U151E U250E ZIP

U151E-U250E-Zip U151E-U250E-ZIP U151E-U250E-ZIP 3048 instructions part uploads sonnax-dev

2017-01-26

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TOYOTA U151E-U250E
ZIP KIT
PART NUMBER U151E-U250E-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
Medium

Small

5
6

Small

Large

Lower Valve Body

Plastic Checkball
Shown in 11 places.

CAUTION

1
6

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 pressure.

Small

2
3
6

Small

Cutaway shows a
side view of lower
valve body with
Sonnax boost valve
kit installed.

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.
©2017 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

U151E-U250E-ZIP-Guide 01-03-17

U151E-U250E ZIP KIT

Quick Guide

Zip Kit Contents & Installation Steps
Step 1 Replace OE B2 Plunger
Valve & Sleeve
Packaging Pocket 1

• Plunger Valve
• Plunger Sleeve

Step

Replace OE B1 Plunger
Valve & Sleeve

Step 5 R
eplace OE Accumulator
Piston
NOTE: Use in the most worn location.
Place O-Ring in deep groove, lubricate with Sonnax Slippery Stick™
O-LUBE and roll on bench to size.
Packaging Pocket 5

• Accumulator Piston
• O-Rings (2)

1 Extra

Packaging Pocket 2

Step 6 Replace OE End Plugs

• Plunger Valve
• Plunger Sleeve

Place O-Ring in groove, lubricate with Sonnax Slippery Stick™ O-LUBE
and roll on bench to size. Install all end plugs with the O-Ring outboard.
Packaging Pocket 6

Step 3 Replace OE Boost Valve,
Sleeve & Plug

CAUTION

NOTE: Ensure Sonnax sleeve is installed at the same
height/location as OE boost sleeve. Failure to do so will
result in incorrect line pressure.

• End Plugs, Large (5)
• O-Rings, Large (7)

2 Extra

Packaging Pocket 7

• End Plug, Medium
• O-Rings, Medium (2)

1 Extra

Packaging Pocket 8
Packaging Pocket 3

• Boost Valve
• Boost Sleeve
• Boost Valve Plug

• End Plugs, Small (4)
• O-Rings, Small (6)

2 Extra

Step 7 Replace OE Checkballs
Step 4 Replace OE Lockup Control
Plunger Valve & Sleeve

Packaging Pocket 9

Plastic Checkballs (11)

NOTE: Reuse OE spring if applicable.
Packaging Pocket 4

• Plunger Valve
• Plunger Sleeve

U151E-U250E-ZIP-Guide 01-03-17

TOYOTA U151E-U250E
ZIP KIT
PART NUMBER U151E-U250E-ZIP

INSTALLATION & TESTING BOOKLET

Torque Specifications

Electronic Cautions

Pan Filter to Valve Body
8 ft-lb

Resetting Shift Adapts

Oil Pan to Transaxle
69 in-lb

Component Pack Clearance
Forward (C1) Clutch
U151E & U250E:
.039–.049"

Low & Reverse (B2) Brake
U151E: .046–.053"
U250E: .029–.048"

2nd (B1) Brake
U151E: .024–.036"
U250E: .021–.036"

Reverse (C2) Input
U151E & U250E:
.024–.032"

Direct (C0) Clutch
U151E: .024–.033"
U250E: .020–.033"

Underdrive (B3) Brake
U151E: .071–.087"
U250E: .065–.087"

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.

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.

Solenoids
Solenoids should be cleaned to remove debris that results in sticking and malfunction.

Underdrive (C3) Clutch
U151E & U250E:
.059–.067"

End Play
Input Shaft
U151E & U250E:
.010–.049"

Underdrive Unit
U151E: .020–.040"
U250E: .008–.027"

Toyota/Lexus U151E/F, U250E Typical Solenoid Firing Order

Direct Clutch Assembly
U151E: .010–.036"
U250E: .008–.038"

Fluid
Toyota Genuine ATF WS PN: JWS3324 or NWS9638
Fluid level should be between the 2 hot marks on the stick:
• Dry Fill: 8.8 liters • Drain and Re-fill: 3.5 liters

Gear

SL1

SL2

SL3

DSL/TCC

1st

Off

ON/M1

2nd

Off

3rd

Off

4th

Off

5th

Off

SLT

Modulates
based on
engine load.

