Sonnax Trans Report V5n2
Sonnax Trans Report V5N2 sonnax_trans_report_v5n2 sonnax_trans_report_v5n2 489 file tech_resource uploads sonnax-dev
Sonnax Trans Report V5N2 sonnax_trans_report_v5n2 sonnax_trans_report_v5n2 483 file tech_resource uploads sonnax-dev
2014-07-08
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TIME TESTED • INDUSTRY TRUSTED
Transmission Report
Volume 5, No. 2 July 2014
Contact Sonnax 8:30 a.m. to 5 p.m. ET (800) 843-2600 • fax (802) 463-4059 • www.sonnax.com
1
Baseball, Solenoids & Apple Pie
Hitting a Sweet Home Run with 55-50SN Rebuilds
Summer is upon us, which means warmer temperatures, baseball, solenoids and apple
pie. Yes, that’s right: solenoids. “What do solenoids have to do with summer, baseball
and apple pie?”, you’re probably wondering. Hang in there!
A common saying from the coach to his team on the eld is, “Know what you’re
gonna do with it.” at’s his way of reminding players to think about the situation.
If there’s one out, a runner on rst and the shortstop gets the ball, players should know to go to second for the force out with
the hopes of turning a double-play at rst. inking that through before the ball is hit increases the player’s reaction time
and – consequently – the chances of a successful outcome. Of course, knowing how the game is played is integral to deciding
what the best play IS, not to mention what moves to make. Continued on page 2...
500+ New Sonnax Parts Listings
12 New Units with Full Valve Body Illustrations!
Audi
01J
Aisin AW
450-43LE
General Motors
6L45–6L90
Honda/Acura
4/5-Speed
Hyundai-Kia
A4CF1 & 2
Toyota
A340E/F
A750E/F
A760/960
U660E/F
ZF
ZF6HP19/26/32
ZF6HP21/28/34
TRANSMISSION
PRODUCTS CATALOG
VOLUME
Catalog Coming
Fall 2014!
AW 55-50/51SN
Now follow Sonnax
on Twitter!
Transmission Tech Bulletin
Transmission Report • July 2014 ©2014 Sonnax Industries, Inc.
2
Hitting a Sweet Home Run with 55-50SN Rebuilds
Approaching the common failure of Aisin AW 55-50SN solenoids is very
similar to the game of baseball. e primary issue with these solenoids is the
sticking nature of the two internal bushings as the ATF or coil temperature
increases. Summertime temperatures add to the heat dilemma, particularly
in stop/go driving when the cooling system is taxed and the solenoids are
exposed to increased heat. Some rebuilders are nding success changing
the bushings out, with a variety to choose from. But knowing how these
solenoids function and how they work with each other can help determine if
there’s a play to make and which is the best choice. Team Sonnax to the rescue!
e three linear 55-50SN solenoids are used to control line rise (SLT), the
converter clutch (SLU) and the oil ow rate and accumulation for the clutch
circuits (SLS). ese solenoids are fed a regulated line pressure of 90 psi
max from the solenoid modulator valve. Excess or reduced pressure to the
solenoids can occur when this valve wears in certain locations, leading to
pintle sticking and inconsistent solenoid valve movement. Just like you must
have a ball and a eld to play baseball, a functional solenoid modulator valve
is a MUST for proper solenoid control. Play ball!
The Lineup First up to bat: the SLU solenoid that controls the apply and
release of the torque converter clutch, the second (B2) clutch and the low
and Reverse (B3) clutch. Hard or soft 1-2 and 2-1 shifts, rm/late TCC ap-
ply, early TCC apply or no converter lockup all can be attributed to a faulty
SLU solenoid. One away!
