ZF8 ZIP IN

2017-11-14

: Sonnax Zf8-Zip-In ZF8-ZIP-IN 4590 instructions part uploads

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ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT ®
PART NUMBER ZF8-ZIP

QUICK GUIDE

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

installation Diagram
ZF8HP45 Upper
Valve Body

ZF8HP45 Lower
Valve Body
2
3

1
3
4
4

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

ZF8-ZIP-Guide 11-14-17
Page 1

ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT®

Quick Guide

Zip Kit Contents & Installation Steps
Step 1 Replace OE Pressure
Regulator Sleeve

Step 5 R
eplace OE Accumulator
Pistons

Packaging Pocket 1

Packaging Pocket 5

• Sleeve

• Accumulator Pistons (7)
• Matching Springs (7)

Step 2 Replace OE Priming Valve
Place scarf-cut seal into shallow groove on valve. Rolling the seal into
a smaller diameter before placing the seal in the groove will help to
keep the seal surface below the valve diameter, allowing for easier
installation. Lubricate seal with Sonnax slippery stick O-LUBE.

NOTE: Due to the design changes on the Sonnax valve,

vacuum testing at the two inboard ports is not a valid

sealing test. The Sonnax valve requires balance fluid to

travel through the valve and push the seal outward to
conform to the worn bore.
Packaging Pocket 2

• Valve
• Seal

Step 6 R
eplace OE Solenoid
O-Rings
Packaging Pocket 6

• O-Rings, (8)

1 Extra

Packaging Pocket 7

• O-Ring (2)

1 Extra

Packaging Pocket 8

• O-Rings, (7)

1 Extra

Packaging Pocket 9

Step 3 Replace Internal
OE End Plugs
Place O-rings into shallow grooves on end plugs. Lubricate with Sonnax
slippery stick O-LUBE. Roll on bench to size. For installation or removal
ease, install with threaded end outboard.

• O-Ring, (2)

1 Extra

Packaging Pocket 10

• O-Rings, (5)

1 Extra

For Outboard White & Orange Solenoids
13.75 x 2mm thick
For Inboard Brown Solenoid
17 x 1.5mm thick
For Inboard Orange Solenoids
18 x 2mm thick
For Outboard Brown Solenoid
17 x 1.5mm thick
For Inboard White Solenoids
18.25 x 2mm thick

Packaging Pocket 3

• Internal End Plugs (8)
• O-Rings (18) 2 Extra

Step 4 Replace OE End Plugs
Place O-rings into shallow groove on end plugs. Lubricate with Sonnax
slippery stick O-LUBE. Roll on bench to size. Install end plugs with small
stem outboard.
Packaging Pocket 4

• End Plugs (3)
• O-Rings (5) 2 Extra

NOTE: The parts listed here may be protected by patent 8,794,108.

ZF8-ZIP-Guide 11-14-17
Page 2

ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT ®
PART NUMBER ZF8-ZIP

Valve Body Identification

This Zip Kit ZF8-ZIP is designed for ZF8HP45, ZF8HP55 and ZF8HP70 units only.

Cautions

Torque Specifications
Mechatronic-to-Case
Torque or Valve Body
Halves Bolts 10Nm/89
in-lb

TECHNICAL BOOKLET

Complete Valve Bodyto-Case
14Nm/10 ft-lb

Plastic Oil Pan to Case
10Nm/89 in-lb

Clearance
Clutch clearance and material is critical (refer to OE
clutch travel specifications). These have fluid balanced
clutch pistons.

Fluid
Complete Fill Required
9.5 qt./8 ltr.

Service Fill Approx.
4.2 qt./4 ltr.

Chrysler Fluid
Mopar 6815795AA

ZF Fluid
ZF Lifeguard 8

Electronics
Do not use an ohm meter with more than .6 voltage supply. The TCM is capable
of limited solenoid adaptation without reprogramming. After any service, resetting
adapts is suggested. In many instances, solenoids can be replaced with new OE or
with qualified used. Original solenoids, if reused, should be returned to their same
location due to a learned flow rate by the TCM. Make every effort to avoid mixing
up the solenoids.
Check the solenoid resistance (5.0 ohms at 20°C/68°F) with the circuit board removed.

