U660E ZIP IN
2017-10-27
: Sonnax U660E-Zip-In U660E-ZIP-IN 3502 instructions part uploads
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TOYOTA/LEXUS U660E, U660F ZIP KIT ® PART NUMBER U660E-ZIP IDENTIFICATION GUIDE Valve Body Identification Guide U760E U660E, U660F Upper Valve Body Casting Upper Valve Body Casting Small Exhaust Groove Extended Exhaust Groove No Transmission Designation U660 Casting Number (may be seen here) Solenoid Casting Solenoid Casting Smaller Solenoid Casting Boss Larger Solenoid Casting Boss U660 Casting Number No Casting Number No Pressure Switch Plate Casting Cutouts Flat Casting NOTE: Large canister solenoid connectors are brown and white. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Pressure Switch Plate NOTE: Large canister solenoid connectors are brown and black. U660E-ZIP-Identify 10-26-17 TOYOTA/LEXUS U660E, U660F ZIP KIT ® PART NUMBER U660E-ZIP QUICK GUIDE Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents. installation Diagram Middle Valve Body Solenoid modulator balance port. Solenoid modulator balance orifice. Drill with .062" bit. Insert .062" aluminum plug into orifice and peen shut. 11 3 2 9 10 4 1 8 7 8 Upper Valve Body 6 5 3 8 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 U660E-ZIP-Guide 10-26-17 Page 1 Toyota/Lexus U660E, U660F ZIP KIT® Quick Guide Zip Kit Contents & Installation Steps Step 1 Replace OE B1 Apply Boost Assembly Step 7 R eplace OE (Short) C1 Accumulator Piston Packaging Pocket 1 Packaging Pocket 7 • Sleeve • Accumulator Piston • Valve • O-Rings (2) 1 extra Step 2 Replace OE Reverse Boost Assembly Step 8 Replace OE (Long) B1, B2, B3 & C2 Accumulator Pistons Packaging Pocket 2 Packaging Pocket 8 • Sleeve • Accumulator Pistons (4) • Valve • O-Rings (6) 2 extra Step 3 Replace OE Small End Plugs Step 9 Replace OE Checkballs CAUTION!: O-rings go on Inboard spool! Inboard retaining port edge on casting should be chamfered prior to installation to prevent O-ring shear. See page 8 of installation and testing booklet for details. NOTE: See pages 6 & 7 in installation and testing booklet for locations. Packaging Pocket 9 • Checkballs (3) Packaging Pocket 3 • End Plugs, Small (6) • O-Rings, Small (9) 3 extra Step 4 Replace OE Solenoid Modulator Valve Lineup CAUTION! Many units use tri-lobed end plug. Note location of OE retainer on tri-lobed OE end plug. See page 8 of installation and testing booklet for assembly details. Step 10 R eplace OE O-Rings on Case Connector & Fluid Temperature Sensor NOTE: See page 8 in installation and testing booklet for locations. Packaging Pocket 10 • Fluid Temperature Sensor O-Ring, Small • Case Connector O-Ring, Large Packaging Pocket 4 • Valve • Sleeve • Spring • End Plug • Shims (2) Step 5 Replace OE Lockup Control Boost Assembly Packaging Pocket 5 • Sleeve • Valve Step 6 Step 11 D rill & Plug Separator Plate Balance Orifice at Solenoid Modulator Valve To prevent solenoid modulator leakage, drill indicated orifice to .062". Plug with aluminum plug and peen in place. Packaging Pocket 11 • Orifice Plugs, .062" dia. (2) • Drill Bit, .062" dia. 1 extra Replace OE Large End Plug CAUTION!: O-ring for this large end plug goes on outboard spool! Packaging Pocket 6 • End Plug, Large • O-Rings, Large (2) 1 extra ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com U660E-ZIP-Guide 10-26-17 Page 2 Toyota/Lexus U660E, U660F ZIP KIT ® PART NUMBER U660E-ZIP INSTALLATION & TESTING BOOKLET TCM Initialized/Memory Reset The U660E TCM learns the performance of the vehicle and adapts the transmission accordingly. When significant transmission or engine repairs are made, the TCM needs to be initialized and/or have the memory reset in accordance with the chart in Figure 2. These