Next up: the SLT solenoid that primarily controls
line pressure in accordance with engine torque
at the primary regulator valve. SLT pressure also
is directed to the secondary regulator valve to
control converter feed pressure and feed the lube
circuit. In addition, SLT pressure inuences the
forward clutch, second coast clutch and 3rd gear
band. A multitude of symptoms could occur from
a faulty SLT solenoid: harsh/delayed Neutral-to-
Drive, harsh Forward, long shifts, low cooler ow,
harsh TCC apply, and 2-3, 3-2, 3-4 and 4-3 shift
complaints. Two down!
e last to bat: the SLS solenoid that controls
clutch apply pressure by regulating Drive or
Reverse uid at the shift pressure control valve
to control apply of the 2nd clutch, second coast
clutch or direct clutch. is means a faulty SLS
solenoid could create harsh Reverse and harsh/
ared 2-3, 3-4, 4-5 shifts. e same symptoms
can be caused by issues at more than one solenoid,
making diagnosis on root cause sticky sometimes.
ree down, and now the home team comes to the
plate!
PERFORMANCE
Performance Upgrades
Sonnax engineers and manufactures the
industry's nest performance and heavy duty
upgrades for these and other applications:
• Dodge-Cummins Diesel
• GM 4L60-E
• GM Powerglide®
Scan code with
smartphone for high performance
and heavy duty options.
Continued from page 1
SLU, Black
SLS, Green
Connector
Down
"B" or "C"
Code
SLT, Blue
Connector
Down
Must Use
Wide Bracket
S1
S2
S3
S4
S5
Valve Body I.D.
55-50SN Late Linear
Solenoid Set
Figure 1
Transmission Report • July 2014©2014 Sonnax Industries, Inc.
Nobody knows transmissions like Sonnax.™
3
Hitting a Sweet Home Run with 55-50SN Rebuilds
PROBLEM SOLUTION Part Number Tool Required
• Flare upshifts/downshift bind-ups
• Excess clutch overlap & distress
1. Oversized C1/K1 Clutch Control Valve Kit
Also fits TF-80SC & TF-81SC 15741-55K F-15741-TL55
& VB-FIX
2. Oversized K2 Clutch Control Valve Kit 15741-57K F-15741-TL57
& VB-FIX
3. Oversized K3 Clutch Control Valve Kit 15741-59K F-15741-TL59
& VB-FIX
• Harsh downshifts
• Flare on 1-2, 2-3 & 5-6 upshift 4. Oversized B1 Clutch Control Valve Kit 15741-61K F-15741-TL61
& VB-FIX
Lower Valve Body
1
2
4
3
Hit a Home Run with
Sonnax Remanufactured Solenoids
Sonnax oers sets of 55-50SN remanufactured linear solenoids
engineered to address not only the sticking bushing, but a host
of other potential failure modes leading to the same drivability
concerns. Sonnax improved the bushings with an exclusive new
design that incorporates better material, a sizing method for perfect
t and nish every time, plus resists sticking
even at elevated temperatures. Base-hit, man
on rst!
Wear between the solenoid valve and “snout”
can result in loss of the critical SLU, SLT,
SLS or solenoid modulator pressure, leading
to various shift symptoms (Figure 2). Sonnax
addresses these concerns by running every
solenoid through a rigorous drive-cycle style
test on a valve body test machine to ensure
that excessive clearance is not occurring
and reducing critical pressures. Single up the
middle, men on rst and second!
Another potential failure mode is relaxation
or coil binding of the internal solenoid spring.
Sonnax tests every solenoid for concerns
in this area too by verifying that the spring
is providing the appropriate force to help
correctly position the solenoid valve. Flare
over 3rd, bases loaded!
Continued on page 4
Sonnax offers whole family of Aisin AW TF-60SN
(VW/Audi 09G, 09K, 09M) parts!
Scan code with smartphone
to view all TF-60SN parts.
Figure 2
Bushings
Spring
Critical
Snout-to-Valve
Body clearance
Critical Valve-to-Snout Clearance
Adjustment
Screw
Wear between the solenoid valve and “snout” can result in loss of the critical SLU,
SLT, SLS or solenoid modulator pressure, leading to various shift symptoms.
TF-60SN Clutch Control Kits
Coming Soon!
Transmission Tech Bulletin
Transmission Report • July 2014 ©2014 Sonnax Industries, Inc.
