U760E ZIP IN

2016-04-29

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TOYOTA/LEXUS U660E,
U760E, U660F
U760F
®
®
ZIP KIT
PART NUMBER U660E-ZIP
U760E-ZIP

IDENTIFICATION GUIDE

Valve Body Identifi
cation Guide
Identification
U760E

U660E, U660F

Upper Valve Body Casting

Upper Valve Body Casting
Extended Exhaust
Groove

Small Exhaust Groove

U660 Casting Number

No Transmission
Designation

Solenoid Casting

Solenoid Casting
Smaller Solenoid
Casting Boss

U660 Casting Number

No Casting Number
No Pressure
Switch Plate
Casting
Cutouts

©2016
©2016 Sonnax
Sonnax Industries,
Industries, Inc.
Inc.
800-843-2600
•
800-843-2600 • 802-463-9722
802-463-9722 •• F:
F: 802-463-4059
802-463-4059 •• www.sonnax.com
www.sonnax.com

Larger Solenoid
Casting Boss

Flat
Casting

Pressure
Switch Plate

U660E-ZIP-Identify.indd
04-29-16
U760E-ZIP-Identify 04-29-16

TOYOTA/LEXUS U760E, U760F
ZIP KIT ®
PART NUMBER U760E-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
U760E Shown

Solenoid modulator
valve balance port.
Solenoid modulator
valve balance orifice.
Drill with .062" bit. Insert
.062" aluminum plug into
orifice and peen shut.

3
2
9

Upper Valve Body
U760E Shown

6
5

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

U760E-ZIP-Guide 04-29-16
Page 1

Toyota/Lexus U760E, U760F 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
CAUTION details.

NOTE: See pages 6 & 7 in installation and testing booklet for locations.
Packaging Pocket 9

• Checkballs, .218" dia. (2)

Packaging Pocket 3

• End Plugs, Small (6)

• O-Rings, Small (9)

3 extra

Step 4 Replace OE Solenoid
Modulator Valve LineUp
CAUTION! Note location of OE retainer on tri-lobed OE end
plug, if applicable. See page 8 of installation and testing
CAUTION booklet for assembly details.
Packaging Pocket 4

• Valve

• Sleeve

• Spring

• End Plug

• Shims (2)

Step 10 R
eplace OE O-Rings on
Case Connector
NOTE: See page 8 in installation and testing booklet for locations.
Packaging Pocket 10

• Case Connector O-Ring, Large

Step 11 D
rill & Plug Separator
Plate Balance Orifice at
Solenoid Modulator Valve

Step 5 Replace OE Lockup
Control Boost Assembly

To prevent solenoid modulator leakage, drill indicated orifice to .062".
Plug with aluminum plug and peen in place.

Packaging Pocket 5

• Orifice Plugs, .062" dia. (2)
• Drill Bit, .062" dia.

• Sleeve

• Valve

Step

CAUTION

Packaging Pocket 11
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

U760E-ZIP-Guide 04-29-16
Page 2

Toyota/Lexus U760E, U760F
ZIP KIT ®
PART NUMBER U760E-ZIP

INSTALLATION & TESTING BOOKLET

TCM Initialized/Memory Reset
The U760E and U760F 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. This TCM was eliminated
on 2012-later models; there is now a pass-through connector that links the transmission connector to the PCM, which also controls the engine.
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.
©2016 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.
U760E-ZIP-Booklet 04-29-16
Page 1

Toyota/Lexus U760E, U760F ZIP KIT®

TIME TESTED • INDUSTRY TRUSTED

Installation & Testing Booklet
Figure 3

Solenoid Energized

Clutch & Brake Application
Selector Position

When selector position in manually operated.

SL2

SL3

SL4

SLU

SLT

P-Park
R-Reverse

X
X

D, S6-2nd

D, S6-3rd

D, S6-4th

X
X
X

D, S6-5th

D, S6-6th

X
X

X
X
X

X
X

N-Neutral

D, S6-1st

S1-1st/Manual

SL1

Zip Kit Instructions

Removal Bolts

1. Valve Body Removal
a. With valve body still in transmission, remove 11 indicated bolts (Figure 4).
b. Remove case connector and internal wire harness assembly from 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 eight indicated bolts (Figure 8), solenoid brackets, solenoids, small
and large cover plate.

