U140E U241E ZIP IN
2017-01-05
: Sonnax U140E-U241E-Zip-In U140E-U241E-ZIP-IN 3047 instructions part uploads
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TOYOTA U140E/F, U240E, U241E ZIP KIT PART NUMBER U140E-U241E-ZIP QUICK GUIDE Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents. installation Diagram Install with open end out. Upper Valve Body 5 Small 3 Large 3 3 Small 1 2 Small 3 Small 3 3 NOTE: Before removing OE boost sleeve, take note of the adjustable step/ pin location and ensure the Sonnax sleeve is installed at the same height/ location. Failure to do so will result in incorrect line rise. Medium 3 Small 3 Large 3 Small Only use here in models that have a hole in the plate at this location. 4 Cutaway shows a side view of lower valve body with Sonnax boost valve kit installed. Lower Valve Body 6 Plastic Checkball Shown in 11 places. In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum testing and additional repair options for higher mileage units or for repairing specific complaints which are beyond the scope of this kit. ©2016 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com U140E-U241E-ZIP-Guide_B 11-03-16 Page 1 U140E/F, U240E, U241E ZIP KIT Quick Guide Zip Kit Contents & Installation Steps Step 1 Replace OE Clutch Apply Control Sleeve & Plunger Valve Step 4 R eplace OE Boost Sleeve & Valve Packaging Pocket 1 • Boost Valve • Boost Sleeve • Boost Plug Packaging Pocket 6 • Plunger Valve • Plunger Sleeve Step 5 R eplace OE Accumulator Pistons Step 2 Replace OE Lockup Control Sleeve & Plunger Valve NOTE: Reuse OE spring if applicable. NOTE: Place O-ring into deepest piston groove. Lubricate with Sonnax Slippery Stick O-LUBE and roll on bench to size. Install into casting bore with the O-Ring inboard. Packaging Pocket 7 Packaging Pocket 2 Accumulator Piston • Plunger Valve • Plunger Sleeve Packaging Pocket 8 Accumulator Piston Packaging Pocket 9 Step 3 Replace OE End Plugs O-Rings (3) NOTE: Install all end plugs with the O-ring outboard. Place O-ring into end plug groove. Lubricate with Sonnax Slippery Stick O-LUBE and roll on bench to size. Packaging Pocket 3 • Small End Plugs (6) • Small O-Rings (9) 1 Extra Step 6 Replace OE Checkballs Packaging Pocket 10 3 Extra Plastic Checkballs (11) Packaging Pocket 4 • Medium End Plug • Medium O-Rings (2) 1 Extra Packaging Pocket 5 • Large End Plugs (2) • Large O-Rings (3) ©2016 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 1 Extra U140E-U241E-ZIP-Guide_B 11-03-16 Page 2 TOYOTA U140E/F, U240E, U241E ZIP KIT PART NUMBER U140E-U241E-ZIP INSTALLATION & TESTING BOOKLET Torque Specifications Electronic Cautions Pan Filter to Valve Body 96 in-lb Resetting Shift Adapts Oil Pan to Transaxle 72 in-lb Component Pack Clearance Forward (C1) Clutch U140E/F: 4-Cyl .069–.082" U140E/F: V6 .082–.095" U240/241E: .056–.069" Low & Reverse (B2) Brake U140E/F: 4-Cyl .040–.048" U140E/F: V6 .043–.051" U240/241E: .043–.049" 2nd (B1) Brake U140E/F: .024–.036" U240E: .024–.029" U241E: .024–.036" Direct (C2) Input U140E/F: .024–.033" U240/241E: .024–.029" Underdrive (C3) Clutch U140E/F: .059–.075" U240E/241E: .058–.067" Underdrive (B3) Brake U140E/F: .071–.087" U240/241E: .074–.082" Post-Adapt Road Test After resetting the ECM, a road test is required. Start the engine and warm it to normal operating temperature. Perform a thorough road test with multiple accelerations from a stop until proper shifting is obtained. TSB TC002-06 Toyota published a