
TEST
18"-Hg
Use putty here
to block passage
as shown during
vacuum test.
3-4 Accumulator Spring
Figure 9
4th
Accumulator
Seal
4th
Accumulator
D-Ring
Chrysler 48RE SURE CURE® KIT Instruction Booklet
©2015 Sonnax Industries, Inc. SC-48RE-IN 08-27-15
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5
TIME TESTED • INDUSTRY TRUSTED
Step Assemble Valve
Body Sections
a.
Install either ve or six OE 1/4" checkballs and one
OE 11/32" checkball into the upper housing
(Figure 12).
b. Install two OE 1/4" checkballs into the upper
side of transfer plate (Figure 13).
c. Install separator plate and lter onto transfer plate
and tighten the ve OE plate bolts to 35 in-lb
(Figure 14).
NOTE: It is helpful for plate alignment to use drill bits in the
two machined holes as shown (Figure 14). Once plates are
aligned, remove drill bits.
d. Set transfer plate onto upper housing. Install the
Sonnax 3/16" checkball (Figure 15).
e. Set separator plate onto transfer plate (Figure 16).
f. Install lower housing onto transfer plate. Install
and torque the valve body bolts (Figure 17).
g. Install boost tube and bend tabs to retain it.
12
Figure 16 Figure 17
Figure 14
1 2
3
4
1
Five OE
Plate Bolts
Two drill bits in OE machined
holes to help with alignment.
Figure 13
1/4" OE
Checkballs
Figure 15
Two drill bits in OE holes
can help with assembly.
Sonnax
3/16"
Checkball
Transfer
Plate
Figure 12
Install Five or Six
1/4" OE Checkballs
NOTE: This
Checkball
may not be
present on
some model
years.
Install One
11/32" Checkball
Chrysler 48RE SURE CURE® KIT Instruction Booklet
08-27-15 SC-48RE-IN ©2015 Sonnax Industries, Inc.
Page 6 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
TIME TESTED • INDUSTRY TRUSTED
Step
Install Adjusting Screw Bracket &
Adjust Pressure Regulator Spring
a. Place line pressure adjusting screw in the bracket.
b. Position OE switch valve spring over boss on bracket.
c. Install Sonnax white-striped spring on the pressure regulator valve.
d. Install the adjusting screw bracket (Figure 18) on valve body, making sure Sonnax
pressure regulator spring and OE switch valve spring are aligned correctly.
e. Temporarily install one of the long valve body bolts in the center bolt hole as
this simplies installation.
f. Install the short upper screw rst, followed by lower screw but do not tighten.
g. Remove the long screw, install a short screw in the center.
h. Starting with the center screw rst, tighten the three bolts retaining the adjust-
ing screw bracket to the valve body.
i. Adjust pressure regulator screw so the inside edge of plate is 1.310" from valve
body casting (Figure 19).
j. Verify pressure adjustment by connecting a pressure gauge to the transmission.
Pressure should be 55–60 PSI in drive.
Step
Install Manual Valve with OE
Manual Lever (Rooster Comb),
Boost Valve Spring Retainer
& Adjust TV Pressure Screw
a. Install Sonnax manual valve (Figure 20).
b.
Install OE detent spring and Sonnax detent ball
(Figure 20)
. Hold in place with
special Chrysler tool #6583.
NOTE: A wood workers gouge tool also works to help install the manual lever.
c. Place the throttle lever (Figure 2) in the upper housing. Install manual lever
over throttle lever while aligning the manual lever with the manual valve
(Figure 21). Remove special Chrysler tool #6583.
d. Install OE throttle lever shaft seal with lip up to keep moisture out.
en install OE washer and Sonnax E-clip (Figure 20).
e. Adjust throttle valve by using special Chrysler tool #C-3763 or equivalent
such as the one shown (Figure 22). e length of the “hammer head” part
of the tool is .627". Compress the TV plunger with tool until the plunger is
bottomed in the valve body. Adjust the TV adjustment screw with an allen
wrench until the screw just contacts the TV lever while the TV lever is in
contact with the TV plunger.
NOTE: The spring is under considerable tension when the TV plunger is fully depressed.
Be sure the spring is compressed and TV plunger is contacting the TV valve while making
this adjustment. TV valve will be fully bottomed in the bore.
13
14
Figure 19
Figure 21
Figure 22
Figure 20
Manual Valve
Boost Valve
Spring Retainer
Shift Linkage
E-Clip Detent Ball
OE Detent Spring
Figure 18
Use long valve body screw to aid in assembly.