procedures require use of Toyota’s Techstream scan tool or their PC-based version of the scan tool, Techstream lite. Figure 1 Automatic Transaxle Parts Replacement Chart Replaced Parts Transaxle Compensation Code Automatic Transaxle Assembly Input Valve Body Assembly Initialize Shift Solenoid Valve SL1 and/or SL2 TCM/ECU Location QR Code Label with Transaxle Compensation Code Memory (Learned Values) Reset Necessary Reset Necessary Shift Solenoid Valve SL3 and/or SL4 TCM* - Possible Road Test Figure 2 Initialize Necessary Reset Input (into the new TCM) TCM* - Impossible Necessary * Note: If possible, read the transaxle compensation code from the previous TCM. Input Transaxle Compensation Code The transaxle compensation code is a unique, 60-digit alphanumeric value found on the QR label at the top of the transmission (Figure 1). Inputting an incorrect code into the TCM may cause shift shock. 1. Shift the shift lever to Neutral or Park. 2. Connect Techstream to the DLC3 (diagnostic link connector). 3. Turn ignition switch on (do not start the engine). 4. Turn tester on. 5. Enter the menu items in the following order: Powertrain / ECT / Utility / A/T Code Registration. 6. Select “Set Compensation Code.” 7. Register the compensation code: a. Press “Input” b. Type in code. Press “OK.” 8. Verify the displayed value is the same as that on the QR label. 9. Press “Next” to set the code to the TCM. Initialize Transaxle Compensation Code This procedure resets the code and, combined with a road test, allows the TCM to relearn. 1. Shift the shift lever to Neutral or Park. 2. Turn the ignition switch off. 3. Connect Techstrean to the DLC3. 4. Turn ignition switch on and push Techstream main switch on. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com 5. Enter the menu items in the following order: Powertrain / ECT / Utility / A/T Code Reset 6. Press “Next” again to proceed. 7. Press “Exit.” Road Test 1. Warm up the engine. 2. From a standstill, achieve highest possible speed with the accelerator pedal opened no more than 15%. Keep the accelerator pedal angle steady while driving the vehicle. 3. Repeat the previous step until shift shock no longer occurs. 4. From a standstill, achieve highest possible speed with the accelerator pedal opened 25% or more. Keep the accelerator pedal angle steady while driving the vehicle. 5. Repeat the previous step until shift shock no longer occurs. Memory Reset This procedure resets the TCM memory so it can memorize new performance information. 1. Turn the ignition switch off. 2. Connect the Techstream to the DLC3. 3. Turn the ignition switch on. 4. Turn Techstream main switch on. 5. Enter the menu items in the following order: Powertrain / ECT / Utility / Reset Memory. 6. Press “Next” to confirm reset. U660E-ZIP-Booklet 10-26-17 Page 1 Toyota/Lexus U660E, U660F ZIP KIT® TIME TESTED • INDUSTRY TRUSTED Installation & Testing Booklet Figure 3 Solenoid Energized Clutch & Brake Application Selector Position C1 C2 B1 When selector position in manually operated. B2 B3 X X F1 SL2 SL3 SL4 SLU SLT X P-Park R-Reverse X X X D, S6-2nd X D, S6-3rd X D, S6-4th X X X X D, S6-5th X D, S6-6th X X X X X X X X X X X X X X X X X X X SL X X N-Neutral D, S6-1st S1-1st/Manual SL1 X X X X X X Removal Bolts Zip Kit Instructions 1. Valve Body Removal a. With the valve body still in the transmission, remove the 11 bolts (Figure 4). b. Remove the case connector and internal wire harness assembly from the transmission as part of the valve body. 2. Valve Body Disassembly a. Disconnect and remove counter gear/turbine speed sensor and valve body bolts (Figure 5). b. Disconnect case connector from all seven solenoids. Remove case connector assembly retaining bolt, bracket and connector/harness