Toyota/Lexus U151E/F, U250E Component Application Chart

Gear Range

Forward
Clutch C1

Reverse
Input
Clutch C2

Direct
Clutch C0

Underdrive
Clutch C3

2nd Brake
B1

Low &
Reverse
Brake B2

Park

Underdrive
Brake B3

No. 1
One Way
Clutch F1

No. 2
One Way
Clutch F2

Reverse

Neutral

ON
ON

D-1st Gear

D-2nd Gear

D-3rd Gear
High Ratio

D-3rd Gear
Low Ratio

ON
ON

D-4th Gear

D-5th Gear

ON
ON

U151E-U250E-ZIP-Booklet 01-03-17
Page 1

TIME TESTED • INDUSTRY TRUSTED

U151E-U250E ZIP KIT

Figure 1

Installation & Testing Booklet

Zip Kit Instructions
1. Valve Body Removal from Case

Bolt
Length

Black

12mm

Red

16.75mm

Green

21.50mm

2. Valve Body Disassembly: Step 1

Yellow

25.00mm

NOTE: See Figure 2 for bolt locations.

Lt Purple

26.50mm

Solenoids can be put into the wrong location in the
valve body. Ensure each of them are put back in their
correct location. Solenoid designs have changed over the
years, see Figure 3 for the most common configuration.

Olive

30mm

Purple

35.50mm

White

41.00mm

Lt Blue

46.50mm

Blue

57.00mm

Orange

62.50mm

Remove the 19 bolts indicated (Figure 1).

a. Remove bolt #1 and locking plate. Remove shift
solenoid SL3 and the SLT solenoid.
b. Remove bolt
solenoid.

Valve Body Removal from Case

Bolt
Color Code

and shift solenoid S4, then SR

c. Remove bolt #3 and shift solenoid DSL.
Figure 2

d. Remove bolt #4 and locking plate. Remove shift solenoid SL2.
e. Remove bolt #5 and locking plate. Remove shift solenoid SL1.

f. Remove the seven #6 bolts.

g. Remove the #7 bolt.
6

3. Valve Body Disassembly: Step 2
NOTE: See Figure 4 for bolt locations.

6
1

a. Remove the light blue #1 bolt, retaining bracket and checkball.
b. Remove the seven remaining light blue bolts.

c. Remove the purple bolt.

Valve Body Disassembly: Step 1
Figure 3

Figure 4

1. DSL (TCC) Solenoid,
11–15 Ohms

2. SL2 Solenoid,
4.5–6.0 Ohms
3. S4 Solenoid,
11–15 Ohms

4. SR Solenoid,
11–15 Ohms
4

7
5

Solenoid Locations and Resistance

01-03-17 U151E-U250E-ZIP-Booklet
Page 2

5. SL3 Solenoid,
4.5–6.0 Ohms
6. SLT Solenoid,
4.5–6.0 Ohms
7. SL1 Solenoid,
4.5–6.0 Ohms

Valve Body Disassembly: Step 2

U151E-U250E ZIP KIT

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

4. Installation

Figure 5

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 4,
reuse the OE spring between the new valve and sleeve.
• The Sonnax O-ringed end plugs in Step 6 must be installed with the O-ring
outboard.

5. Valve Body Assembly: Step 1
NOTE: See Figure 5 for bolt locations.

a. Loosely install the purple bolt.
Valve Body Assembly: Step 1

b. Loosely install the seven, unnumbered light blue bolts.
c. Loosely install the light blue #8 bolt, retaining bracket and checkball.

Figure 6

d. Torque all bolts to 90 in-lb.

6. Valve Body Assembly: Step 2
NOTE: See Figure 6 for bolt locations and torque specifications.

a. Loosely install bolt #1.

b. Loosely install the seven #2 bolts.

c. Install shift solenoid SL1 and locking plate. Loosely install bolt #3.
6

d. Install shift solenoid SL2 and locking plate. Loosely install bolt #4.

e. Install shift solenoid DSL. Loosely install bolt #5.

1
3

f. Install the SR solenoid, then shift solenoid S4. Loosely install bolt #6.
g. Install shift solenoid SL3 and the SLT solenoid. Install the locking plate and
loosely install bolt #7.
h. Torque all bolts as indicated in chart (Figure 6).