Chrysler 48RE SURE CURE® KIT Instruction Booklet
©2015 Sonnax Industries, Inc. SC-48RE-IN 08-27-15
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 7
TIME TESTED • INDUSTRY TRUSTED
Figure 23
Sheet Metal
Screw
OE
Intermediate
Shaft
OE Cup
Plug
The screw will pull
the plug out after
the head bottoms
out on the shaft.
IMPORTANT! This adjustment is critical on 2005-later models which use a
Transmission Throttle Valve Actuator (TTVA). The ECM needs to see the TTVA
rotate a set number of degrees. At .627", the TV shaft will move 52°. Depending
on the tolerance in the software, this may set trouble codes if the adjustment is
out of range. After installing the valve body in the vehicle, reset the TTVA by performing a
Key On Engine Off cycle for 30 seconds. Turn ignition key off. Now the TTVA will be reset.
f. Install OE boost valve, OE spring, Sonnax boost valve spring retainer (Figure 20)
and OE cover plate.
Step Install Intermediate Shaft Pilot
& End Plug Kit
1. Disassembly
a. Using a sheet metal screw, remove and discard the OE cup plug from the OE
intermediate shaft (Figure 23).
b. Using a steel rod (3/16" x 17"), drive the OE shaft pilot out from the cup plug
end of the OE intermediate shaft, then discard pilot (Figure 24).
2. Installation (Figure 25)
a. Clean the OE intermediate shaft bore thoroughly.
b. Install the Sonnax cup plug by driving it into the OE intermediate shaft.
NOTE: An AXOD servo pin works well for this.
c. Install the Sonnax shaft pilot into position by driving it in the front of the
intermediate shaft. If the OE intermediate shaft does not have an internal
stop to locate the pilot, position it so that .230"–.280" of the pilot protrudes
out of the shaft.
Step
Install Output Pilot Bushing (Figure 26)
a. Remove and discard pilot bushing.
b. Press the Sonnax output shaft pilot bushing
into the OE overdrive output shaft (Figure 27).
Step Install
6-Tab
Thrust Washers
(Figure 28)
Step Install
Turbine Shaft Seals
(Figure 29)
CAUTIONCAUTION
CAUTIONCAUTION
15
16
17
18
Shaft Pilot
Figure 25
End Plug
OE
Intermediate Shaft
Output
Pilot
Bushing
Figure 26
OE Overdrive
Output Shaft
Output Shaft
Bushing
Figure 27
Figure 24
3/16" x 17" Steel Rod
OE
Intermediate
Shaft
Drive OE pilot out
of cup plug end.
Turbine Shaft Seals Figure 29
Figure 28
6-Tab Thrust Washers
Chrysler 48RE SURE CURE® KIT Instruction Booklet
08-27-15 SC-48RE-IN ©2015 Sonnax Industries, Inc.
Page 8 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
TIME TESTED • INDUSTRY TRUSTED
1. Bore & Reaming Preparation
a. Clean the bore thoroughly in a solvent tank.
b. Generously lubricate the bore and reamer with cutting uid (i.e.
Mobilmet S-122, Lubegard® Bio-Tap, Tap Magic™, etc.). For
best results, provide a continuous ow of water-soluble cutting
uid (i.e. Mobilmet S-122) during the reaming process.
c. e reamers should be turned using a low RPM, high-torque
air drill regulated to a maximum of 200 RPM.
d. Examine the bore after cleaning for surface nish, debris and
burrs. Flashing and burrs on the exit side of land and in bores
must be carefully removed. A small piece of Scotch-Brite™
material attached to a wire and powered with a drill motor
is ideal for the task. Scotch-Brite™ is a very abrasive material
and all residual debris must be cleaned to ensure particles do
not migrate or remain imbedded into the surface. Post cleaning
involves several progressive steps with solvent on a lint-free rag.
CAUTIONS AND SUGGESTIONS:
Turning the reamer backward will dull it prematurely.
Pushing on the reamer will result in poor surface nish and
inadequate and sporadic material removal.
Never use a crescent wrench, ratchet or pliers to turn the reamer.
A dull reamer will cut a smaller hole. Reamers can be sharpened,
but should only be done by a professional tool sharpener. Actual
life of a Sonnax reamer before resharpening or replacing averages
50–70 bores.
2. Bore Reaming
Use the associated “F-Tool” kit and VB-FIX reaming xture as illus-
trated below to ream the bore. See specic reaming instructions for
each bore on page 2 of this booklet.
NOTE: If more than one reaming procedure is needed, follow specic
instructions given with associated Sonnax part/kit to ensure correct ream-
ing process is completed.
Generic F-Tool Bore Reaming Instructions (For use with Steps and Steps .)
2
3

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