4
Aisin AW 55-50/51SN Solutions
Early/Short
59947-68K
Late/Long
59947-70K
Early/Long
59947-69K
1.408" 1.510" 1.510"
Finally, one of the most dicult and
time-consuming issues with these linear
solenoids is adjusting the pressures. By
turning the adjustment screw inward
or outward, the spring force on the
valve is altered, which increases or
decreases the SLT, SLS or SLU solenoid
pressure. Because these solenoids are so
interdependent, small adjustments can
aect many areas in the drive cycle. Getting
each properly adjusted to the now-aging
transmission and to any other corrections
made to the valve body, clutches, etc. is
no easy task. Sonnax solves the adjustment
dilemma by incorporating a pre-calibration
setting on each solenoid that works
across vehicle platforms, eliminating
time-consuming tuning at the shop after
installation (Figure 3). Grand-slam!
Aisin AW 55-50SN, 55-51SN, AF23/33 and RE5F22A linear
solenoids are used to control line rise (SLT), the converter clutch
(SLU) and the oil ow rate and accumulation for the clutch circuits
(SLS).
Sonnax recommends replacing faulty OE and aftermarket solenoids
with these 100% tested and calibrated remanufactured solenoids.
Specially developed with an exclusive Sonnax process to eliminate
sticking solenoid problems, these kits are ideal to pair with Zip Kit
AW55-50SN-ZIP.
Remanufactured Solenoid Kits
SLS Solenoid
Green
SLU Solenoid
Black
SLT Solenoid
Blue
Zip Kit
In addition to sets of fully tested and calibrated linear solenoids,
Sonnax provides a full array of 55-50SN solutions for various shift
concerns, including a brand-new 55-50SN Zip Kit that addresses the
most common issues without the need for reaming. Now that’s as
sweet as a plate of warm apple-pie with some vanilla ice-cream!
Set a Winning Line Up!
Sonnax offers the most effective, easy-to-install, affordable
combination of parts for tackling troublesome Aisin AW 55-50/51SN units
Each kit contains a set of
SLS, SLT & SLU solenoids.
Continued from page 3
Figure 3
Sonnax (Black) vs. New OE (Gray) Solenoid Pressure
Sonnax pre-calibrates the 55-50SN remanufactured solenoids to precisely match
OE performance, eliminating the need for tuning after installation.
Transmission Report • July 2014©2014 Sonnax Industries, Inc.
Nobody knows transmissions like Sonnax.™
5
Aisin AW 55-50/51SN Solutions
Part No. AW55-50SN-ZIP
Solenoid Modulator Assembly
Solenoid Relay
Valve Kit
Boost Valve & Sleeve
Secondary Regulator Valve Assembly Pressure Regulator Assembly
Lockup Relay Control Valve Kit LPC Accumulator Piston Kit
B5 Control
Spring
Lockup Control
Valve Kit
Springs (6)
O-Ringed End Plug Kit
(4 Small) (1 Large)
Aisin AW 55-50/51SN Zip Kit®
The Rookie All-Star!
Meet the newest member of the Zip Kit team,
the perfect starter against the Aisin AW 55-50/51SN.
Installs Easily with
No Reaming
or Special Tools Required
Stops Leaks
so the Valve Body Works
the Way It’s Supposed To
Bonus Tech Booklet
for Installation, Plus
Diagnostics & Repair
The First Step in Correcting
Common 55-50/51SN Shift Problems
Zip Kit AW55-50SN-ZIP targets the root cause of multiple
complaints by sealing the critical circuit pressure losses in Aisin AW
55-50/51SN valve bodies (also ts AF 23/33 and RE5F22A units).
e kit contains uniquely designed parts to prevent the loss of
pressures within the main line, lockup, solenoid and SLT circuits. e
kit also seals multiple circuits known to suer from end plug leakage.
e Zip Kit quick guide provides clear and easy instructions on one
sheet to get the unit sealed up and back on the road fast. In addition
to general rebuilding tips and technical information, the technical
booklet included in this kit contains vacuum testing information and
locations at other key areas of the valve body.
Transmission Tech Bulletin
Transmission Report • July 2014 ©2014 Sonnax Industries, Inc.
6
Sonnax Roadshow 2014
Watch for the Sonnax tech van
coming to a city near you!
