Sonnax Trans Report V7n1
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TIME TESTED • INDUSTRY TRUSTED
Transmission Report
Volume 7, No. 1 March 2016
Contact Sonnax 8:30 a.m. to 5 p.m. ET (800) 843-2600 • fax (802) 463-4059 • www.sonnax.com
1
Introducing the
Ford 6R140 Zip Kit®
The Quick, Affordable Fix for Common Shift Problems
Sonnax Zip Kit 6R140-ZIP eectively restores normal shift quality in
Ford 6R140 units to get your vehicle back on the road fast. Featuring
a winning combination of uniquely designed parts, this innovative kit
targets the root cause of valve body problems by sealing up critical circuit
pressure losses in the most common wear areas of the transmission.
One-page instructions deliver clear installation steps, and parts install
quickly and easily with no special tools or reaming required. Also
included is a detailed technical booklet which provides additional
rebuild and inspection tips for comprehensive valve body repair. Visit
www.sonnax.com for more details.
Kit Includes:
• TCC Apply Boost Valve Kit
• Converter Limit Valve, Sleeve & Spring
• Accumulator Pistons (3)
• O-Ringed End Plug Kit
• Internal O-Ringed End Plug Kit
• Accumulator Springs (3)
Pinball Wizard U341E/F TCC Slip Diagnosis
If you’ve been in the transmission business for a while you have no doubt had someone bring a vehicle
to you that no one else can seem to gure out. e customer may have tried self-diagnosis by navigating
various web forums and trying to pick through the (usually questionable) tech advice found there.
After he got frustrated, perhaps a friend who “knows transmissions” oered a “Buddy
Deal” to x the problem. When that failed, he made the rounds to the local repair shops.
Each shop takes a stab at it, but in the end he shows up in your shop with a complaint
that has not been resolved. is guy has pin-balled from back yard to back yard and shop
to shop, and by the time he gets to you he is on full-tilt.
ese scenarios typically happen with vehicles that are not brought into the shop for
regular maintenance, and usually involve transmissions that do not have great technical
information available. ese are fundamental causes of misdiagnosis, the pinball eect,
and the unhappy customers that result. Continued on page 2
Transmission Report • March 2016
2
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Continued from page 1
e U341E/F transmission is a prime example of a problem child that many transmission shops have not worked
on yet, and the technical information available is scarce. In particular this transmission has had common concerns of
torque converter slip along with two related diagnostic trouble codes (DTCs):
• P0741 — Torque Converter Clutch Solenoid Performance (SL, ON-OFF type)
• P2757 — Torque Converter Clutch Pressure Control Solenoid Performance (SLU, PWM-type)
Both DTCs signify a mechanical or hydraulic problem causing no lockup; these codes do not indicate an electrical
problem. e key word in the code denition is “performance”. If the codes were electrical in nature, they would
instead refer to the “circuit”.
e U340/U341E/F series valve bodies are very similar, but changed from an ON-OFF to a modulated SLU-type
TCC control, a modication that occurred over a span of years and has not been documented very well. One of the
biggest hurdles is nding out which type you have, as they are both found in a range of Toyota and Scion vehicles. A
good indicator on whether it is an ON-OFF or a modulated SLU-type is by simply referring to which DTC is set:
• P0741 denotes ON-OFF type
• P2757 denotes SLU-type
e SLU-type valve body had some changes that incorporated a new lockup control valve, along with a new plunger
and sleeve assembly that the ON-OFF did not have (Figure 1). Figure 2 shows this bore is empty for the ON-
OFF type. is is a quick way to identify whether the valve body you are working on is an ON-OFF or SLU type.
Another way to identify the two is to note the dierence between the ON-OFF solenoid (Figure 3) and the SLU
solenoid (Figure 4). Figure 5 shows a close-up of the two solenoids side by side. By the way, the SLU solenoid is the
same as that found on the U660E. In a pinch, the SLU from a U660E can be swapped with the U341E SLU for
solenoid diagnostic purposes.
Pinball Wizard U341E/F TCC Slip Diagnosis
Lockup Control Valve
Plunger & Sleeve
SLU-Type valve body with lockup control valve
Figure 1
3
©2016 Sonnax Industries, Inc.
XXXXXXXXX
e modulated SLU-type has been more
problematic than the ON-OFF type. e
root cause of the TCC-related problems on
the SLU-type is typically related to wear
in both the lockup control valve bore and
at the outboard plunger valve and sleeve.
is creates a loss of TCC apply pressure,
especially in the plunger and sleeve area
because the plunger is near an exhaust.
