SC AODE 4R75E IN
: Sonnax Sc-Aode-4R75E-In SC-AODE-4R75E-IN 4472 instructions part uploads
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4R70E, 4R70W, 4R75E, 4R75W, AODE SURE CURE KIT PART NUMBER SC-AODE-4R75E INSTRUCTION BOOKLET 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 3 5 4 8 A 6 B To ensure bypass/TCC system has full control, drill "A" & "B" holes out to .062". 9 10 7 Eight checkballs to install, see locations on valve body. 1 2 Reference page 3 in technical booklet. 13 11 14 12 See Technical booklet for installation details during overhaul. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com SC-AODE-4R75E-IN 09-15-17 Page 1 TIME TESTED • INDUSTRY TRUSTED 4R70E, 4R70W, 4R75E, 4R75W, AODE SURE CURE KIT Instruction Booklet Sure Cure Contents & Installation Steps Step 1 Ream Main Pressure Regulator Valve Bore Step 7 Install Oversized Solenoid Regulator Valve & Spring Packaging Pocket 5 Step 2 R eam Solenoid Regulator Valve Bore PART INSTALLATION: To implement best practices and avoid chip contamination, wait until all valve body reaming operations are finished before installing Sonnax products. Detailed installation instructions are explained later in this booklet. F-TOOL REAMING: Visit Sonnax web site www.sonnax.com for general F-Tool reaming fixture instructions, as well as best practices for bore preparation, cautions and suggestions on bore reaming. Step 3 Install Oversized Main PR Valve, Oversized Boost Valve & Sleeve • Valve • Spring Step 8 R eplace Overdrive Servo Regulator Valve & Sleeve NOTE: '01–Later applications only. Remove OE clip and save for reuse. Remove and discard OE overdrive servo regulator valve and sleeve. NOTE: Remove the inboard overdrive servo regulator valve and ensure that it is free in its bore. The inboard valve is commonly stuck as OD servo retaining ring often breaks and pieces of the snap ring lodge in this bore. Packaging Pocket 6 • Valve • Sleeve Reuse OE Spring. Reference page 4 for detailed instructions. Packaging Pocket 1 Step 9 Replace OE Checkballs • Oversized Main PR Valve • Boost Valve • Boost Sleeve Refer to page 1 for locations. Packaging Pocket 7 Step 4 Replace Bypass Clutch Control Valve Plunger, Sleeve & Spring Packaging Pocket 2 • Plunger • Sleeve • Spring Step 5 P erform Separator Plate Modifications • Checkballs (8) 10 Install Valve Body Step Retainer Plate NOTE: Used on '01–later applications only. Installation requires drilling of separator plate and valve body casting so it can be threaded. Reference page 6 for detailed instructions. Packaging Pocket 8 • Retainer Plate • Gasket • Bolts (2) Packaging Pocket 3 • Drill bit, .062" (not shown) Step 6 Replace 2-3 Shift Valve End Plug Remove OE clip and save for reuse. Remove and discard OE 2-3 shift valve end plug. Install O-ring on Sonnax end plug in shallow groove. Lubricate with Sonnax O-Lube or equivalent, roll on bench to size. Install O-ringed plug into bore, O-ringed land first. Reinstall OE clip. Packaging Pocket 4 • Plug • O-Rings (2) 1 extra 09-15-17 SC-AODE-4R75E-IN Page 2 ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 4R70E, 4R70W, 4R75E, 4R75W, AODE SURE CURE KIT Instruction Booklet TIME TESTED • INDUSTRY TRUSTED Sure Cure Steps During Transmission Overhaul Step 11 Install Intermediate Clutch Spiral Retaining Ring Reference page 6 for detailed instructions. Packaging Pocket 9 • Spiral Retaining Ring • Locking Ring Step 12 Replace Output Shaft Seals. Inspect Direct Piston & Direct Clutch Drum. Reference page 7 for detailed instructions. Packaging Pocket 10 • Output Shaft Seals (2) Step 13 Install Pump Cover & Input Shaft Seals NOTE: There are 2 types of rings for the stator '02-Earlier and '03-Later. Reference page 7 for detailed instructions. Packaging Pocket 11 • Pump Cover Seals; Early (2), Late (2) • Input Shaft Seals (2) Step 14 Replace Overdrive Servo Pin Reference page 8 for detailed instructions. Packaging Pocket 12 • Servo Pin • O-Rings; Large (1), Medium (1) ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com SC-AODE-4R75E-IN 09-15-17 Page 3 4R70E, 4R70W, 4R75E, 4R75W, AODE SURE CURE KIT PART NUMBER SC-AODE-4R75E INSTRUCTION BOOKLET Valve Body Verification Verify that this kit fits your valve body. Rough forging must begin with RF-F6 or 1L3P located below stiffener plate (Figure 1). This kit fits '96–later units. It will NOT work on '91–'95 units. Figure 1 Pressure Regulator Valve AODE Valve Body Figure 2 76948-BST OE Spring Boost Valve Tool Kit F-76948-TL Requires VB-FIX Boost Sleeve Tool Kit: 76948-TL4 Does not require VB-FIX Step 1 Ream Pressure Regulator Valve Bore (Figure 2) Figure 3 Figure 4 1. Disassembly a. Remove OE retainer and save for reuse. b. Remove and discard OE boost valve and sleeve. c. Remove OE pressure regulator valve spring and save for reuse. Valve d. Remove and discard OE pressure regulator valve. 