Sonnax Trans Report V5n3

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TIME TESTED • INDUSTRY TRUSTED

Transmission Report

Volume 5, No. 3 October 2014

Contact Sonnax 8:30 a.m. to 5 p.m. ET (800) 843-2600 • fax (802) 463-4059 • www.sonnax.com

1

Money in the Bank - The GM/Ford Joint Venture

Similar to other manufacturers, GM and Ford have made

major changes to their transmission lineups over the past

few years. Spurred by Federal fuel economy and emissions

standards, 6-, 7-, 8-, 9- and 10-speed units are now common

in our industry. To help address the needs for these

additional designs, GM and Ford entered into a joint venture

agreement to engineer and develop transmissions.

e rst units to fall under this agreement were the GM

Hydramatic 6T70 and the Ford Powertrain 6F50. While

these units do share a lot of hard part interchangeability,

some of the design dierences include:

• Valve Body • Case

• TCM • Final Drive

e 6T70 and 6F50 were the rst of the co-engineered GM

and Ford products to enter the market in 2007. e 6T70 is

available in several dierent variants, including Generation 1

and Generation 2 designs for both the 6T70 and 6T75. Ford

variants include the 6F50 and 6F55.

Another GM front-wheel drive 6-speed also shares its

engineering features with a Ford application. e GM

Hydramatic 6T40 was co-engineered with the Ford 6F35.

Like its cousin the 6T70, the 6T40 also is available in

several variants depending on the year and model of the

vehicle. ese 6T40 variants include the 6T45 and 6T50 (all

available in Gen. 1 or Gen. 2 designs) and the newer 6T41

and 6T46 (also known as Gen. 3 of the 6T40 and 6T45).

e 6T40/6F35 families of transmissions were released for

the 2008 model year, and they have become some of the

most widely produced transmissions in service today.

Continued on page 2

ATRA Powertrain Expo

Oct. 30 to Nov. 2

Booth #421

SEMA Show

Nov. 4 to 7

Booth #20261

Visit Sonnax at

ATRA Powertrain Expo & SEMA Show

Sonnax will be exhibiting at two of the hottest back-to-back trade

shows in the industry! Visit us on the show oor to get an up-close

look at our featured line-up of cutting edge products and talk shop

with our team.

ATRA Powertrain Expo

Known as the largest gathering of dedicated transmission professionals

in the world, this show takes place at the Rio All-Suite Hotel & Casino

in Las Vegas and will be packed with the latest technical information

via popular seminars and trusted industry professionals. Get FREE

admission with a complimentary pass from Sonnax. Find us on

Facebook for more details!

SEMA Show

Featuring more than 2,000 new products on display and 2300+

exhibiting companies lling over a million square feet of the Las

Vegas Convention Center, this trade-only event is known as the

premier automotive specialty products tradeshow in the world.

Enjoy educational seminars, product demonstrations, special events,

networking opportunities and more all in one exciting place!

Vegas here we come!

Transmission Tech Bulletin

Transmission Report • October 2014 ©2014 Sonnax Industries, Inc.

2

Money in the Bank - The GM/Ford Joint Venture

Continued from page 2

Let’s take a look at the layout of both of these

transmission families:

6T70/6T75/6F50/6F55

GM applications mount the TEHCM (transmission electro-

hydraulic control module) internal to the transmission, while Ford

utilizes an externally mounted TCM. e TEHCM includes:

• Six PWM solenoids (PCS1, PCS2, PCS3, PCS4, PCS5

and TCC)

• Two on/o shift solenoids (SS1/SS2)

• Four pressure switches (Gen. 1 only)

A lter plate is used to protect the TEHCM (GM) and

solenoids from contamination on both the Ford and GM

applications. e lter plate must be replaced any time the

TEHCM/solenoid body is separated from the valve body.

e GM and Ford hydraulic system layout includes 15 valves

housed within the upper and lower valve bodies. e Ford

solenoid body houses:

• Six PWM solenoids (SSA, SSB, SSC, SSD, Line, TCC)

• One on/o solenoid (SSE)

Both Ford and GM designs service the solenoids as part of the

assembly rather than as individual components.

6T40/6T45/6T41/6T46/6T50/6F35

GM applications mount the TEHCM internal to the

transmission while Ford uses an externally mounted TCM.

e TEHCM (GM)/solenoid body (Ford) includes:

• Six PWM solenoids (PCS1, PCS2, PCS3, PCS4, PCS5

and TCC)

• One on/o shift solenoid (SS1)

e GM Gen. 1 TEHCM is also equipped with pressure

switches for adaptive control functions. A lter plate is used

to protect the TEHCM and solenoids from contamination

on both the GM and Ford applications. e lter plate must

be replaced any time the TEHCM/solenoid body is separated

from the valve body. See chart on page 6 for details.

e GM hydraulic system layout includes 11 valves housed in

the upper and lower valve bodies. Ford application hydraulic

systems include 10 valves and six solenoids. Unlike the GM

applications, the solenoids are designed to be replaced and are

available with dierent ow characteristics, similar to other

Ford applications.