During the pinball process many shops
typically throw torque converters and
numerous SLU solenoids at the problem,
then replace valve bodies with “good
used”. But good used valve bodies are
extremely hard to nd and after numerous
replacements you will realize that a large
percentage of them have the same problem.
Stopping this leakage and verifying the
torque converter clutch is okay are the keys
to keeping this vehicle from bouncing back to you with TCC-related complaints. Reaming the bore and installing
Sonnax oversized lockup control valve kit 37740-08K will restore optimal pressure for renewed TCC control.
Repairing the root cause will keep those hard-to-x vehicles from continuing the pinball process, which will also
bring word of mouth business to the “Pinball Wizard” who uses this information to gure out how to end the game
once and for all.
Pinball Wizard U341E/F TCC Slip Diagnosis
ON/OFF Solenoid SLU Solenoid
Figure 5
Empty Bore
Figure 2
ON-OFF type valve body
without lockup control
valve
Figure 3
ON-OFF
Solenoid
Figure 4
SLU
Solenoid
Transmission Report • March 2016
4
Toyota/Lexus U341E/F
Valve Body Repairs
Symptoms Description Part No. Tooling
• TCC apply & release concerns
• TCC codes
• No lockup
• Converter shudder & slip
Oversized Lockup Control Valve Kit 37740-08K F-37740-TL8 & VB-FIX
• Harsh TCC apply & release
• Excess TCC slip
• TCC codes
• Erratic TCC apply pressure
Oversized Secondary Pressure
Regulator Valve Kit 37740-07K F-37740-TL7 & VB-FIX
• Harsh shifts
• Burnt clutches
• Delayed engagement
• Reverse slip
Boost Valve Kit 37740-01K
• Harsh shifts
• Burnt clutches
• Delayed engagement
• Reverse slip
Oversized Pressure Regulator &
Boost Valve Kit 37740-03K F-37740-TL3 & VB-FIX
1
2
3
4
1
2
4
U341E Lower
Valve Body
U341E Upper
Valve Body
3
5
©2016 Sonnax Industries, Inc.
Watch online as Sonnax High Performance Product Line Manager, Gregg Nader, delivers an in-depth
look at four featured GM 6L80-series transmission upgrades and repairs. Find this video and more in
the Tech Resources section at www.sonnax.com.
GM 6L80/90 Performance Upgrades
NEW 1-2-3-4 Piston
GM 6L80/6L90 1-2-3-4 pistons commonly crack due to cantilevered stress
on the cast material. ough the OE part has been through several revisions
in attempt to correct this, all OE versions are still known to suer from
unwanted chronic cracking. Sonnax 1-2-3-4 piston 104984-01 is made
from stronger, billet aluminum, making it a reliable solution for
lasting results.
• Superior design renements provide additional strength
• Prevents breakage and delivers maximum performance
Pump Slide Spring
Sonnax high-performance pump
slide spring 104534-HD is able to
keep the pump slide in a maximum-
volume position to hold line pressure
and prevent clutch failure, despite
increased pressure and high
engine speed.
• Spring is stier than OE
• Designed specically for high-
RPM conditions
Line Pressure Booster Kit
Sonnax kit 6L80-LB1 combines
10% stronger-than-OE pressure
regulator spring and a large ratio
boost valve for an impressive, yet
aordable performance upgrade. It
allows the transmission to respond
intelligently to driving conditions
by delivering the right amount of pressure exactly
when you need it; a moderate increase under light
throttle, and progressively greater pressure as the
transmission is worked harder.
• Fits all 6L45-6L90 applications
• Easy installation with no special tools or
reaming required
Zip Kit®
Tackle the root cause of multiple
shift problems with Sonnax Zip Kit
6L45-6L90-ZIP. Featuring a
winning combination of uniquely-
designed parts, this kit eectively
stops critical circuit pressure losses
to get your vehicle back on the road
fast.
• Quick, hassle-free installation with no special tools
or reaming required
• Detailed tech booklet provides clear installation
steps, diagnostics and solutions for comprehensive
valve body repair.
4-5-6 Clutch Apply Piston Kit
Tackle failure of the 4-5-6 clutch
assembly due to OE design
shortcomings including insucient
clutch piston-to-plate apply surface
area, and exing and bowing of
the backing plate with Sonnax kit
104960-01K.
• Rigid backing plate design
outperforms OE and aftermarket plates
• Increased apply ring surface area strengthens and
reinforces assembly
Transmission Report • March 2016
6
Sonnax Wins Big –
Thanks to YOU!