Technical Service Bulletin regarding computer hardware problems in 2001-2003 RAV4 vehicles. Resetting the ECM will not eliminate shifting complaints for this unit. A new ECM will be required. Solenoids End Play Input Shaft U140E/F: .010–.049" U240E/241E: .011–.049" The ECM (engine control module) has memorized values which must be relearned after transmission repair. Use a scan tool (OE factory tool recommended) to reset the ECM. Solenoids should be cleaned to remove debris that results in sticking and malfunction. Underdrive Unit U140E/F: .020–.039" U240E/241E: .008–.027" Direct Clutch Assembly U140E/F: .008–.037" U240E/241E: .008–.035" Fluid Toyota Type T-IV Toyota/Lexus U140E/F, U240E, U241E Clutch Application Chart Gear Range C1 C2 C3 B1 B2 Park ON Reverse ON Neutral D-1st Gear ON D-2nd Gear ON D-3rd Gear ON ON D-Overdrive ON ON 2-1st Gear ON 2-2nd Gear ON Low-1st Gear ON B3 F1 F2 SL1 Controls B1 Brake SL2 Controls C2 Clutch S4 Controls 3-4 Shift 1st ON ON Off 2nd Off ON Off ON Gear ON ON ON ON Toyota/Lexus U140E/F, U240E, U241E Solenoid Function & Apply Chart ON 3rd Off Off ON ON ON 4th Off ON ON ON ON SLT: Controls line pressure. DSL: Controls lockup clutch. ON ON ON ON ON ON ©2016 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com ON ON ON ON N-D ENGAGEMENT: 3rd gear is commanded during the engagement, then 1st after the engagement is complete. ON U140E-U241E-ZIP-Booklet_B 11-03-16 Page 1 U140E/F, U240E, U241E ZIP KIT TIME TESTED • INDUSTRY TRUSTED Figure 1 Installation & Testing Booklet Zip Kit Instructions Bolt Color Code Bolt Length Red 10mm Green 12mm Blue 14mm 1. Valve Body Removal from Case NOTE: See color chart for bolt lengths. Remove the 17 bolts indicated (Figure 1). Purple 25mm 2. Valve Body Disassembly: Step 1 White 30mm NOTE: See Figure 2 and 3 for bolt locations. Yellow 41mm The solenoids have differing resistance amounts (Figure 2). Ensure each of the solenoids are put back in their correct location. Orange 45mm a. Remove the five solenoids and bolts shown in Figure 2. NOTE: Reference Figure 3 for steps b through e. b. Remove the eight upper valve body bolts, #1 and #2. Valve Body Removal from Case c. Remove the seven upper valve body cover bolts, #3 and #4. d. Remove bolt #5, bracket and checkball. Figure 2 3 e. Remove checkball, location A. Solenoid Resistance Chart Solenoid Identification 2 1. DSL Solenoid 2. SL2 Shift Solenoid 3. S4 Shift Solenoid 1 4. SLT Solenoid 5. SL1 Shift Solenoid Bolt Torque Specifications 5 Solenoid Locations and Resistance 4 = 58 in-lb. Solenoid U140E U140F U240E U241F SL1 5.1–5.5 ohms 5.0–5.6 ohms 5.0–5.6 ohms 5.0–5.6 ohms SL2 5.1–5.5 ohms 5.1–5.5 ohms 5.1–5.5 ohms 5.1–5.5 ohms S4 11-15 ohms 11–15 ohms 11–15 ohms 11–15 ohms DSL 11–15 ohms 11–13 ohms 11–13 ohms 11–13 ohms SLT 5.0–5.6 ohms 5.1–5.5 ohms 5.1–5.5 ohms 5.1–5.5 ohms = 97 in-lb. Figure 3 A 3 1 3 5 3 1 3 1 3 2 1 4 1 3 1 1 Valve Body Disassembly: Step 1 11-03-16 U140E-U241E-ZIP-Booklet_B Page 2 ©2016 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com U140E/F, U240E, U241E ZIP KIT Installation & Testing Booklet TIME TESTED • INDUSTRY TRUSTED 3. Valve Body Disassembly: Step 2 Figure 4 NOTE: See Figure 4 for bolt locations. a. Remove the seven lower valve body bolts shown. b. Hold separator plate against lower valve body. Lift off of upper valve body and lay on bench with separator plate side up. c. Remove separator plate from lower valve body. Note the location of all the checkballs and retainers. Verification on page 8 in booklet. 