U151E U250E ZIP

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

2017-01-26

: Sonnax U151E-U250E-Zip U151E-U250E-ZIP 1728 file instruction uploads

Open the PDF directly: View PDF .
Page Count: 10

PART NUMBER U151E-U250E-ZIP QUICK GUIDE

installation Diagram

Install with open end out.

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.

Cutaway shows a

side view of lower

valve body with

Sonnax boost valve

kit installed.

CAUTIONCAUTION

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TOYOTA U151E-U250E

ZIP KIT

Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents.

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 specic complaints which are beyond the

scope of this kit.

Upper Valve Body

Plastic Checkball

Shown in 11 places.

Medium

Small

Large

Lower Valve Body

Small

U151E-U250E ZIP KIT Quick Guide

Zip Kit Contents & Installation Steps

Step Replace OE B2 Plunger

Valve & Sleeve

Packaging Pocket 1

• Plunger Valve

• Plunger Sleeve

Step Replace OE B1 Plunger

Valve & Sleeve

Packaging Pocket 2

• Plunger Valve

• Plunger Sleeve

Step Replace OE Boost Valve,

Sleeve & Plug

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.

Packaging Pocket 3

• Boost Valve

• Boost Sleeve

• Boost Valve Plug

Step

Replace OE Lockup Control

Plunger Valve & Sleeve

NOTE: Reuse OE spring if applicable.

Packaging Pocket 4

• Plunger Valve

• Plunger Sleeve

CAUTIONCAUTION

Step Replace 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

Step Replace OE End Plugs

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

• 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

• End Plugs, Small (4)

• O-Rings, Small (6) 2 Extra

Step Replace OE Checkballs

Packaging Pocket 9

Plastic Checkballs (11)

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

Torque Specifications

Pan Filter to Valve Body

8 ft-lb

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"

Underdrive (C3) Clutch

U151E & U250E:

.059–.067"

End Play

Input Shaft

U151E & U250E:

.010–.049"

Underdrive Unit

U151E: .020–.040"

U250E: .008–.027"

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-ll: 3.5 liters

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

Gear SL1 SL2 SL3 S4 SR DSL/TCC SLT

1st ON ON Off Off Off ON/M1

Modulates

based on

engine load.

2nd Off ON Off Off Off Off

3rd ON Off Off Off ON ON

4th Off Off ON Off ON ON

5th Off Off ON ON ON ON

Electronic Cautions

Resetting Shift Adapts

e 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 accelera-

tions from a stop until proper shifting is obtained.

Solenoids

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

Gear Range

Forward

Clutch C1

Reverse

Input

Clutch C2

Direct

Clutch C0

Underdrive

Clutch C3

2nd Brake

Low &

Reverse

Brake B2

Underdrive

Brake B3

No. 1

One Way

Clutch F1

No. 2

One Way

Clutch F2

Park ON

Reverse ON ON ON

Neutral ON

D-1st Gear ON ON ON ON

D-2nd Gear ON ON ON ON

D-3rd Gear

High Ratio ON ON ON

D-3rd Gear

Low Ratio ON ON ON ON

D-4th Gear ON ON ON ON

D-5th Gear ON ON ON

Toyota/Lexus U151E/F, U250E Component Application Chart

TOYOTA U151E-U250E

ZIP KIT

PART NUMBER U151E-U250E-ZIP INSTALLATION & TESTING BOOKLET

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1

U151E-U250E ZIP KIT Installation & Testing Booklet

Page 2 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

Zip Kit Instructions

1. Valve Body Removal from Case

Remove the 19 bolts indicated (Figure 1).

2. Valve Body Disassembly: Step 1

NOTE: See Figure 2 for bolt locations.

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 conguration.

a. Remove bolt #1 and locking plate. Remove shift

solenoid SL3 and the SLT solenoid.

b. Remove bolt #2 and shift solenoid S4, then SR

solenoid.

c. Remove bolt #3 and shift solenoid DSL.

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.

3. Valve Body Disassembly: Step 2

NOTE: See Figure 4 for bolt locations.

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 2

Figure 4

Valve Body Removal from Case

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

5. SL3 Solenoid,

4.5–6.0 Ohms

6. SLT Solenoid,

4.5–6.0 Ohms

7. SL1 Solenoid,

4.5–6.0 Ohms

Figure 3

5 6

Solenoid Locations and Resistance

Bolt

Color Code

Bolt

Length

Black 12mm

Red 16.75mm

Green 21.50mm

Yellow 25.00mm

Lt Purple 26.50mm

Olive 30mm

Purple 35.50mm

White 41.00mm

Lt Blue 46.50mm

Blue 57.00mm

Orange 62.50mm

Figure 1

Valve Body Disassembly: Step 1

Figure 2

U151E-U250E ZIP KIT Installation & Testing Booklet

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3

TIME TESTED • INDUSTRY TRUSTED

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 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.

b. Loosely install the seven, unnumbered light blue bolts.

c. Loosely install the light blue #8 bolt, retaining bracket and checkball.

d. Torque all bolts to 90 in-lb.