assembly (Figure 6). c. Remove four indicated bolts (Figure 7) and pressure switch and TFT sensor assembly. Bolt Length A Red 25mm B Green 30mm C Blue 35mm D Yellow 45mm E Pink 55mm Torque all to 8 ft-lbs Case connector and internal wire harness assembly. C d. Remove eight indicated bolts (Figure 8), solenoid brackets, solenoids, small and large cover plate. e. Remove remaining eight bolts (Figure 9) and line pressure relief spring and ball. Bolt Color Code B Figure 4 A D B 3. Installation Install Zip Kit parts as shown on diagram of separate quick guide sheet included in this Zip Kit. NOTE: Special rebuilding tips for steps 3, 4 and 10 are on page 8 of this booklet. E Sonnax recommends vacuum testing critical wear areas not covered by this kit to determine whether additional Sonnax parts are required (see pages 4–5). B B B B B 4. Valve Body Reassembly a. Reinstall the eight bolts (Figure 9) and line pressure relief spring and ball. b. Reinstall the solenoid brackets, solenoids, small and large cover plate and eight bolts (Figure 8). c. Reinstall pressure switch and TFT sensor assembly and four bolts (Figure 7). d. Reinstall case connector assembly retaining bracket, bolt and connector/harness assembly (Figure 6). Attach wire harness from bracket and connect to all seven solenoids. 10-26-17 U660E-ZIP-Booklet Page 2 e. Connect and reinstall counter gear/turbine speed sensor and valve body bolts (Figure 5). f. When reinstalling the valve body, first temporarily tighten the two bolts marked () in Figure 4 as they are positioning bolts. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Toyota/Lexus U660E, U660F ZIP KIT® Connector/Harness Assembly Figure 5 Counter Gear/Turbine Speed Sensor Installation & Testing Booklet Disassembly & Reassembly Bolts Figure 6 Release H D G D Turbine Speed Sensor Disconnect SL4 Solenoid (PCSD) B3 Brake 5.0–5.6 ohm SL3 Solenoid (PCSC) B1 Brake 5.0–5.6 ohm SL1 Solenoid (PCSA) C1 Clutch 5.0–5.6 ohm (Blue & Black Wires) (Pink & Black Wires) SL2 Solenoid (PCSB) C2 Clutch 5.0–5.6 ohm Figure 7 SLU Solenoid TCC & B2 Brake 5.0–5.6 ohm (White & Black Wires) (Orange & Black Wires) TIME TESTED • INDUSTRY TRUSTED Bolt Color Code Bolt Length A Red 15.5mm B Green 16mm C Lt Blue 25mm D Yellow 50mm E Pink 55mm F Dk Blue 60mm G Orange 70mm H Teal 75mm I Brown 80mm J Purple 85mm Torque all to 8 ft-lbs SLT Solenoid Line Pressure 5.0–5.6 ohm (Grey & Black Wires) (Green & Black Wires) J C J SL Solenoid • Lockup Relay Valve • B2 Brake Clutch Apply Control Valve • Reverse Sequence Valve 11–15 ohm J (1 Blue Wire) Pressure Switch & TFT Sensor Assembly CAUTION!: Do not interchange solenoids. If SLU and SLT are interchanged, this will cause both line and TCC apply issues. SLT has five slots, SLU has four slots. All solenoid resistance values at 20oC/68oF. Figure 8 B E I Figure 9 D F D D I I G I I E E E C Line pressure relief spring and ball. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com U660E-ZIP-Booklet 10-26-17 Page 3 TIME TESTED • INDUSTRY TRUSTED Toyota/Lexus U660E, U660F 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 B1 Accumulator Piston B2 Accumulator Piston • Harsh 1-2 or 5-6 shift • Burnt B1 brake • Harsh Reverse engagement • Burnt B2 brake Replace with Sonnax Part No. 47740-11K* Replace with Sonnax Part No. 47740-11K* B3 Accumulator Piston • Harsh/Delayed Forward engagement • Burnt C1 clutch Replace with Sonnax Part No. 47740-12K* • Harsh Reverse engagement • Harsh 2-3 or 4-5 shift • Burnt B3 brake Replace with Sonnax Part No. 47740-11K* C2 Accumulator Piston Secondary Pressure Regulator Valve • Overheated transmission • Bushing/Bearing failures • Lube-related failures • Harsh 3-4 shift • Burnt C2 clutch Replace with Sonnax Part No. 