4. Installation Install Zip Kit parts as shown on diagram of separate quick guide sheet included in this Zip Kit. • When installing the lockup control plunger valve and sleeve kit in Step 2, reuse the OE spring in between the new valve and sleeve if applicable. • The Sonnax O-ringed end plugs in Step 3 must be installed with the O-ring outboard. Valve Body Disassembly: Step 2 and Valve Body Assembly: Step 1 Figure 5 5. Valve Body Assembly: Step 1 NOTE: See Figure 4 for bolt locations. a. Loosely install the seven bolts. b. Torque all bolts to 97 in-lb. 6. Valve Body Assembly: Step 2 NOTE: See Figure 5 for bolt locations and torque specifications. 2 A 4 2 1 2 4 2 4 2 5 4 a. Reinstall checkball, location A. 3 4 2 4 4 b. Install checkball and bracket, then loosely install bolt #1. c. Loosely install the seven upper valve body cover bolts, #2 and #3. d. Loosely install the eight upper valve body bolts #4 and #5. e. Torque all bolts in previous steps according to specs in Figure 5. f. Install the five solenoids and bolts shown in Figure 2 and torque per spec indicated. 7. Valve Body Reinstallation to Case NOTE: See Figure 6 for bolt locations. a. Loosely install all 17 bolts. Reference bolt color and length chart on previous page. Valve Body Assembly: Step 2 Bolt ID & Color Code Installation Torque Specs Bolt #1 58 in-lb Bolt #2 58 in-lb Bolt #3 58 in-lb Bolt #4 97 in-lb Bolt #5 97 in-lb Figure 6 b. Torque all bolts to 8 ft-lb. Valve Body Reinstallation to Case ©2016 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com U140E-U241E-ZIP-Booklet_B 11-03-16 Page 3 TIME TESTED • INDUSTRY TRUSTED U140E/F, U240E, U241E ZIP KIT Installation & Testing Booklet Critical Wear Areas & Vacuum Test Locations NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear and Sonnax parts noted for replacement. Upper Valve Body – Bottom Side • U 241E Shown Here End Plugs, Multiple Locations C2 (Direct) Exhaust Valve • Shift concerns • Clutch failure • C2 Clutch burned • Slipping/Flares in 3rd and 4th Replace with Sonnax Part No. 57917E-20K NOTE: Six Locations = Clutch Apply Control Plunger Valve Assembly • Clutch failure • Burnt clutches • Shift concerns Replace with Sonnax Part No. 57917E-05K C2 (Direct) Lockup Valve • C2 Clutch burned • Slipping/Flares in 3rd and 4th Secondary Regulator Valve • Harsh lockup • Burnt converter • TCC apply & release concerns Replace with Sonnax Part No. 57917E-16K Requires F-57917E-TL16 & VB-FIX Lockup Control Valve • TCC apply & release concerns • TCC codes • Burnt converter Replace with Sonnax Part No. 27741-25K Requires F-27741-TL25 & VB-FIX NOTE: Test both ports at the same time. Lockup Control Plunger Assembly • Burnt converter • TCC codes • TCC apply & release concerns Replace with Sonnax Part No. 57917E-03K NOTE: Vacuum testing of lockup control plunger assembly not possible while in casting. Perform visual inspection to identify wear. Lockup Relay Valve • TCC apply & release concerns • Overheating • TCC codes • Burnt converter Solenoid Modulator Valve • Harsh/Flare upshifts • TCC slip or cycling • Low cooler flow B1 (2nd Gear Brake) Control Valve • Overheating • Excessive Reverse pressure • Bind-up • B1 Brake clutches burned • 2nd Quality poor Replace with Sonnax Part No. 57917E-13K Requires F-57917E-TL13 & VB-FIX *Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately. 