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.
©2017 Sonnax Industries, Inc. ZF8-ZIP-Guide 11-14-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
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 specific complaints which are beyond the scope of this kit.
ZF8HP45 Upper
Valve Body
4
5
1
3
3
2
4
4
ZF8HP45 Lower
Valve Body
ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT® Quick Guide
©2017 Sonnax Industries, Inc. ZF8-ZIP-Guide 11-14-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2
Step Replace OE Pressure
Regulator Sleeve
Packaging Pocket 1
• Sleeve
Step 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 uid to
travel through the valve and push the seal outward to
conform to the worn bore.
Packaging Pocket 2
• Valve
• Seal
Step 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.
Packaging Pocket 3
• Internal End Plugs (8)
• O-Rings (18) 2 Extra
Step 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
1
2
3
4
Step Replace OE Accumulator
Pistons
Packaging Pocket 5
• Accumulator Pistons (7)
• Matching Springs (7)
Step Replace OE Solenoid
O-Rings
Packaging Pocket 6 For Outboard White & Orange Solenoids
• O-Rings, (8) 1 Extra 13.75 x 2mm thick
Packaging Pocket 7 For Inboard Brown Solenoid
• O-Ring (2) 1 Extra 17 x 1.5mm thick
Packaging Pocket 8 For Inboard Orange Solenoids
• O-Rings, (7) 1 Extra 18 x 2mm thick
Packaging Pocket 9 For Outboard Brown Solenoid
• O-Ring, (2) 1 Extra 17 x 1.5mm thick
Packaging Pocket 10 For Inboard White Solenoids
• O-Rings, (5) 1 Extra 18.25 x 2mm thick
5
6
Zip Kit Contents & Installation Steps
NOTE: The parts listed here may be protected by patent 8,794,108.
Cautions
Electronics
Do not use an ohm meter with more than .6 voltage supply. e 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 qualied used. Original solenoids, if reused, should be returned to their same
location due to a learned ow rate by the TCM. Make every eort 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 Specications & Reassembly Tips
e red tag on pan shows the uid type Mopar 6815795AA (green) and that uid
temperature must be 122°F to check the level. Dry ll is approximately 8.5 qts./8.0l
(Figure 1).
Zip Kit Instructions
1. Valve Body Removal from Case
a. Remove 14 bolts to drop valve body from case (Figure 2).
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. e valve body may have to pried down on the front end because of the
suction and output tubes (Figure 6)
Torque Specifications
Mechatronic-to-Case
Torque or Valve Body
Halves Bolts 10Nm/89
in-lb
Complete Valve Body-
to-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
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.
Valve Body Identication This Zip Kit ZF8-ZIP is designed for ZF8HP45, ZF8HP55 and ZF8HP70 units only.
Figure 1
Fill & Check Plug
Drain Plug
Gently pull connector
out of the case.
Figure 4
Figure 2
2
1
14
12
13
11
10
9
8
7
6
5
4
3
40 Torx Bolts
Figure 3
1 2 3
OSS
4
Lift up metal bracket
to release connector
from TCM.
ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT®
PART NUMBER ZF8-ZIP TECHNICAL BOOKLET
©11-14-17 Sonnax Industries, Inc. ZF8-ZIP-Booklet 11-14-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
11-14-17 ZF8-ZIP-Booklet ©2017 Sonnax Industries, Inc.
Page 2 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
TIME TESTED • INDUSTRY TRUSTED
ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT® Technical Booklet
2. Valve Body Disassembly
a. Disconnect three TCM harness retaining bolts (Figure 7).
b. Remove remaining ve 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).
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 cross-
reference numbers (Figure 14).
Figure 5
B Release Rubber
Feed Tube
Figure 6
Output
Tube
Suction
Tube
Figure 7
1
2
3
Remove three TCM harness retaining bolts.
4
1
2
3
5
Remove five remaining TCM harness retaining bolts.
Figure 8 Figure 10
TCM Removed
Gently pry sides,
to lift up TCM from
valve body.
Lift TCM Up
ESD (Electro-Static
Discharge) WARNING!
Wear ground strap
when handling TCM.
Figure 9
©2017 Sonnax Industries, Inc. ZF8-ZIP-Booklet 11-14-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3
ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT® Technical Booklet
Valve Body Separator Plate Application Chart
OE Valve
Body Code
Number Stamped on
Original Plate
Order Sonnax
Part Number
Valve Body
Generation
A048/B048 1087-327-175 35740-048 ZF8HP45
&
ZF8HP70
A054/B054 1087-327-189 35740-054
A071/B071 1068-327-162
Figure 14
4
1
23
5
Remove 17 remaining bolts.