47740-11K* Test: Test this port with valve blocked inboard .125" with OE retainer. Replace with Sonnax Part No. 47740-26K Requires F-47740-TL26 & VB-FIX Reverse Sequence Valve • Delayed Reverse engagement • Low Reverse pressure • Burnt B2 or B3 brake C1 Accumulator Piston Test: Test this port with valve blocked outboard .125" with OE retainer and sealing port on back with thumb. Test: Test each port with valve blocked outboard .125" with OE retainer. • Converter apply/release complaints • Converter codes • Overheated transmission Lockup Relay Valve Lockup Control Boost Assembly • Converter apply/release complaints • Converter codes; P2757 • Overheated transmission Replace with Sonnax Part No. 47740-06K* Lockup Control Valve • Converter apply/release complaints • Converter codes; P2757 • Overheated transmission Replace with Sonnax Part No. 47740-30K Requires F-47740-TL30 & VB-FIX End Plugs • Loss of critical line & SLT pressures • Shift complaints • Burnt clutches & brakes Replace with Sonnax Part No. 47740-21K* NOTE: Several Locations = *Items with an asterisk (*) are included in this Zip Kit. 10-26-17 U660E-ZIP-Booklet Page 4 ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Toyota/Lexus U660E, U660F 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. B1 Apply Boost Assembly • 1-2 & 5-6 shift complaints • Burnt B1 brake Middle Valve Body • Lower Side Replace with Sonnax Part No. 47740-19K* B1 Apply Control Valve • 1-2 & 5-6 shift complaints • Burnt B1 brake Test: Block this port and port on back when testing. Note: Seal port on back when testing. Primary Pressure Regulator Valve Note: Seal port on back when testing. • High/Low line pressure • Harsh/Soft shifts • Burnt clutches/brakes Replace with Sonnax Part No. 47740-02K Requires F-47740-TL2 & VB-FIX Sequence Valve • Shift complaints • Burnt clutches/brakes Test: Test this port with valve blocked inboard .218" dia. checkball. Clutch Control Valve • 4-5 Flare/Harsh • Delayed Reverse Replace with Sonnax Part No. 47740-22K Requires F-47740-TL22 & VB-FIX C2 Clutch Apply Control Valve Note: Seal port on back when testing. • Slipping 4th, 5th, 6th gear • Burnt C2 clutch B2 Apply Control Valve • Delayed Reverse engagement • Burnt B2 brake Replace with Sonnax Part No. 47740-27K Requires F-47740-TL27 & VB-FIX Middle Valve Body • Upper Side B2 Control Valve • Delayed Reverse engagement • Burnt B2 brake Note: Seal when testing B1 apply control valve. Solenoid Modulator Valve* Note: Seal when testing B1 apply boost assembly. • Shift complaints • Solenoid codes • TCC clip • Loss of control pressures Replace with Sonnax Part No. 47740-24K Requires F-47740-TL24 & VB-FIX Note: Seal when testing pressure regulator valve. Reverse Boost Assembly • Delayed Reverse • Low line pressure in Reverse • Burnt B2 & B3 brakes Replace with Sonnax Part No. 47740-17K* Note: Seal when testing B2 apply control valve. *Items with an asterisk (*) are included in this Zip Kit. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com U660E-ZIP-Booklet 10-26-17 Page 5 TIME TESTED • INDUSTRY TRUSTED Toyota/Lexus U660E, U660F ZIP KIT® Installation & Testing Booklet OE Exploded View Upper Valve Body NOTE: Depending upon vehicle application, the OE springs shown may not be present. Upper Valve Body Descriptions I.D. No. Description 101 Lockup Control Valve (inboard) Lockup Control Boost Assembly (outboard) 102 Lockup Relay Valve 103 Reverse Sequence Valve 104 Secondary Pressure Regulator Valve 105 B3 Accumulator Piston 106 B1 Accumulator Piston 107 B2 Accumulator Piston 108 C1 Accumulator Piston 109 C2 Accumulator Piston 110 Lube Relief Check Valve 111 Converter Relief Check Valve 108 107 106 .218" dia. Checkball 105 104 109 .393" dia. Checkball .218" dia. Checkball 103 102 101 110 111 10-26-17 U660E-ZIP-Booklet Page 6 ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Toyota/Lexus U660E, U660F ZIP KIT® Installation & Testing Booklet TIME TESTED • INDUSTRY TRUSTED Middle Valve Body .393" dia. Checkballs Filter 201 202 .218" dia. Checkball 203 204 .393" dia. Checkballs Filter 205 206 207 208 209 Upper Valve Body Descriptions I.D. No. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Description 201 B1 Apply Control Valve (inboard) B1 Apply Boost Assembly (outboard) 202 Primary Pressure Regulator Valve (inboard) Reverse Boost Assembly (outboard) 203 Sequence Valve 204 Clutch Control Valve 205 C2 Clutch Apply Control Valve 206 B2 Apply Control Relay Valve (inboard) B2 Apply Control Valve (outboard) 207 B2 Control Valve (inboard) B2 Control Relay Valve (outboard) 208 Manual Valve 209 Solenoid Modulator Valve U660E-ZIP-Booklet 10-26-17 Page 7 Toyota/Lexus U660E, U660F ZIP KIT® TIME TESTED • INDUSTRY TRUSTED Installation & Testing Booklet Additional Technical Tips for Installation Steps 3, 4 & 10 from the Quick Guide Narrow Bore Length Figure 10 Large Outer Chamfer Retainer Port Sharp Edge End Plug Location Modified Edge Modified End Plug Location Figure 11 Retainer Middle Setting Tri-Lobed End Plug Narrow Setting Two OE Solenoid Modulator End Plug Variations End Plugs The large outer chamfer on the small end plug bores makes the outer bore too narrow for an O-ring to seal properly. The Sonnax O-ringed end plugs require the O-ring to seal at the bore inboard of the retainer port. To prevent O-ring shear during assembly, the sharp edge must be broken. This can be done by inserting a narrow file or small screwdriver through the retainer port and reworking the edge (Figure 10). To install the O-ringed end plug after the edge has been modified, place the O-ring in the narrow plug groove. Lubricate the plug and O-ring with O-Lube and roll on bench to size. Carefully push the plug into the bore. As the O-ring contacts the modified edge, gently compress the exposed portion with a small screwdriver blade inserted through the retainer port. Step 4 Replace OE Solenoid Wide Setting Two Spooled End Plug Step 3 Replace OE Small OE Tri-Lobed End Plug Figure 12 Selective Shims Modulator Valve Lineup During disassembly of OE solenoid modulator lineup, note location of the tri-lobed end plug (if applicable) retainer (Figure 11). This adjusts solenoid modulator pressure. Follow options A–D if a tri-lobed end plug is used. If a standard two-spooled end plug is used, proceed to option E. Option A: If OE retainer is installed at the most narrow location, no Sonnax shims are required. Option B: If OE retainer is installed at the middle spool location, one Sonnax shim is required. Solenoid Modulator Valve Lineup Option C: If OE retainer is installed at the widest spool location, two Sonnax shims are required. Replace with Sonnax Small O-Ring Case Connector & Internal Wire Harness Assembly Replace with Sonnax Large O-Ring Page 8 should be placed over valve spring stem, between valve spool face and spring (Figure 12). NOTE: Sonnax end plug can be swapped end for end for best fit of sleeve in bore. Option E: For standard two-spooled OE plug, do not use any shims. Install as pictured (Figure 12), omitting the shims. Step 10 Replace OE O-Rings on Pressure Switch & TFT Sensor Assembly 10-26-17 U660E-ZIP-Booklet Option D: Shims Figure 13 Case Connector & Fluid Temperature Sensor Replace the O-rings in the case connector and internal wire harness assembly, as well as in the pressure switch and TFT sensor assembly as shown in these locations (Figure 13). ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
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