11-03-16 U140E-U241E-ZIP-Booklet_B Page 4 ©2016 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com U140E/F, U240E, U241E ZIP KIT 20 15 Installation & Testing Booklet TIME TESTED • INDUSTRY TRUSTED 10 25 0 30 VACUUM TEST 5 For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com. Upper Valve Body – Top Side • U241E Shown Here C2 (Direct) Accumulator Piston B1 (2nd Gear) Accumulator Piston • C2 Clutch Burned • 2-3 Concerns • B1 Brake clutches burned • 1-2 Quality poor Replace with Sonnax Part No. 57917E-19K Replace with Sonnax Part No. 57917E-19K Items without part numbers are valid vacuum test locations for indicated drivability complaints, but do not have corresponding Sonnax parts due to low percentage of bore wear. ©2016 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com U140E-U241E-ZIP-Booklet_B 11-03-16 Page 5 TIME TESTED • INDUSTRY TRUSTED U140E/F, U240E, U241E ZIP KIT Installation & Testing Booklet Critical Wear Areas & Vacuum Test Locations NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear and Sonnax parts noted for replacement. Lower Valve Body – Bottom Side • U241E Shown Here Pressure Regulator Valve • Low/High line pressure • Soft/Harsh shifts • Clutch and brake failure • High line pressure in Reverse • Low converter pressure Replace with Sonnax Part No. 57917E-08K Requires 57917E-TL8 C2 (Direct Clutch) Control Valve • C2 Clutch burned • Slipping/Flares in 3rd and 4th Boost Valve Assembly • High line pressure in Reverse • Low line rise in Drive • Soft shifts Replace with Sonnax Part No. 57917E-01K B2 (1st and Reverse Brake) Control Valve • B2 Brake clutches burned • Delayed Reverse • Delayed engagement in manual low B1 (2nd Gear Brake) Control Valve End Plugs, Multiple Locations • B1 Brake clutches burned • 2nd Quality poor • Shift concerns • Clutch failure Replace with Sonnax Part No. 57917E-20K NOTE: Three Locations = *Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately. 11-03-16 U140E-U241E-ZIP-Booklet_B Page 6 ©2016 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com U140E/F, U240E, U241E ZIP KIT Installation & Testing Booklet TIME TESTED • INDUSTRY TRUSTED OE Exploded View Upper & Lower Valve Body • U241E Shown Here Upper Valve Body Bottom Side Shown Upper Valve Body Descriptions I.D No. Description 110 101 C2 Lockup Valve 102 Secondary Regulator Valve 103 Lockup Control Valve 104 Lockup Relay Valve 105 Solenoid Modulator Valve 106 B3 Orifice Control Valve 103 107 B1 Lockup Valve 104 108 Clutch Apply Control Valve 109 C2 Exhaust Valve 110 Three-Way Check Valve 101 109 102 108 107 106 105 111 Upper Valve Body Descriptions I.D. No. 112 101 Description 111 C2 Accumulator Piston 112 B1 Accumulator Piston Upper Valve Body Top Side Shown ©2016 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com U140E-U241E-ZIP-Booklet_B 11-03-16 Page 7 TIME TESTED • INDUSTRY TRUSTED U140E/F, U240E, U241E ZIP KIT Installation & Testing Booklet OE Exploded View Upper & Lower Valve Body • U241E Shown Here Checkball is not used in all units. Only use in models that have a corresponding hole in the separator plate at this location. Lower Valve Body Descriptions I.D No. Description 201 C2 Control Valve 202 Main Regulator Valve 203 B2 Control Valve 204 B1 Control Valve 205 3-4 Shift Valve 206 Manual Valve 201 202 203 204 205 206 Lower Valve Body Bottom Side Shown Lower Valve Body Top Side Shown 11-03-16 U140E-U241E-ZIP-Booklet_B Page 8 ©2016 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
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