Bolt Color
Code

Bolt
Length

Red

25mm

Green

30mm

Blue

35mm

Yellow

45mm

Torque all to 8 ft-lbs

Case connector and internal
wire harness assembly.

Figure 4

D
B

d. Remove remaining eight bolts (Figure 9).

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 eight indicated bolts (Figure 9).
b. Reinstall solenoid brackets, solenoids, small and large cover plate and eight
bolts (Figure 8).
c. Reinstall case connector assembly retaining bracket, bolt and connector/harness
assembly (Figure 6). Attach wire harness from bracket and connect to all seven
solenoids.

e. When reinstalling valve body, first temporarily
tighten the two bolts marked () in Figure 4 as
they are positioning bolts.

d. Connect and reinstall counter gear/turbine speed sensor and valve body bolts
(Figure 5).

04-29-16 U760E-ZIP-Booklet
Page 2

Toyota/Lexus U760E, U760F ZIP KIT®

Installation & Testing Booklet

Connector/Harness
Assembly

Figure 5

Figure 6
Release

A
F
A

A
E

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)

(Red &
Black Wires)

TIME TESTED • INDUSTRY TRUSTED

Disassembly &
Reassembly Bolts
Bolt Color
Code

Bolt
Length

Green

16mm

Purple

35.5mm

Yellow

50mm

Dk Blue

60mm

Orange

70mm

Teal

75mm

Brown

80mm

Torque all to 8 ft-lbs
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)

SLT Solenoid
Line Pressure
5.0–5.6 ohm
(Grey &
Black Wires)

(Green &
Black Wires)

SL Solenoid
• Lockup Relay Valve
• B2 Brake Clutch
Apply Control Valve
• Reverse Sequence
Valve
11–15 ohm

(1 Blue Wire)

CAUTION!: Do not interchange solenoids. If SLU and
SLT are interchanged, this will cause both line and TCC
CAUTION apply issues. SLT has five slots, SLU has four slots.

All solenoid resistance values at 20oC/68oF.

Figure 8

Figure 9
C

A
G
B

G
G

G
C

U760E-ZIP-Booklet 04-29-16
Page 3

TIME TESTED • INDUSTRY TRUSTED

Toyota/Lexus U760E, U760F 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 • U760E Shown

B2 Accumulator Piston
• Harsh Reverse engagement
• Burnt B2 brake

B1 Accumulator Piston
• Harsh 1-2 or 5-6 shift
• Burnt B1 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*

B3 Accumulator Piston
C2 Accumulator Piston

• Harsh Reverse engagement
• Harsh 2-3 or 4-5 shift
• Burnt B3 brake

• Harsh 3-4 shift
• Burnt C2 clutch

Replace with Sonnax Part No.
47740-11K*



Replace with Sonnax Part No.
47740-11K*

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

Reverse Sequence
Valve

• Loss of critical line & SLT pressures
• Shift complaints
• Burnt clutches & brakes



Test: Test this port with valve blocked
outboard .125" with OE retainer and sealing
port on back with thumb.



• Converter apply/release complaints
• Converter codes; P0741
• Overheated transmission

End Plugs

Replace with Sonnax Part No.
47740-21K*
NOTE: Several Locations =

• Delayed Reverse engagement
• Low Reverse pressure
• Burnt B2 or B3 brake

Lockup Relay Valve

Test: Test this port with valve blocked
inboard .125" with OE retainer.

Lockup Control Boost
Assembly
• Converter apply/release complaints
• Converter codes; P2757, P0741
• Overheated transmission
Replace with Sonnax Part No.
47740-06K*

Test: Test each port with valve blocked
outboard .125" with OE retainer.

Lockup Control Valve
• Converter apply/release complaints
• Converter codes; P2757, P0741
• Overheated transmission
Replace with Sonnax Part No.
47740-30K Requires F-47740-TL30 & VB-FIX

*Items with an asterisk (*) are included in this Zip Kit.
04-29-16 U760E-ZIP-Booklet
Page 4

Toyota/Lexus U760E, U760F 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.

B1 Apply Boost Assembly

Middle Valve Body – Lower Side
U760E Shown

• 1-2 & 5-6 Shift complaints
• Burnt B1 brake
Replace with Sonnax Part No.
47740-40K*
Test: Block this port and
port on back when testing.