Both the Ford and GM pumps for these lower torque

transmissions house two valves each.

6T40 (Gen. 1) Control

Valve Body Assembly

Pump Blowoff

Ball Valve

Pressure

Regulator Valve

TCC Control

Valve

TCC Blowoff

Ball Valve

3-5-Reverse Clutch

Regulator Valve

2-6 Clutch

Reg. Valve

1-2-3-4 Clutch

Reg. Valve

1-2-3-4 Clutch

Boost Valve

Reverse

& 4-5-6

Clutch Reg.

Valve

Transmission Report • October 2014©2014 Sonnax Industries, Inc.

Nobody knows transmissions like Sonnax.™

3

Money in the Bank - The GM/Ford Joint Venture

Clutch Select & Clutch Regulator Valves

e Ford and GM designs include two additional families of

valves rst seen in the GM 6L series transmissions: “Clutch

Select Valves and Clutch Regulator Valves.” e clutch select

valves control which clutches are allowed to apply/release,

while the clutch regulator valves control the actual shift and

the aggressiveness of that shift.

Product Concerns/Issues

ese transmissions represent a very large and growing

segment of the transmission repair market. Wear issues with

the valve body components and multiple DTC’s are common

at mileages above 50K.

Once again, Sonnax comes to the rescue by

producing an innovative product line-up to

address common concerns such as:

• P0741, P0742,P0752, P0872, P0877 or P0989 codes

• Delayed/Harsh engagements

• No/Slipping 4/5/6

• No TCC

• TCC Shudder/slip

• Transmission overheat,

• 1-2, 2-3, 3-4, 4-5 or 5-6 Shift are

• Lack of lube ow

• No/Slipping 3/5

• Burnt 3/5/R or 4/5/6 clutches

• Binding on the shift

• Erratic shift timing

• Low line pressure

Rest assured, Sonnax components target the root cause

of the concerns including:

• Compensator, AFL, PR, TCC, boost/latch, isolator and

clutch regulator valves

• Pressure switch rebuild kits (which will save you hundreds

of dollars on each repair)

• End plug leakage

• Accumulator leakage

Repair parts are conveniently available either in a Zip Kit®,

or as individual repair kits based on your specic needs.

See the chart on page 6, contact your Sonnax distributor

or visit www.sonnax.com for details.

Sonnax has a

range of parts

available for these

units. For details,

see application chart

on page 6.

6T40 (Gen. 1)

Pump Body

Manual Valve

Actuator Feed

Limit Valve

Clutch Select &

Shuttle Valve

TCC Regulator

Apply Valve

Compensator Feed

Limit Valve

Transmission Tech Bulletin

Transmission Report • October 2014 ©2014 Sonnax Industries, Inc.

4

GM First Generation 6T40, 6T45 & 6T50 Solutions

Oversized TCC Regulator

Valve Kit

Helps cure:

• Harsh/No TCC Apply

• Codes 741, 742

Note: Requires tool kit F-144740-TL16

& the VB-FIX reaming fixture.

144740-16K

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Oversized TCC Control

Valve Kit

Helps cure:

• TCC apply/release complaints

• Low cooler flow

Note: Requires tool kit F-144510-TL5C

& the VB-FIX reaming fixture.

144510-05K

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for 2014

First Generation 6T40, 6T45, 6T50

Transmission Solutions

9

Oversized Pressure

Regulator Valve Kit

Helps cure:

• Harsh/Soft shifts

• Burnt clutches

Note: Requires tool kit F-144510-TLC

& the VB-FIX reaming fixture.

144510-01K

3

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Oversized Clutch

Boost Valve

Helps cure:

• Slips/Flares/Burnt clutches

• Delayed engagement

Note: Requires tool kit F-144740-TL22

& the VB-FIX reaming fixture.

144740-22

4

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3

7

7

7

7

5

4

Goes into the TCM portion

of the Mechatronic.

Transmission Report • October 2014©2014 Sonnax Industries, Inc.

Nobody knows transmissions like Sonnax.™

5

GM First Generation 6T40, 6T45 & 6T50 Solutions

6T40-ZIP Parts Not Shown

Zip Kit®

It’s easy to restore and extend vehicle shift

quality with Zip Kits. Uniquely designed

Sonnax parts target the root cause of valve

body complaints and stop critical circuit pres-

sure losses in the most common

problem areas of the transmission.

