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
©2017 Sonnax Industries, Inc. U660E-ZIP-Identify 10-26-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
Valve Body Identication Guide
U760E
Upper Valve Body Casting
U660E, U660F
Upper Valve Body Casting
No Transmission
Designation
Small Exhaust Groove
U660 Casting Number
(may be seen here)
Extended Exhaust
Groove
Solenoid Casting
No Casting Number
Smaller Solenoid
Casting Boss
Casting
Cutouts
No Pressure
Switch Plate
Solenoid Casting
U660 Casting Number
Larger Solenoid
Casting Boss
Flat
Casting
Pressure
Switch Plate
NOTE: Large canister solenoid connectors
are brown and black.
NOTE: Large canister solenoid connectors
are brown and white.
PART NUMBER U660E-ZIP QUICK GUIDE
1
2
5
6
7
Middle Valve Body
Upper Valve Body
3
4
8
8
3
8
10
9
11
Solenoid modulator
balance orice. Drill
with .062" bit. Insert .062"
aluminum plug into orice
and peen shut.
Solenoid modulator
balance port.
©2017 Sonnax Industries, Inc. U660E-ZIP-Guide 10-26-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
TOYOTA/LEXUS U660E, U660F
ZIP KIT®
Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents.
installation Diagram
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.
Toyota/Lexus U660E, U660F ZIP KIT® Quick Guide
Step Replace OE B1 Apply
Boost Assembly
Packaging Pocket 1
• Sleeve • Valve
Step Replace OE Reverse
Boost Assembly
Packaging Pocket 2
• Sleeve • Valve
Step
Replace OE Small End Plugs
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.
Packaging Pocket 3
• End Plugs, Small (6) • O-Rings, Small (9) 3 extra
Step 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.
Packaging Pocket 4
• Valve  Sleeve  Spring • End Plug  Shims (2)
Step Replace OE Lockup
Control Boost Assembly
Packaging Pocket 5
• Sleeve • Valve
Step 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
1
2
3
4
5
6
Step Replace OE (Short)
C1 Accumulator Piston
Packaging Pocket 7
• Accumulator Piston • O-Rings (2) 1 extra
Step
Replace OE (Long) B1, B2,
B3 & C2 Accumulator Pistons
Packaging Pocket 8
• Accumulator Pistons (4) • O-Rings (6) 2 extra
Step Replace OE Checkballs
NOTE: See pages 6 & 7 in installation and testing booklet for locations.
Packaging Pocket 9
• Checkballs (3)
Step Replace 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
Step Drill & Plug Separator
Plate Balance Orice at
Solenoid Modulator Valve
To prevent solenoid modulator leakage, drill indicated orice to .062".
Plug with aluminum plug and peen in place.
Packaging Pocket 11
• Orifice Plugs, .062" dia. (2) 1 extra
• Drill Bit, .062" dia.
7
8
9
10
11
Zip Kit Contents & Installation Steps
©2017 Sonnax Industries, Inc. U660E-ZIP-Guide 10-26-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2
TCM Initialized/Memory Reset
e U660E TCM learns the performance of the vehicle and adapts the transmission accordingly. When signicant 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. ese procedures
require use of Toyota’s Techstream scan tool or their PC-based version of the scan tool, Techstream lite.
Input Transaxle Compensation Code
e transaxle compensation code is a unique, 60-digit alphanu-
meric 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
is 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 o.
3. Connect Techstrean to the DLC3.
4. Turn ignition switch on and push Techstream main switch on.
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
is procedure resets the TCM memory so it can memorize new
performance information.
1. Turn the ignition switch o.
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 conrm reset.
Figure 1 Automatic Transaxle Parts Replacement Chart
Replaced Parts
Transaxle
Compensation
Code
Road Test Memory
(Learned Values)
Automatic Transaxle
Assembly Input Reset
Valve Body Assembly Initialize Necessary Reset
Shift Solenoid Valve
SL1 and/or SL2 Necessary
Shift Solenoid Valve
SL3 and/or SL4 Initialize Necessary Reset
TCM* - Possible Input
(into the new TCM)
TCM* - Impossible Necessary
* Note: If possible, read the transaxle compensation code from the previous TCM.
Figure 2
TCM/ECU
Location
QR Code Label
with Transaxle
Compensation
Code
Toyota/Lexus U660E, U660F
ZIP KIT®
PART NUMBER U660E-ZIP INSTALLATION & TESTING BOOKLET
©2017 Sonnax Industries, Inc. U660E-ZIP-Booklet 10-26-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
Toyota/Lexus U660E, U660F ZIP KIT® Installation & Testing Booklet
10-26-17 U660E-ZIP-Booklet ©2017 Sonnax Industries, Inc.
Page 2 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
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 trans-
mission 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.
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.
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.
Sonnax recommends vacuum testing critical wear areas not covered by this kit to
determine whether additional Sonnax parts are required (see pages 4–5).
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.
Clutch & Brake Application Solenoid Energized
When selector position in manually operated.