6. Valve Body Assembly: Step 2

NOTE: See Figure 6 for bolt locations and torque specications.

a. Loosely install bolt #1.

b. Loosely install the seven #2 bolts.

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

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

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

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).

7. Valve Body Reinstallation to Case

NOTE: See Figure 7 for bolt locations.

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

lengths.

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

bolts to the same 8 ft-lb.

Valve Body Assembly: Step 1

Figure 5

Figure 7

Valve Body Reinstallation to Case

Valve Body Assembly: Step 2

Figure 6

Bolt ID & Color Code Installation Torque Specs

Bolt #1 90 in-lb

Bolt #2 90 in-lb

Bolt #3 58 in-lb

Bolt #4 8 ft-lb

Bolt #5 8 ft-lb

Bolt #6 8 ft-lb

Bolt #7 58 in-lb

U151E-U250E ZIP KIT Installation & Testing Booklet

Page 4 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

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

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 • U250E Shown Here

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.

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*

B2 (Low/Reverse) Switch Valve

• B2 Brake clutches burned

• Delayed Reverse

• Loss of engine braking in manual low

4-5 Shift Valve

• Delayed 3rd

• UD/C3 Clutch burned

• Delayed or no 5th gear

U151E-U250E ZIP KIT Installation & Testing Booklet

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5

TIME TESTED • INDUSTRY TRUSTED

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.

Lower Valve Body – Top Side • U250E Shown Here

For specic vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

VACUUM

TEST

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.

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.

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

End Plugs, Multiple Locations

• Shift concerns

• Clutch failure

Replace with Sonnax Part No.

27741-20K*

NOTE: Two Locations =



B2 (Low/Reverse) Switch Valve

• B2 Brake clutches burned

• Delayed Reverse

• Loss of engine braking in manual low

U151E-U250E ZIP KIT Installation & Testing Booklet

Page 6 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

*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.

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 • U250E Shown Here End Plugs, Multiple Locations

• Shift concerns

• Clutch failure

Replace with Sonnax Part No.

27741-20K*

NOTE: Eight locations =

Solenoid Modulator Valve

• Harsh/Flare upshifts

• TCC slip or cycling

• Low cooler ow/overheating

Replace with Sonnax Part No.

27741-13K Requires F-27741-TL13 & VB-FIX

B3 Orice 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.

B1 (2nd) Accumulator Piston

• B1 Brake clutches burned

• Slipping/Flares in 2nd, 4th & 5th

Replace with Sonnax Part No.

57917E-19K*†



B2 (Low/Reverse)

Control Valve

• B2 Brake burned

• Delayed Reverse

• Delayed engagement in manual 1st

Accumulator Control Valve

• Shift concerns

• Burnt clutches & brakes

C0 (Direct)

Accumulator Piston

• C0 Clutch burned

• Slipping/Flares in 3rd, 4th & 5th

Replace with Sonnax Part No.

57917E-19K*†

C0 (Direct) Control Valve

• C0 Clutch burned

• Slipping/Flares in 3rd, 4th & 5th

Solenoid Relay Valve

• Shift concerns

U151E-U250E ZIP KIT Installation & Testing Booklet

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 7

TIME TESTED • INDUSTRY TRUSTED

Upper Valve Body – Top Side • U250E Shown Here

For specic vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

VACUUM

TEST

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

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.

B1 (2nd) Control Valve

• B1 Brake clutches burned

• Slipping/Flares in 2nd, 4th & 5th

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*†

Lockup Relay Valve

• TCC apply & release concerns

• TCC codes

• Burnt converter overheating

Lockup Control

Plunger Assembly

• Burnt converter

• TCC apply & release concerns

• TCC codes

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.

C1 (Forward) Control Valve

• C1 Clutch burned

• Delayed engagement

• Slipping/Flares in 1st, 2nd & 3rd

NOTE: Seal ports on opposite side when testing.

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: Place

clay here to

isolate circuit.

U151E-U250E ZIP KIT Installation & Testing Booklet

Page 8 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

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 Orice Control Valve

210 B2 Control Valve

211 Solenoid Modulator Valve

212 C0 Accumulator Piston

213 B1 Accumulator Piston

214 C1 Accumulator Piston

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

OE Exploded View

Upper & Lower Valve Body • U250E Shown Here

211

Upper Valve Body

Bottom Side Shown

210

209

208

207

206

201

202

203

205

204

214

101

102

106

105

104

103

Accumulator Pistons

Installed on Top Side

Lower Valve Body

Top Side Shown

Installed on

Bottom Side

212

213

U151E U250E ZIP

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

Navigation menu

Versions of this User Manual:

Views

Navigation