Every year, Transmission Digest
accepts nominations for the top
10 tools and top 10 products in the
powertrain aftermarket industry.
Readers vote for their favorites
in each of the two categories to
determine the winners.
The results are in: Sonnax won seven
top product awards, and four top tool
awards! Thank you all for your trust
and support of Sonnax products – we
couldn’t have done it without you!
GM 6L45-6L90
Pressure Switch Installation Tool Kit: 124740-TL30
Patent-pending tool kit is key to eective, aordable
pressure switch rebuilds.
Vacuum Test Stand Kit: VACTEST-01K
Essential equipment for proper vacuum testing.
Vacuum Test Guides
Better diagnostics = better rebuilds and fewer comebacks.
Sonnax Roadshow
Hands-on, on-site training in cutting-edge diagnostic and
transmission repair techniques.
Transmission Digest Top 10 Awards
7
©2016 Sonnax Industries, Inc.
4L60/E
Heavy Duty &
Performance
Catalog Vol. 3
Sonnax parts have made
the 4L60/E the leading
performance transmission
in the world. New for 2016,
an expanded catalog for
this classic unit is your best
upgrades guide for all rebuild
levels, from street enthusiast
to extreme racing.
• Ramp up durability with
heavy-duty parts
• Rule the track with elite
racing components
• Learn killer tips for the
best builds
View online or request
a free copy TODAY at
www.sonnax.com.
Chrysler 47RE/47RH & 48RE
Smart-Tech® High Capacity Input
Shaft & Piston Kit: 22121B-02K
20% More direct clutch torque
capacity – no modications required.
Chrysler 48RE
Converted Valve Body: CHR135
e breakthrough solution for 48RE valve body shortage.
GM 6L45-6L90
Zip Kit®: 6L45-6L90-ZIP
Tackle common shift problems straight from the source.
GM 6L45-6L90 & 6T70/6T75
Pressure Switch Rebuild Kit: 124740-30K
Save hundreds by rebuilding the TEHCM, instead of buying
an expensive replacement.
GM 6L80/6L90
4-5-6 Clutch Apply Piston Kit: 104960-01K
Overcome insucient clutch piston-to-plate apply surface
area, and exing and bowing of the backing plate.
Ford 4R100
Performance Pack: HP-4R100-01
Powerhouse kit for a stronger, faster, more reliable
transmission.
Ford 4R70W Series
Smart-Tech® Forward Clutch Drum: 76654-01K
One-piece forged material provides increased strength and
durability over the OE stamped drum.
Sonnax Industries Inc.
1 Automatic Drive
P.O. Box 440
Bellows Falls, VT
05101-0440
TIME TESTED • INDUSTRY TRUSTED
Transmission Report
Volume 7, No. 1 March 2016
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
To update your address or request to stop this mailing,
please call (800) 843-2600, 8:30 a.m. to 5 p.m. ET,
or e-mail to news@sonnax.com.
PRSRT STD
US POSTAGE
PAID
PUTNEY, VT
PERMIT #1
Sonnax is a leading diversied supplier of specialized drivetrain products to the automotive and commercial vehicle industries, and to
industrial sectors utilizing drivetrain technology. We design, manufacture and distribute replacement components worldwide.
Featured in this issue
U341E Slip Diagnosis
Ford 6R140 Zip Kit®
U341E/F Valve Body Repairs
6L80/90 Performance Upgrades
Transmission Digest Top 10 Winners
4L60/E Performance Catalog, Vol. 3
ZF6 Gen. 1 & Gen. 2 Identication
& Repair Techniques
• Introduction to the ZF6
• Differences between Gen. 1 and Gen. 2
• Solenoid and valve operation and diagnosis
• Valve wear repair techniques
• Common transmission and non-transmission
related issues
Live webinars with Sonnax Tech
Specialist Steve Garrett deliver
transmission expertise into
your hands!
• Convenient, 1-hour lunchtime sessions
• Join via computer or phone/tablet
• Ask questions and request additional tech support
• Download detailed handouts and
access full webinar after each event
Choose to attend any of ve sessions:
• Tues. March 22 at noon EST or MST
• Wed. March 23 at noon CST or PST
• Wed. March 23 at 7 a.m. AEDT (Australia)
Sign up TODAY at www.sonnax.com/webinars
Can’t make it to the live event? No problem! e recorded
presentation and slides are posted online after the nal session
and are freely available anytime you want them.