Valve Body Assembly: Step 2
Bolt ID & Color Code

Installation Torque Specs

Bolt #1

90 in-lb

Bolt #2

90 in-lb

Bolt #3

58 in-lb

a. Loosely install all 19 bolts. Reference the color chart on previous page for bolt
lengths.

Bolt #4

8 ft-lb

Bolt #5

8 ft-lb

b. First tighten the two #1 positioning bolts to 8 ft-lb. Torque the remaining
bolts to the same 8 ft-lb.

Bolt #6

8 ft-lb

Bolt #7

58 in-lb

7. Valve Body Reinstallation to Case
NOTE: See Figure 7 for bolt locations.

Figure 7

Valve Body Reinstallation to Case

U151E-U250E-ZIP-Booklet 01-03-17
Page 3

TIME TESTED • INDUSTRY TRUSTED

U151E-U250E 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 • U
250E Shown Here
4-5 Shift Valve

B2 (Low/Reverse) Switch Valve

• Delayed 3rd
• UD/C3 Clutch burned
• Delayed or no 5th gear

• B2 Brake clutches burned
• Delayed Reverse
• Loss of engine braking in manual low

B2 (Low/Reverse) Apply
Control Plunger
• B2 Brake clutches burned
• Delayed Reverse
• No engine braking in manual low
Replace with Sonnax Part No.
27741-06K*

B1 (2nd) Apply
Control Plunger
• B1 Brake clutches burned
• 2-3 or 4-3 Bind-up
• Harsh upshifts
Replace with Sonnax Part No.
27741-04K*
NOTE: Seal port on opposite side when testing.

Boost Valve
• Low line rise in Drive
• Soft shifts
• High line pressure in Reverse
Replace with Sonnax Part No.
27741-01K*

Clutch Apply Control Valve
• Flare shifts and bind-ups
• Burnt Forward/C1 Clutch, Direct/C0 Clutch
and 2nd/B1 Brake
Replace with Sonnax Part No.
27741-18K Requires F-27741-TL18 & VB-FIX
NOTE: Stroke valve to ensure it is not stuck.

*Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately.

01-03-17 U151E-U250E-ZIP-Booklet
Page 4

U151E-U250E 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.

Lower Valve Body – Top Side • U250E Shown Here
End Plugs, Multiple Locations

B2 (Low/Reverse) Switch Valve

• Shift concerns
• Clutch failure

• B2 Brake clutches burned
• Delayed Reverse
• Loss of engine braking in manual low

Replace with Sonnax Part No.
27741-20K*
NOTE: Two Locations =



Pressure Regulator Valve
• Low/High line pressure
• Soft/Harsh shifts
• Clutch & brake failures
• High line pressure in Reverse
• Low converter pressure
Replace with Sonnax Part No.
27741-08K Requires 57917E-TL8



Clutch Apply Control Valve
• Flare shifts and bind-ups
• Burned Forward/C1 Clutch, Direct/C0 Clutch
& 2nd/B1 Brake



Replace with Sonnax Part No.
27741-18K Requires F-27741-TL18 & VB-FIX
NOTE: Stroke valve to ensure it is not stuck.

B1 (2nd) Apply
Control Plunger
• B1 Brake clutches burned
• 2-3 or 4-3 Bind-up
• Harsh 1 through 4 maneuver shifts
Replace with Sonnax Part No.
27741-04K*
NOTE: Seal this port and test on opposite side.

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.
©2017 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

U151E-U250E-ZIP-Booklet 01-03-17
Page 5

TIME TESTED • INDUSTRY TRUSTED

U151E-U250E ZIP KIT

Installation & Testing Booklet

Upper Valve Body – Bottom Side • U
250E Shown Here

End Plugs, Multiple Locations
• Shift concerns
• Clutch failure

Solenoid Modulator Valve

Replace with Sonnax Part No.
27741-20K*
NOTE: Eight locations =

• Harsh/Flare upshifts
• TCC slip or cycling
• Low cooler flow/overheating



Replace with Sonnax Part No.
27741-13K Requires F-27741-TL13 & VB-FIX

B2 (Low/Reverse)
Control Valve



• B2 Brake burned
• Delayed Reverse
• Delayed engagement in manual 1st

B3 Orifice Control Valve
• UD/B3 Brake clutches burned
• Shift concerns



Replace with Sonnax Part No.
27741-16K Requires F-15741-TL18 & VB-FIX
NOTE: Stroke valve to ensure it is not stuck.