Technical Tips
Transmission Specifications & Reassembly Tips
The red tag on pan shows the fluid type Mopar 6815795AA (green) and that fluid
temperature must be 122°F to check the level. Dry fill is approximately 8.5 qts./8.0l
(Figure 1).

Drive-Cycle Relearn
Verify transmission fluid temp is 122°F, then perform 6–10
light throttle up and coast down shift cycles for partial relearn.
Figure 1

Zip Kit Instructions
1. Valve Body Removal from Case
a. Remove 14 bolts to drop valve body from case (Figure 2).

Fill & Check Plug

b. Remove 4 bolts and lift up metal bracket to release connector from TCM (Figure 3).
c. Remove connector from case (Figure 4).
d. Remove valve body from case. Note the location of B release tube in case under
valve body in case the tube comes out of its location when the valve body is
removed (Figure 5).
e. The valve body may have to pried down on the front end because of the
suction and output tubes (Figure 6)

Drain Plug

Figure 2
1

3
2

Figure 3

Figure 4

5
4

8
9

10
11
1

12
13

40 Torx Bolts

Lift up metal bracket
to release connector
from TCM.

4 OSS

Gently pull connector
out of the case.

ZF8-ZIP-Booklet 11-14-17
Page 1

ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT®

TIME TESTED • INDUSTRY TRUSTED

Figure 5

Technical Booklet

2. Valve Body Disassembly
a. Disconnect three TCM harness retaining bolts (Figure 7).

B Release Rubber
Feed Tube

b. Remove remaining five bolts to remove TCM from valve body
(Figure 8).
c. Gently pry TCM lifting up from valve body until removed
(Figures 9 & 10).
d. Remove 17 bolts to split valve body apart (Figure 11).
e. Pry valve body halves away from separator plate where indicated
(Figure 12).

Figure 6

NOTES: The separator plate has a bonded gasket which may
delaminate during disassembly (Figure 13). If any damage or
delamination to the gasket is present, a new separator plate
should be used.

These separator plates are specifically calibrated, requiring either the OE
valve body code or an identification number stamped on original plate
(Figures 13 & 14) for reorder. See Sonnax application chart for crossreference numbers (Figure 14).

Suction
Tube

Gently pry sides,
to lift up TCM from
valve body.

Output
Tube

Lift TCM Up

Figure 9

Figure 7

Remove three TCM harness retaining bolts.

ESD (Electro-Static
Discharge) WARNING!
Wear ground strap
when handling TCM.

Figure 8

Figure 10

2
1

Remove five remaining TCM harness retaining bolts.

11-14-17 ZF8-ZIP-Booklet
Page 2

TCM Removed

ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT®

Technical Booklet

3. Installation

Install Zip Kit parts as shown on diagram of separate quick guide
sheet included in this Zip Kit.

See identification and locations of replacement OE solenoids
(Figures 15 & 16).
Sonnax recommends vacuum testing critical wear areas not covered
by this kit to determine whether additional Sonnax parts are
required (see pages 4–7).

Figure 11

11
13

Remove 17 remaining bolts.
Figure 12

Figure 15

Pry valve body halves away from separator plate.

Figure 13

Solenoid Identification & Location Chart

Figure 16

Solenoid I.D.

MV-1

EDS-7
LP

EDS-2
TCC

EDS-5
C

EDS-4
E

EDS-3
B

EDS-6
D

EDS-1
A

Chrysler

SOL
Park

SOL
LPS

SOL
TCC

SOL
C

SOL
E

SOL
B

SOL
D

SOL
A

Valve Body Separator Plate Application Chart
OE Valve
Body Code

Number Stamped on
Original Plate

Order Sonnax
Part Number

A048/B048

1087-327-175

35740-048

A054/B054

1087-327-189

35740-054

A071/B071

1068-327-162

OE valve
body codes

Figure 14
Valve Body
Generation
ZF8HP45
&
ZF8HP70

OE valve
body part
number

Separator plate is same for ZF8HP45 & ZF8HP70.

