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

Large

Small

1
2
Small

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

Small

Large

Small

Only use here in
models that have a
hole in the plate at
this location.

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)

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

Park
ON

Reverse

Neutral
D-1st Gear

D-2nd Gear

D-3rd Gear

D-Overdrive

2-1st Gear

2-2nd Gear

Low-1st Gear

SL1 Controls
B1 Brake

SL2 Controls
C2 Clutch

S4 Controls
3-4 Shift

1st

Off

2nd

Off

Gear

ON
ON
ON

Toyota/Lexus U140E/F, U240E, U241E
Solenoid Function & Apply Chart

3rd

Off

4th

Off

SLT: Controls line pressure.
DSL: Controls lockup clutch.

ON
ON

N-D ENGAGEMENT: 3rd gear is commanded during the
engagement, then 1st after the engagement is complete.

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

e. Remove checkball, location A.

Solenoid Resistance Chart

Solenoid Identification

1. DSL Solenoid
2. SL2 Shift Solenoid
3. S4 Shift Solenoid

4. SLT Solenoid
5. SL1 Shift Solenoid
Bolt Torque Specifications
5
Solenoid Locations and Resistance

= 58 in-lb.

Solenoid

U140E

U140F

U240E

U241F

SL1

5.1–5.5
ohms

5.0–5.6
ohms

SL2

5.1–5.5
ohms

11-15
ohms

11–15
ohms

DSL

11–15
ohms

11–13
ohms

SLT

5.0–5.6
ohms

5.1–5.5
ohms

= 97 in-lb.

Figure 3

3
1

3
2
1

Valve Body Disassembly: Step 1

11-03-16 U140E-U241E-ZIP-Booklet_B
Page 2

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
4

2
5
4

a. Reinstall checkball, location A.

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

U140E/F, U240E, U241E ZIP KIT

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

25
0
30
VACUUM
TEST

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

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

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

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

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

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