B1 Apply Control Valve
• 1-2 & 5-6 Shift complaints
• Burnt B1 Brake

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

Test: Test this port
with valve blocked
inboard .218" dia.
checkball.

Replace with Sonnax Part No.
47740-02K Requires F-47740-TL2 & VB-FIX

Sequence Valve
• Shift complaints
• Burnt clutches/brakes



B2 Apply
Control Valve

Note: Seal port on
back when testing.**

• Delayed Reverse engagement
• Burnt B2 brake
Replace with Sonnax Part No.
47740-27K Requires F-47740-TL27 & VB-FIX

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
• Slipping 4th, 5th, 6th gear
• Burnt C2 clutch
Test: Test this port and port on back
when testing B2 Apply Control Valve.**

Middle Valve Body – Back Side
U760E Shown

B2 Control Valve

Note: Seal when
testing B1 apply
control valve.

• Delayed Reverse engagement
• Burnt B2 brake
Replace with Sonnax Part No.
47740-35K Requires F-47740-TL35 & VB-FIX

Note: Seal when
testing B1 apply
boost assembly.

Solenoid Modulator
Valve

Note: Seal when
testing pressure
regulator valve.

• Shift complaints • Solenoid codes
• TCC slip • Loss of control pressures
Replace with Sonnax Part No.
47740-25K Requires F-47740-TL24 & VB-FIX

** These two passages are connected. The mat
will provide the seal for the Middle Valve Body,
Upper side. The passage indicated (**) will also
need to be sealed to Vacuum test the circuit.

Reverse Boost
Assembly
• Delayed Reverse
• Low line pressure in Reverse
• Burnt B2 & B3 brakes

Note: Seal when
testing B2 apply
control valve.**

Replace with Sonnax Part No.
47740-38K*

*Items with an asterisk (*) are included in this Zip Kit.
©2016 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

U760E-ZIP-Booklet 04-29-16
Page 5

TIME TESTED • INDUSTRY TRUSTED

Toyota/Lexus U760E, U760F ZIP KIT®

Installation & Testing Booklet

OE Exploded View
Upper Valve Body • U760E Shown
NOTE: Depending upon vehicle application, the OE springs shown may not be present.

111
110
101
102
103
.393" dia. Checkballs
.218" dia. Checkball

104

105
109
Plastic Check Valve

Upper Valve Body Descriptions

I.D. No.
106
107

108

04-29-16 U760E-ZIP-Booklet
Page 6

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 U760E, U760F ZIP KIT®

Installation & Testing Booklet

TIME TESTED • INDUSTRY TRUSTED

Middle Valve Body • U760E Shown

.393" dia.
Checkballs

201

Filter

202

Line Pressure
Blow-Off
Checkvalve
& Spring

203
.218" dia.
Checkball

204
.393" dia. Checkballs

205
Filter

206

207
208

209

Middle 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

U760E-ZIP-Booklet 04-29-16
Page 7

Toyota/Lexus U760E, U760F 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

Step 3 Replace OE Small

Figure 10

Large Outer Chamfer

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. 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).

Retainer Port
Sharp Edge

End Plug Location

Modified Edge

Modified End Plug Location
Figure 11

Retainer

B. 1 Shim

C. 2 Shims

To install O-ringed end plug after the edge has been
modified, place O-ring in the narrow plug groove.
Lubricate plug and O-ring with O-Lube and roll on
bench to size. Carefully push plug into the bore. As
O-ring contacts the modified edge, gently compress
exposed portion with a small screwdriver blade inserted
through retainer port.

Step 4 Replace OE Solenoid
Modulator Valve Lineup

A. No Shims

OE Solenoid Modulator Lineup

OE Tri-Lobed End Plug

Sonnax
Selective Shims

Figure 12

During disassembly of OE solenoid modulator lineup, note location of the tri-lobed
end plug (if applicable) retainer (Figure 11).
CAUTION
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
Sonnax Solenoid Modulator Valve Kit

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
Figure 13

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.

NOTE: Sonnax end plug can be swapped end for end for
best fit of sleeve in bore.
Replace with
Sonnax Large
O-Ring

04-29-16 U760E-ZIP-Booklet
Page 8

Case Connector
& Internal Wire
Harness Assembly

Step 10 Replace OE O-Ring on
Case Connector
Replace O-ring in the case connector and internal wire harness
assembly (Figure 13).
©2016 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

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