Selector Position C1 C2 B1 B2 B3 F1 SL1 SL2 SL3 SL4 SLU SLT SL
P-Park X X
R-Reverse X X X X
N-Neutral X X
D, S6-1st
X X X X
D, S6-2nd
X X X X X
D, S6-3rd
X X X X X
D, S6-4th
X X X X X
D, S6-5th
X X X X X
D, S6-6th
X X X X X
S1-1st/Manual X X X
Figure 3
e. Connect and reinstall counter gear/turbine speed
sensor and valve body bolts (Figure 5).
f. When reinstalling the valve body, rst temporar-
ily tighten the two bolts marked () in Figure 4
as they are positioning bolts.
E
B
A
C
D
BBBB
B
B
Figure 4
Case connector and internal
wire harness assembly.
Removal Bolts
Bolt Color
Code
Bolt
Length
ARed 25mm
BGreen 30mm
CBlue 35mm
DYellow 45mm
EPink 55mm
Torque all to 8 ft-lbs
Toyota/Lexus U660E, U660F ZIP KIT® Installation & Testing Booklet
©2017 Sonnax Industries, Inc. U660E-ZIP-Booklet 10-26-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3
Disassembly &
Reassembly Bolts
Bolt Color
Code
Bolt
Length
ARed 15.5mm
BGreen 16mm
CLt Blue 25mm
DYellow 50mm
EPink 55mm
FDk Blue 60mm
GOrange 70mm
HTeal 75mm
IBrown 80mm
JPurple 85mm
Torque all to 8 ft-lbs
Figure 6
Connector/Harness
Assembly
H
Release
Figure 5
D
D
G
Counter Gear/Turbine
Speed Sensor
Disconnect Turbine Speed Sensor
Figure 8
F
I
B
E
I
I
I
I
Figure 9
D
D
D
E
E
E
C
G
Line pressure relief spring and ball.
All solenoid resistance values at 20C/68F.
C
J
Figure 7
SL4 Solenoid
(PCSD)
B3 Brake
5.0–5.6 ohm
(Green &
Black Wires)
SL3 Solenoid
(PCSC)
B1 Brake
5.0–5.6 ohm
(Blue &
Black Wires)
SL1 Solenoid
(PCSA)
C1 Clutch
5.0–5.6 ohm
(Pink &
Black Wires)
SL2 Solenoid
(PCSB)
C2 Clutch
5.0–5.6 ohm
(Orange &
Black Wires)
SLU Solenoid
TCC & B2 Brake
5.0–5.6 ohm
(White &
Black Wires) SLT Solenoid
Line Pressure
5.0–5.6 ohm
(Grey &
Black Wires)
SL Solenoid
• Lockup Relay Valve
• B2 Brake Clutch
Apply Control Valve
• Reverse Sequence
Valve
11–15 ohm
(1 Blue Wire)
Pressure Switch &
TFT Sensor Assembly
J
J
CAUTION!: Do not interchange solenoids. If SLU and
SLT are interchanged, this will cause both line and TCC
apply issues. SLT has ve slots, SLU has four slots.
Toyota/Lexus U660E, U660F ZIP KIT® Installation & Testing Booklet
10-26-17 U660E-ZIP-Booklet ©2017 Sonnax Industries, Inc.
Page 4 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
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.
*Items with an asterisk (*) are included in this Zip Kit.
B3 Accumulator Piston
• Harsh Reverse engagement
• Harsh 2-3 or 4-5 shift
• Burnt B3 brake
Replace with Sonnax Part No.
47740-11K*
Lockup Relay Valve
• Converter apply/release complaints
• Converter codes
• Overheated transmission
B2 Accumulator Piston
• Harsh Reverse engagement
• Burnt B2 brake
Replace with Sonnax Part No.
47740-11K* C1 Accumulator Piston
• Harsh/Delayed Forward
engagement
• Burnt C1 clutch
Replace with Sonnax Part No.
47740-12K*
C2 Accumulator Piston
• Harsh 3-4 shift
• Burnt C2 clutch
Replace with Sonnax Part No.
47740-11K*
Reverse Sequence
Valve
• Delayed Reverse engagement
• Low Reverse pressure
• Burnt B2 or B3 brake
Lockup Control Boost
Assembly
• Converter apply/release complaints
• Converter codes; P2757
• Overheated transmission
Replace with Sonnax Part No.
47740-06K*
Test: Test this port
with valve blocked
inboard .125" with
OE retainer.
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.
Upper Valve Body
Secondary Pressure
Regulator Valve
• Overheated transmission
• Bushing/Bearing failures
• Lube-related failures
Replace with Sonnax Part No.
47740-26K Requires F-47740-TL26 & 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 =
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
B1 Accumulator Piston
• Harsh 1-2 or 5-6 shift
• Burnt B1 brake
Replace with Sonnax Part No.
47740-11K*
Toyota/Lexus U660E, U660F ZIP KIT® Installation & Testing Booklet
©2017 Sonnax Industries, Inc. U660E-ZIP-Booklet 10-26-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5
For specic vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.