ZF8-ZIP-Booklet 11-14-17
Page 3

TIME TESTED • INDUSTRY TRUSTED

ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT®

Technical 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.

0
30
VACUUM
TEST

Upper Valve Body • ZF8HP45 Shown
NOTE: Do not use this information for ZF8HP55
units as valve locations and porting differ. See
page 8 for ZF8HP55 information.

NOTE: Critical wear areas and vacuum test
locations shown for ZF8HP45 and ZF8HP70 only.

Holding Valve B2
• B Clutch failure
• 5-6 Flare

TC Pressure Valve
• TCC codes & overheating
• Harsh downshifts
Replace with Sonnax Part No.
35740-18K
Requires F-35740-TL5 & VB-FIX

B2 Clutch NIC Valve
• B Clutch burned
• Delayed/No Forward &
Reverse
• NIC (Neutral Idle Control)
concerns

End Plugs



Replace with Sonnax Part No.
35740-22
Requires F-35740-TL22 & VB-FIX

• Burnt clutches
• Harsh/Soft/Flare shifts
• Pressure loss
Replace with Sonnax Part No.
35740-30K
End Plugs (3) =
Internal End Plugs (8) =



Clutch Holding Valve



• Bump/Flare shifts
• Burnt clutches
• Gear ratio & solenoid codes
Replace with Sonnax Part No.
35740-20K
Requires F-35740-TL20 & VB-FIX

Position Valve
• Delayed Forward & Reverse
• Delayed engagement

Accumulator Pistons
• EDS codes
• Firm shifts
• Harsh engagement

Test with dampener
upside down and test
plate orifice off center
from rubber piston end

Replace with Sonnax Part No.
95740-15K Contains 7 sets
Patent No. 8,794,108

11-14-17 ZF8-ZIP-Booklet
Page 4

ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT®

Technical Booklet

Critical Wear Areas & Vacuum Test Locations

0
30
VACUUM
TEST

Lower Valve Body • ZF8HP45 Shown

NOTE: Critical wear areas and vacuum test
locations shown for ZF8HP45 and ZF8HP70 only.

TC Switch Valve

• Harsh/Erratic line pressure
• Restricted converter/lube flow

• No lockup
• Excess TCC slip
Replace with Sonnax Part
No. 35740-05
Requires F-35740-TL5 & VB-FIX

Test both
passages
together.

• Converter shudder & TCC slip
• TCC codes • Overheated converter
Replace with Sonnax Part No.
35740-13K
Requires F-35740-TL13 & VB-FIX

Clutch Valve B1



Replace with Sonnax Part No.
35740-03

TCC Valve



Pressure Regulator Sleeve

NOTE: Do not use this information for ZF8HP55
units as valve locations and porting differ. See
page 8 for ZF8HP55 information.

Close this passage on
the other side with
the palm of your hand.

• Slip on take off
• Gear ratio errors
• B Clutch failure

Pressure Regulator
Valve

Close port on
opposite side
when testing.

• Harsh/Soft shifts
• High line pressure
• Burnt clutches

Clutch Holding Valve
• Bump/Flare shifts
• Burnt clutches
• Gear ratio & solenoid codes

Replace with Sonnax Part No.
35740-01K
Requires F-35740-TL & VB-FIX

Park Pawl Release
Valve

Test both
passages
together.

Replace with Sonnax Part No.
35740-20K
Requires F-35740-TL20 & VB-FIX

Clutch Valve D

• Park will not release
• Park position errors

• Gear ratio errors 4-8th Gears
• Slips in Reverse
• D Clutch failure

Clutch Valve A
• Slip in Drive or Reverse
• Gear ratio errors
• A Clutch failure

Remove spring when
testing. Center valve
spool in opening.