Note: Ratent Pending

Pressure Switch Rebuild Kit

Helps cure:

• Codes 0752, 0872, 0877, 0989

• Shift concerns

144510-09K Patent Pending

5

Compensator Feed

Regulator Valve Kit

Helps cure:

• Bump/Flare/Harsh shifts

• Burnt clutches

104740-09K

6

Oversized Solenoid

Regulator Valve

Helps cure:

• Solenoid codes

• Harsh/Slipping shifts

Note: Requires tool kit 144740-TL.

144740-01

8

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O-Ringed End Plug Kit

Helps cure:

• Shift concerns

• Burnt clutches

144740-02K Fits 6 locations

7

6

2

1

7

7

8

Proper identication of this valve body and pump is

critical! See pages 104–105 of the new Sonnax Trans-

mission Product Calalog (Vol. 9) for details or view the

valve body ID guide online at www.sonnax.com.

Main Control

Valve Body

Pump Assembly

WARNINGWARNING

WARNINGWARNING

Scan code with Smartphone

to view valve body ID guide.

Transmission Tech Bulletin

Transmission Report • October 2014 ©2014 Sonnax Industries, Inc.

6

GM/Ford Application Chart

GM Ford GM Ford

6T40/45/50

Generation 1 6F35

6T70/75

Generation 1 6F50/55

Compensator Feed Regulator Valve

Bump shifts; CPC codes; Erratic shift quality; Harsh

shifts

104740-09K 144740-04K

Oversized Solenoid Regulator or AFL Valve

Harsh shifts; Low clutch oil pressure; No 4th, 5th or 6th

gear; Slipping shifts

144740-01

144740-TL

144740A-01

144740-TL

124740-01; F-104740-TL12

Oversized TCC Regulator Valve Kit

Codes 741, 742; Harsh TCC apply; Loss of fuel

economy; Low TCC apply pressure; No lock-up; TCC

slip; Overheated fluid & TCC lining

144740-16K

F-144740-TL16

144740-19K

F-144740-TL19

124740-24K; F-124740-TL24

O-Ringed End Plug Kit

Burnt clutches; Pressure loss; Shift concerns; TCC

apply concerns

144740-02K 144740-03K 124740-02K

Oversized Clutch Latch or Boost Valve

Burnt clutches; Delayed engagement; Harsh shifts; Shift

quality is not load sensitive; Slide shifts; Slip codes;

Slips & flares

144740-22

F-144740-TL22

144740-21

F-144740-TL21

144740-23; F-144740-TL22

4-5-6 Accumulator Piston Kit

3-4 Flare/harsh; 4-5-6 Clutch burned; Ratio codes;

Slipping

124740-04K

Isolator Valve Spring

Line pressure instability; No line rise 124740-16

Isolator Valve Kit

Burnt clutches; Harsh shifts; Line pressure instability;

Low line pressure; No line rise; Shift concerns

124740-03K

Oversized Pressure Regulator Valve Kit

Burnt clutches; Erratic line pressure; Low converter &

lube flow; Overheating; Poor shift quality; TCC apply &

release concerns

144510-01K

F-144510-TLC

144510-03K

F-144510-TL3C

124740-12K; F-124740-TL12

Pressure Switch Rebuild Kit

DTC's P0752, P0872, P0877, P0989; Loss of shift

control; Replacement of TEHCM necessary

144510-09K †124740-28K*†;

124740-TL30*†;

124740-30K*;

Oversized TCC Control Valve Kit

Excess TCC slip; TCC apply & release complaints; TCC

codes; Low converter & lube flow; Low cooler flow;

Overheating; TCC lining failure; Shudder

144510-05K;

F-144510-TL5C

144510-07K;

F-144510-TL7C

124740-14K; F-124740-TL14

Oversized 3-5-R Clutch Regulator Valve Kit, 1.35 Ratio

2-3 Flare; 4-5 Flare; Slips in Reverse; Delayed Reverse;

Slips in 3rd gear; Slips in 5th gear; 3-5-Reverse clutch

burned; Ratio codes; Bind-ups

124740-26K; F-124740-TL26

Oversized 3-5-R Clutch Regulator Valve Kit, 1.83 Ratio

2-3 Flare; 4-5 Flare; Slips in Reverse; Delayed Reverse;

Slips in 3rd gear; Slips in 5th gear; 3-5-Reverse clutch

burned; Ratio codes; Bind-ups

124740-21K; F-124740-TL21

Oversized 2-6 Clutch Regulator Valve Kit

1-2 Flare; 5-6 Flare; Slips in 2nd gear; Slips in 6th gear;

No 2nd gear; No 6th gear; Ratio codes; 2-6 Clutch

burned; Erratic shift timing

124740-17K; F-124740-TL17

Zip Kit®

Burnt brake clutches; Burnt clutches; Delayed

engagement; Inadequate lubrication; Low pressure;

Slips & flares; Soft shifts; TCC apply & release

concerns; TCC codes

6T40-ZIP†6F35-ZIP 6T70-ZIP*†6F50-ZIP

GM and Ford agreed to a joint venture agreement to

engineer and develop transmissions. Use this chart to

nd Sonnax parts for each of the resulting units.