20
25
15
0
10
5
30
VACUUM
TEST
Middle Valve Body
• Upper Side
Middle Valve Body • Lower Side
Note: Seal when
testing B2 apply
control valve.
Note: Seal when
testing pressure
regulator valve.
Note: Seal when
testing B1 apply
control valve.
Note: Seal when
testing B1 apply
boost assembly.
Reverse Boost
Assembly
• Delayed Reverse
• Low line pressure in Reverse
• Burnt B2 & B3 brakes
Replace with Sonnax Part No.
47740-17K*
B1 Apply Control Valve
• 1-2 & 5-6 shift complaints
• Burnt B1 brake
Note: Seal port on
back when testing.
Test: Block this port
and port on back
when testing.
B1 Apply Boost Assembly
• 1-2 & 5-6 shift complaints
• Burnt B1 brake
Replace with Sonnax Part No.
47740-19K*
Test: Test this port
with valve blocked
inboard .218" dia.
checkball.
Primary Pressure
Regulator Valve
• High/Low line pressure
• Harsh/Soft shifts
• Burnt clutches/brakes
Replace with Sonnax Part No.
47740-02K Requires F-47740-TL2 & VB-FIX
Note: Seal
port on back
when testing.
Sequence Valve
• Shift complaints
• Burnt clutches/brakes
Note: Seal port on
back when testing.
B2 Apply Control Valve
• Delayed Reverse engagement
• Burnt B2 brake
Replace with Sonnax Part No.
47740-27K Requires F-47740-TL27 & VB-FIX
Solenoid Modulator
Valve*
• Shift complaints • Solenoid codes
• TCC clip • Loss of control pressures
Replace with Sonnax Part No.
47740-24K Requires F-47740-TL24 & VB-FIX
*Items with an asterisk (*) are included in this Zip Kit.
B2 Control Valve
• Delayed Reverse engagement
• Burnt B2 brake
C2 Clutch Apply
Control Valve
• Slipping 4th, 5th, 6th gear
• Burnt C2 clutch
Clutch Control Valve
• 4-5 Flare/Harsh
• Delayed Reverse
Replace with Sonnax Part No.
47740-22K
Requires F-47740-TL22 & VB-FIX
Toyota/Lexus U660E, U660F ZIP KIT® Installation & Testing Booklet
10-26-17 U660E-ZIP-Booklet ©2017 Sonnax Industries, Inc.
Page 6 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
108
107
106
109
105
104
111
110
103
102
101
.393" dia. Checkball
.218" dia. Checkball
.218" dia. Checkball
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
Toyota/Lexus U660E, U660F ZIP KIT® Installation & Testing Booklet
©2017 Sonnax Industries, Inc. U660E-ZIP-Booklet 10-26-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 7
209
.393" dia.
Checkballs
208
207
206
205
204
203
202
201
Filter
Filter
.218" dia.
Checkball
.393" dia. Checkballs
Middle Valve Body
Upper Valve Body Descriptions
I.D. No. 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
Toyota/Lexus U660E, U660F ZIP KIT® Installation & Testing Booklet
10-26-17 U660E-ZIP-Booklet ©2017 Sonnax Industries, Inc.
Page 8 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
Step
Replace OE Small
End Plugs
e large outer chamfer on the small end plug bores
makes the outer bore too narrow for an O-ring to seal
properly. e 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. is can be done by inserting
a narrow le 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
modied, 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 modied edge, gently
compress the exposed portion with a small screwdriver
blade inserted through the retainer port.
Step Replace OE Solenoid
Modulator Valve Lineup
During disassembly of OE solenoid modulator
lineup, note location of the tri-lobed end plug
(if applicable) retainer (Figure 11). is 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.
Option C: If OE retainer is installed at the widest spool
location, two Sonnax shims are required.
Option D: Shims should be placed over valve spring
stem, between valve spool face and spring
(Figure 12).
Option E: For standard two-spooled OE plug, do not
use any shims. Install as pictured (Figure 12),
omitting the shims.
Step Replace OE O-Rings on
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).
3
4
10
Additional Technical Tips for Installation Steps 3, 4 & 10
from the Quick Guide
Figure 10
Narrow Bore Length Large Outer Chamfer
Retainer Port
Sharp Edge Modified Edge
End Plug Location Modied End Plug Location
Figure 13
Replace with
Sonnax Small
O-Ring
Replace with
Sonnax Large
O-Ring
Case
Connector
& Internal
Wire
Harness
Assembly
Pressure Switch
& TFT Sensor
Assembly
Figure 11
Middle
Setting
Wide
Setting
Two OE Solenoid Modulator
End Plug Variations OE Tri-Lobed End Plug
Retainer
Tri-Lobed
End Plug
Two
Spooled
End Plug
Narrow Setting
Figure 12
Solenoid Modulator Valve Lineup
Selective Shims
NOTE: Sonnax end
plug can be swapped
end for end for best
t of sleeve in bore.

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