Accumulator Control Valve



• Shift concerns
• Burnt clutches & brakes



C0 (Direct) Control Valve
• C0 Clutch burned
• Slipping/Flares in 3rd, 4th & 5th



C0 (Direct)
Accumulator Piston
• C0 Clutch burned
• Slipping/Flares in 3rd, 4th & 5th
Replace with Sonnax Part No.
57917E-19K*†

B1 (2nd) Accumulator Piston
• B1 Brake clutches burned
• Slipping/Flares in 2nd, 4th & 5th

Solenoid Relay Valve
• Shift concerns

Replace with Sonnax Part No.
57917E-19K*†
*Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately.
†
One accumulator piston kit included in Zip Kit, choose most worn location.
01-03-17 U151E-U250E-ZIP-Booklet
Page 6

U151E-U250E 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 • U250E Shown Here
Lockup Relay Valve
• TCC apply & release concerns
• TCC codes
• Burnt converter overheating

Lockup Control Valve
• TCC apply & release concerns
• TCC codes
• Burnt converter
Replace with Sonnax Part No.
27741-25K Requires F-27741-TL25 & VB-FIX

Lockup Control
Plunger Assembly
• Burnt converter
• TCC apply & release concerns
• TCC codes
Replace with Sonnax Part No.
57917E-03K

NOTE: Place
clay here to
isolate circuit.

NOTE: Vacuum testing of lockup control plunger assembly not possible
while in casting. Perform visual inspection to identify wear.

B1 (2nd) Control Valve
• B1 Brake clutches burned
• Slipping/Flares in 2nd, 4th & 5th

Secondary Pressure
Regulator Valve
• Harsh lockup
• Converter apply/release complaints
• Burnt converter
Replace with Sonnax Part No.
57917E-16K Requires F-57917E-TL16 & VB-FIX

C1 (Forward) Control Valve
• C1 Clutch burned
• Delayed engagement
• Slipping/Flares in 1st, 2nd & 3rd
NOTE: Seal these ports and test on opposite side.

C1 (Forward)
Accumulator Piston
• C1 Clutch burned
• Delayed engagement
• Slipping/Flares in 1st, 2nd & 3rd
Replace with Sonnax Part No.
57917E-19K*†

C1 (Forward) Control Valve
• C1 Clutch burned
• Delayed engagement
• Slipping/Flares in 1st, 2nd & 3rd
NOTE: Seal ports on opposite side when testing.

U151E-U250E-ZIP-Booklet 01-03-17
Page 7

TIME TESTED • INDUSTRY TRUSTED

U151E-U250E ZIP KIT

Installation & Testing Booklet

OE Exploded View
Upper & Lower Valve Body • U250E Shown Here
Installed on Top Side

Upper Valve Body Descriptions

I.D No.

Description

201

Lockup Relay Valve

202

Lockup Control Valve & Plunger
Valve Assembly

203

B1 Control Valve

204

Secondary Regulator Valve

205

C1 Control Valve

206

Solenoid Relay Valve

207

C0 Control Valve

208

Accumulator Control Valve

209

B3 Orifice Control Valve

210

B2 Control Valve

211

Solenoid Modulator Valve

212

C0 Accumulator Piston

213

B1 Accumulator Piston

214

C1 Accumulator Piston

Upper Valve Body
Bottom Side Shown

211

201

210

202
209

203
208
204

207
205
206
Accumulator Pistons
Installed on Top Side

213
214

Lower Valve Body Descriptions

I.D. No.

Description

101

Manual Valve

102

B2 Switch Valve & Plunger Valve

103

4-5 Shift Valve

104

B1 Switch Valve & Plunger
Valve Assembly

105

Main Pressure Regulator Valve
& Boost Valve Assembly

106

Clutch Apply Control Valve

01-03-17 U151E-U250E-ZIP-Booklet
Page 8

Installed on
Bottom Side

212

Lower Valve Body
Top Side Shown

101

102
103
104
105
106

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U151E U250E ZIP

U151E-U250E-Zip U151E-U250E-ZIP U151E-U250E-ZIP 3048 instructions part uploads sonnax-dev

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