Note: Sonnax F-Tool kits designed to service a specific bore

require the VB-FIX, a self-aligning valve body reaming fixture.

*Available late 2014

†Patent Pending

Transmission Report • October 2014©2014 Sonnax Industries, Inc.

Nobody knows transmissions like Sonnax.™

7

Technical Writer/Tech Support

Representative

Brian's Years on the Team: 1

Brian Wing arrived in the Sonnax

family last year, bringing 20 years

of automotive diagnostic and repair

experience with him.

A factory-trained BMW Master

technician and erstwhile shop foreman,

he eventually left the dealer to open a

general repair shop, which he operated

for nine years before coming to Sonnax.

He enjoys many of the outdoor

activities Vermont has to offer,

including snowboarding, camping

and shooting. Brian’s duties include

technical writing and providing

technical assistance to diagnosticians

and builders in support of the

installation of Sonnax parts.

A common call we get on the tech assistance line concerns AW

55-50SN troubles. Flares, harsh shifts, bind-ups, slipping, burnt

clutches, you name it. As you know, these valve bodies are com-

plex and much of the hydraulic circuitry is interdependent, which

can make diagnosis sketchy.

Fortunately, we’ve found that a majority of these issues can be

traced to common root causes and we’ve got you covered with

solutions. Installing a remanufactured linear solenoid kit along

with a Zip Kit® will cure many of these symptoms in short order so

you can get your customer back on the road with condence.

Remember, after replacing any parts or making adjustments to

these units, the adaptations must be

reset. As always, we’re here to answer

any questions you might have, so feel

free to call.

Shop Talk

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

Sonnax employs a team of

skilled technicians dedicated to

working one-on-one 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!

Early/Short

59947-68K

Late/Long

59947-70K

Early/Long

59947-69K

1.408" 1.510" 1.510"

AW55-50SN-ZIP

Remanufactured Linear

Solenoid Kits

Each kit includes an SLT,

SLU and SLS Solenoid

Sonnax Industries Inc.

1 Automatic Drive

P.O. Box 440

Bellows Falls, VT

05101-0440

TIME TESTED • INDUSTRY TRUSTED

Transmission Report

Volume 5, No. 3 October 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

Is this newsletter getting into the right hands?

To update an address or request we stop this mailing to you,

please call (800) 843-2600, 8:30 a.m. to 5 p.m. ET,

or send an e-mail to news@sonnax.com.

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Free Tech Resources,

Industry Events & More!

Sign up for Sonnax E-news

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PRSRT STD

US POSTAGE

PAID

PUTNEY, VT

PERMIT #1

New Transmission Products

Catalog Coming Soon!

The much-anticipated Transmission Products Catalog –

Vol. 9 is jam-packed with 500+ new part listings, 12 new

units featuring full valve body illustrations, valuable tech

tips and more!

There are several easy ways to get your copy:

• If you are a subscriber to Transmission Digest

magazine, a catalog will be mailed directly to you

with the November issue. Gears subscribers will

receive a copy at a later date.

• Catalogs will be available at both the ATRA

Powertrain Expo and SEMA Show in Las Vegas.

• Visit www.sonnax.com

and ll out the catalog

request form

to receive a

copy by mail.

Valve Body Xpress

Now a Division of Sonnax

Sonnax recently

purchased Valve Body

Xpress (VBX) and

Valve Body Xtras of Paulsboro, N.J. Founded in 2002, Valve

Body Xpress (VBX) is a leading remanufacturer of automatic

transmission valve bodies and solenoids, while Valve Body

Xtras is a VBX subsidiary focused on valve body components.

is exciting acquisition combines the extensive resources of

two successful companies to better meet the numerous repair

challenges of increasingly sophisticated modern transmissions.

Sonnax is well-known worldwide in the industry for its

innovative engineering, exceptional quality and outstanding

technical support and training. e volume of valve

bodies rebuilt by VBX and the company’s hands-on

remanufacturing expertise opens the door to expanded

Sonnax product development and testing capabilities. e

transmission aftermarket will benet from this collaboration,

whether a shop chooses to rebuild their valve bodies with

Sonnax parts or purchase a VBX rebuilt unit. Visit

www.sonnax.com to learn more.

Featured in this issue

GM/Ford Joint Venture

Sonnax at 2014 Expo & SEMA

1st Gen. 6T40/45/50 Sonnax Solutions

Troubleshooting 55-50SN Tip