4R70W Valve Body 2. Ream Bore Spring NOTE: This bore requires the use of tool kit 76948-TL4 or tool kit F-76948-TL and the alignment fixture VB-FIX (not included in this kit). NOTE: Sonnax 76948-BST can be used if necesary to ensure that the pressure regulator valve moves freely. NOTE: The oversized valve in this kit will also service the split spool design shown (Figure 3). Sonnax PR valve replaces both OE valve styles found in '96-later units. Tool KIt Figure 5 NOTE: Do not install valves at this time. Wait until all reaming operations are finished. Step 2 Ream Solenoid Regulator Valve Bore (Figure 4) 1. Disassembly a. Remove OE retainer and save for reuse. b. Remove and discard OE spring and solenoid regulator valve. 2. Reaming Bore NOTE: This bore requires the use of tool kit F-76948-TL47 and the alignment fixture VB-FIX (not included in this kit). 09-15-17 SC-AODE-4R75E-IN Page 4 Line on back of sleeve indicates the two orifice hole locations, placed at 3 & 9 o’clock position. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 4R70E, 4R70W, 4R75E, 4R75W, AODE SURE CURE KIT Step 3 Install Oversized Main Pressure Regulator Valve, OE Spring & Oversized Boost Valve & Sleeve Instruction Booklet TIME TESTED • INDUSTRY TRUSTED Step 8 Replace Overdrive Servo Regulator Valve & Sleeve a. Install Sonnax oversized main pressure regulator valve, smaller diameter first. b. Reinstall OE pressure regulator valve spring. NOTE: The small OE boost spring was eliminated in later applications and is not required. If your application originally had the spring, it may be reinstalled into the Sonnax boost assembly if desired. Use of the spring will provide slightly quicker Reverse line rise pressure. c. Install Sonnax boost valve assembly into bore, ensuring sleeve snout enters OE spring I.D. d. Reinstall OE retainer. Step 4 Replace Bypass Clutch Control Valve Plunger, Sleeve & Spring (Figure 5) a. Remove OE clip and set aside for reuse. b. Remove and discard OE plunger sleeve, plunger valve and spring. c. Remove plunger valve from Sonnax sleeve, set aside for reuse. d. With enclosed Sonnax drill bit, drill thru existing Sonnax sleeve cross-orifice hole and out other side of sleeve. Remove debris and burrs. Reinstall Sonnax plunger into sleeve. e. Install Sonnax orange spring and plunger valve and sleeve assembly into bore and draw a line on the back of the sleeve indicating the two orifice hole locations and place at the 3 and 9 o'clock position(Figure 5). f. Reinstall OE clip. Step 9 Replace OE Checkballs Step 10 Install Valve Body Retainer Plate Kit (Figure 6) 1. Tools Required • 13/64" or #9 sharp drill bit • 1/4" and 5/16" drill bits • 6.0mm x 1.0mm thread tap Retainer plate, gasket and bolts. 2. Installation & Assembly a. Install the separator plate onto the valve body and align the plate with the original alignment bolts. Step 5 Perform Separator Plate Modifications Step 6 Replace 2-3 Shift Valve End Plug Figure 6 Figure 7 2 Cast in-place bolt holes Step 7 Install Oversized Solenoid Regulator Valve (Figure 4) a. Ensure valve bore and body are clean and clear of debris. b. Install Sonnax valve, longer spool end pointed inward. c. Install Sonnax spring, ensuring it seats over outboard valve stem. d. Compress spring and reinstall OE retainer. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Underside of 4R70W Valve Body SC-AODE-4R75E-IN 09-15-17 Page 5 TIME TESTED • INDUSTRY TRUSTED 4R70E, 4R70W, 4R75E, 4R75W, AODE SURE CURE KIT Underside of 4R70W Valve Body Instruction Booklet b. Locate the two cast in-place bolt hole locations on the underside of the valve body as shown in (Figure 7). Figure 8 c. In a drill press use a 5/16" drill bit to clean up the cast in-place bolt hole locations and establish a true center for drilling further with the 13/64" or #9 drill. Partial Drill WARNING: Do not drill deeper than 1/16" with the 5/16" drill bit (Figure 8). WARNING d. After true center is established, use a 13/64" or #9 drill bit to drill all the way through the valve body AND separator plate with a piece of wood underneath to prevent the plate from deforming as the drill bit cuts through. e. Remove the separator plate and enlarge the two drilled holes with a 1/4" drill bit. De-burr the new holes in the separator plate. Bolts Retainer Plate f. With a 6.0 x 1.0mm thread tap, cut new threads in the drilled holes in the valve body. De-burr the gasket surface, making sure there are no high spots. Figure 9 g. Install Sonnax checkballs using the locations on page 1. Proper position of retainer plate sitting on valve body. h. Assemble the valve body gaskets and separator plate using normal procedures. i. Install the Sonnax gasket, valve body retainer plate and two screws and torque to 80-100 in-lb. (9-11Nm.) (Figure 9). The following steps are to be performed during unit overhaul: Gasket Spiral Ring Drill & Tap Figure 10 Step 11 Install Intermediate Clutch Spiral Retaining Ring 1. Disassembly Remove and discard the OE retaining ring from the intermediate roller clutch or mechanical diode assembly. 