New Training for 2014!
From 2011 to 2013, the Sonnax Roadshow team presented more than
50 valve body diagnostics and reaming seminars throughout the United
States and Canada. ese free events were hosted by Sonnax distributor
partners and trained thousands of rebuilders in cutting-edge diagnostic
and transmission repair techniques.
Building on three years of success, the Roadshow is
charting a new course to reach an even larger audience.
e Sonnax team will travel cross country to work one-on-one with
rebuilders in their shops, helping to troubleshoot valve bodies, evaluate
repair options and teach advanced skills pioneered by Sonnax.
Rebuilders will gain valuable, hands-on experience while learning some
of the best techniques in the industry, and be able to apply these eective
methods to signicantly improve their daily procedures.
Roadshow in Bossier City, La.
Don’t miss any exciting
developments!
Follow Sonnax Roadshow updates
on Facebook and Twitter, or become
a Sonnax Insider to get updates by
e-mail, RSS and more! Visit
www.sonnax.com for details.
Transmission Report • July 2014©2014 Sonnax Industries, Inc.
Nobody knows transmissions like Sonnax.™
7
Honda 4/5 Speed Valve I.D.
3.04"
Overall Length
.511" Each Spool Diameter
Sonnax employs a team of skilled technicians dedicated
to working one-on-with industry professionals.
Whether you’re trying to identify the right Sonnax part for a problem
unit, build a powerhouse performance tranny or nd help with
reaming and diagnostics, Sonnax is here for you!
Technical Questions?
• Call (800) 843-2600
• E-mail info@sonnax.com or use the
“Contact Us” form at www.sonnax.com
• Visit the Sonnax Facebook page
• Tweet @SonnaxVT
Technical Support Representative
Tory's Years on the Team: 7.5
Special Skills:
• Explaining where and how to use
Sonnax products
• Troubleshooting problems
with repairs
• Roadshow assistant presenter
Background:
• 20+ Years in the industry
• Associate’s degree in
automotive technology
• Technician experience with Ford,
Mazda, Saab and
Volkswagen vehicles
Hobbies:
• Gearhead - loves cars,
snowmobiles and motorcycles
• Movies, classic rock music and
all forms of home and mobile
Infotainment equipment
Question:
I am interested in Honda converter charge regulated pressure
regulator valve 98892-04K. Will it t my application?
Answer:
This pressure regulator valve actually ts most 4/5-speed Honda/
Acura units. The only exceptions are the A6VA, AOYA, BOYA,
MPOA, MPJA, APXA, MPXA, MP1A, PX4B, MPRA, RO, MPZA,
M5HA, M1WA, M5DA, MPWA and MPYA.
When in doubt, check the OE valve. As long as it has three
spools that measure .511" in O.D. and is 3.04" in overall length,
the Sonnax valve should work.
Shop Talk
Honda/Acura
OE Converter Charge Regulated
PR Valve Measurements
Sonnax Industries Inc.
1 Automatic Drive
P.O. Box 440
Bellows Falls, VT
05101-0440
TIME TESTED • INDUSTRY TRUSTED
Transmission Report
Volume 5, No. 2 July 2014
Sonnax designs, manufactures, tests and distributes a wide variety of components
used to remanufacture torque converters, rebuild automatic transmissions, upgrade
driveshafts and protect the driveline from over-torque damage.
Sonnax is a 100% Employee-Owned Company
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PRSRT STD
US POSTAGE
PAID
PUTNEY, VT
PERMIT #1
Featured in this issue
55-50/51SN Solenoids & Zip Kit®
Transmission Parts Catalog Vol. 9
Sonnax Roadshow 2014
Honda 4/5 Speed Valve Identication Tips
Install the all-new 55-50SN Zip Kit alongside
Sonnax remanufactured solenoids for the easiest,
most effective and affordable valve body repairs!
Hit a Home Run Against
55-50/51SN Problems
See pages
4-5 for details
Remanufactured Solenoid Kits
Sonnax on Twitter!
Follow @SonnaxVT for
new product announcements,
special events, tech tips and more!
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