• Harsh/Flare/Neutral shifts
• Gear ratio & solenoid codes
• Wrong gear starts

Clutch Valve C

Clutch Valve E

Replace with Sonnax Part No.
35740-21K
Requires F-35740-TL20 & VB-FIX

• Slip on take off
• Gear ratio codes
• C Clutch failure

• Slip on 1-2
• Gear ratio codes
• E Clutch failure








Priming Valve

End Plugs
• Burnt clutches
• Harsh/Soft/Flare shifts
• Pressure loss
Replace with Sonnax Part No.
35740-30K
End Plugs (3) =
Internal End Plugs (8) =





ZF8-ZIP-Booklet 11-14-17
Page 5

TIME TESTED • INDUSTRY TRUSTED

ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT®

Technical Booklet

OE Exploded View
Upper Valve Body • ZF8HP45 Shown
NOTE: Do not use this information for ZF8HP55
units as valve locations and porting differ. See
page 8 for ZF8HP55 information.

NOTE: Valve lineup locations shown
for ZF8HP45 and ZF8HP70 only.

101
105
102

103

106

104

Upper Valve Body Descriptions

I.D.
No.

11-14-17 ZF8-ZIP-Booklet
Page 6

Description

ZF
Chrysler
Valve Name Valve Name

101

Holding Valve B2

HV-B2

102

Clutch Valve B2 - B Clutch NIC
(Neutral Idle Control)

KV-B2

CV-B2

103

Holding Valve A

HV-A

104

Holding Valve D

HV-D

105

Torque Converter Pressure Valve

WD-V

TC-V

106

Position Valve (Outboard)
Default Position Valve (Inboard)

Pos-V,
PosD-V

ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT®

Technical Booklet

OE Exploded View
Lower Valve Body • ZF8HP45 Shown

201

NOTE: Valve lineup locations shown
for ZF8HP45 and ZF8HP70 only.

203
202

NOTE: Do not use this information for ZF8HP55
units as valve locations and porting differ. See
page 8 for ZF8HP55 information.

205
204
Lower Valve Body Descriptions

I.D.
Description
No.

ZF Valve
Name

Chrysler
Valve Name

SYS-DR-V

LP-V (Inboard)
RED-V (Outboard)

201

Main Pressure Regulator
Valve and Sleeve

202

Torque Converter Switch Valve

SV-WD

SV-TC

203

Torque Converter Clutch Valve

WK-V

TCC-V

204

Clutch Valve B1

KV-B1

CV-B1

205

Holding Valve B1

HV-B1

206

Priming Valve

DR-RED-V

PR-V

207

Park Pawl Release Valve

PS-V

Park-V

208

Holding Valve C

HV-C

209

Clutch Valve C

KV-C

CV-C

210

Clutch Valve E

KV-E

CV-E

211

Holding Valve E

HV-E

212

Clutch Valve D

KV-D

CV-D

213

Clutch Valve A

KV-A

CV-A

209 210

212 213

211

ZF8-ZIP-Booklet 11-14-17
Page 7

TIME TESTED • INDUSTRY TRUSTED

ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT®

OE Exploded View

Technical Booklet

• ZF8HP55 Shown
NOTE: Do not use this information for ZF8HP45 and
ZF8HP70 units as valve locations and porting differ.
See pages 4 – 7 for this information.

NOTE: Valve lineup locations
shown for ZF8HP55 only.

Upper Valve Body

Upper Valve Body Descriptions

103

102
104

I.D.
No.

Description

ZF Valve
Name

101

Holding Valve D

HV-D

102

Holding Valve A

HV-A

103

Holding Valve B2

HV-B2

104

TC Pressure Valve

WD-V

Lower
Valve Body

202
101
203

201

204 205
206

Lower Valve Body Descriptions

I.D. No.

Description

201

Manual Valve

202

Pressure Regulator Valve

203

TC Switch Valve

SV-WD

204

TC Clutch Valve

WK-V

205

Clutch Valve B1

KV-B1

206

Holding Valve B1

HV-B1

207

Priming Valve

208

Holding Valve C

HV-C

209

Clutch Valve C

KV-C

210

Clutch Valve E

KV-E

211

Holding Valve E

HV-E

212

Stationary Aluminum Valve

SV-1

213

Clutch Valve D

KV-D

214

Clutch Valve A

KV-A

11-14-17 ZF8-ZIP-Booklet
Page 8

ZF Valve Name
SYS-DR-V

DR-RED-V

207

208

209

210

211

213

214

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

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