2. Installation Locking Ring a. Install the locking ring, cup side facing up as shown in (Figure 10). Figure 12 3 1 Drum 5 6 Figure 11 2 4 Proper Staking Technique 09-15-17 SC-AODE-4R75E-IN Page 6 Proper Staking Sequence b. Walk the spiral ring into the retaining groove as pictured (Figure 11). NOTE: The locking ring may need to be moved for correct spiral ring positioning. c. Make sure the spiral ring is fully seated in the groove all the way around the assembly. d. Stake the locking ring in six equally spaced places around the outside as shown (Figure 12). ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 4R70E, 4R70W, 4R75E, 4R75W, AODE SURE CURE KIT Instruction Booklet TIME TESTED • INDUSTRY TRUSTED Step 12 Install Output Shaft Seals 1. Disassembly & Inspection a. Remove and discard the OE seals on the output shaft and replace with the Sonnax seals as shown (Figure 13). Figure 13 Seals CAUTION: Don't nick the sealing ring lands as this can cause ring damage. CAUTION b. Inspect the checkball in the direct piston (Figure 14) as it is prone to sticking. Clean and flush with solvent or WD-40® and reseat with a small punch and hammer. 2. Installation & Testing Output Shaft a. Assemble the direct clutch drum onto the output shaft (Figure 15). c. Squirt ATF into the feed hole for direct clutch feed. d. Apply 30–60 psi of air pressure into the feed hole. e. Verify that there are no leaks Figure 14 Direct Piston Checkball Location NOTE: If there are leaks, look for a worn bushing in the drum or leaks in the ring grooves or the check ball seat. Step 13 Install Pump Cover & Input Shaft Seals 1. Installation Figure 15 a. Install seals onto the pump cover (Figure 16). NOTE: Two sets of seals are included. Select the correct size/style for the applicat ion. The early style is a solid ring (.110" width), the late style is a butt-cut ring (.083" width). Sizing of the early/solid style is required after installation. A mixture of ATF and STP can be used to lubricate the solid seals while sizing with finger pressure. b. Press input shaft out of the Forward drum. Sand ring surface lighty with 320 grit sand paper, using a crosshatch pattern (Figure 19). c. Install solid seals onto the input shaft. Resize with your fingers. Pre-lube seals and install into the stator for final sizing. No Leaks Here 2. Inspect & Verify b. Inspect the check balls in the Forward drum shown (Figure 19), as they are prone to sticking. Flush with solvent or WD-40® . Also be sure that the orifice shown, is free of debris that can come from parts washers. e. An AOD Forward drum can be used to size the early stator seals (Figure 17). The seals can also be sized with the Forward drum, although it may take a little longer. Carefully use the back of a pick to work the seal into the drum and let sit for a while so the seal will stay conformed. f. Verify correct Forward piston return spring for the application you are working on (Figure 18). Selective Seals: Early = .110" thick Late = .083" thick Figure 16 Pump Cover Seals Input Shaft Seals Input shaft removed from the forward drum. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com SC-AODE-4R75E-IN 09-15-17 Page 7 TIME TESTED • INDUSTRY TRUSTED 4R70E, 4R70W, 4R75E, 4R75W, AODE SURE CURE KIT Figure 17 Instruction Booklet Step 14 Replace Overdrive Servo Pin (Figure 20) a. U se bore brush to remove sharp edges of overdrive servo pin bore in case. b. Install O-rings on Sonnax servo pin. c. Lubricate O-rings and roll pin on clean flat surface to size O-rings into pin grooves. Use an AOD Forward drum to use as sizing tool, as it has a larger bevel on it for the seals. You will need to remove the input shaft (early seals only). Set the stator down onto the AOD drum. Work the edges of the seals with pick and ease the stator down into the drum until you need it for assembly later. Verify correct forward piston return spring is used. 2000–Earlier TECH TIP: If a firmer 3-4 shift is desired, place Sonnax washer on pin against shoulder to pre-load spring. NOTE: Following step is easier if piston is compressed in bench vise to facilitate retaining clip installation. d. Install OE spring seat followed by springs, piston and retaining clip. e. Set servo travel according to OE specifications. Figure 18 2001–Later Figure 20 Piston Sleeve Clockwise Wind Counter Clockwise Wind Figure 19 Large Spring Sand Here Forward Clutch Drum Servo Piston Small Spring Spring Retainer Washer • 1st Checkball • 2nd Checkball is located inside drum under piston. This orfice ends up full of debris when run through parts washer. Be sure to clean. 09-15-17 SC-AODE-4R75E-IN Page 8 Overdrive Servo Pin Retainer Plate O-Rings ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
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