Figure 11
9
6
78
10 12
11
13
16
14 15 17
Pry valve body halves away from separator plate.
Figure 12
Separator plate is same for ZF8HP45 & ZF8HP70.
Figure 13
OE valve
body codes
OE valve
body part
number
3. Installation
Install Zip Kit parts as shown on diagram of separate quick guide
sheet included in this Zip Kit.
See identication 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).
Solenoid Identification & Location Chart
Solenoid I.D. A B C D E F G H
ZF 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
Figure 16
Figure 15
A B CDE F GH
11-14-17 ZF8-ZIP-Booklet ©2017 Sonnax Industries, Inc.
Page 4 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
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.
Upper Valve Body • ZF8HP45 Shown
20
25
15
0
10
5
30
VACUUM
TEST
20
25
15
0
10
5
30
VACUUM
TEST
Accumulator Pistons
• EDS codes
• Firm shifts
• Harsh engagement
Replace with Sonnax Part No.
95740-15K Contains 7 sets Patent No. 8,794,108
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
B2 Clutch NIC Valve
• B Clutch burned
• Delayed/No Forward &
Reverse
• NIC (Neutral Idle Control)
concerns
Replace with Sonnax Part No.
35740-22
Requires F-35740-TL22 & VB-FIX
End Plugs
• Burnt clutches
• Harsh/Soft/Flare shifts
• Pressure loss
Replace with Sonnax Part No.
35740-30K
End Plugs (3) =
Internal End Plugs (8) =
TC Pressure Valve
• TCC codes & overheating
• Harsh downshifts
Replace with Sonnax Part No.
35740-18K
Requires F-35740-TL5 & VB-FIX
Position Valve
• Delayed Forward & Reverse
• Delayed engagement
Holding Valve B2
• B Clutch failure
• 5-6 Flare
Test with dampener
upside down and test
plate orifice off center
from rubber piston end
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.
©2017 Sonnax Industries, Inc. ZF8-ZIP-Booklet 11-14-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5
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.
Lower Valve Body • ZF8HP45 Shown
20
25
15
0
10
5
30
VACUUM
TEST
20
25
15
0
10
5
30
VACUUM
TEST
End Plugs
• Burnt clutches
• Harsh/Soft/Flare shifts
• Pressure loss
Replace with Sonnax Part No.
35740-30K
End Plugs (3) =
Internal End Plugs (8) =
TC Switch Valve
• No lockup
• Excess TCC slip
Replace with Sonnax Part
No. 35740-05
Requires F-35740-TL5 & VB-FIX
Test both
passages
together.
Clutch Valve B1
• Slip on take off
• Gear ratio errors
• B Clutch failure
Test both
passages
together.
Priming Valve
• Harsh/Flare/Neutral shifts
• Gear ratio & solenoid codes
• Wrong gear starts
Replace with Sonnax Part No.
35740-21K
Requires F-35740-TL20 & VB-FIX
Park Pawl Release
Valve
• Park will not release
• Park position errors
Clutch Valve A
• Slip in Drive or Reverse
• Gear ratio errors
• A Clutch failure
Clutch Valve E
• Slip on 1-2
• Gear ratio codes
• E Clutch failure
Clutch Valve C
• Slip on take off
• Gear ratio codes
• C Clutch failure
NOTE: Do not use this information for ZF8HP55
units as valve locations and porting differ. See
page 8 for ZF8HP55 information.
Pressure Regulator Sleeve
• Harsh/Erratic line pressure
• Restricted converter/lube flow
Replace with Sonnax Part No.
35740-03
Remove spring when
testing. Center valve
spool in opening.
Pressure Regulator
Valve
• Harsh/Soft shifts
• High line pressure
• Burnt clutches
Replace with Sonnax Part No.
35740-01K
Requires F-35740-TL & VB-FIX
Clutch Valve D
• Gear ratio errors 4-8th Gears
• Slips in Reverse
• D Clutch failure
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
Close port on
opposite side
when testing.
Close this passage on
the other side with
the palm of your hand.
TCC Valve
• Converter shudder & TCC slip
• TCC codes • Overheated converter
Replace with Sonnax Part No.
35740-13K
Requires F-35740-TL13 & VB-FIX
NOTE: Critical wear areas and vacuum test
locations shown for ZF8HP45 and ZF8HP70 only.
Test both
passages
together.
11-14-17 ZF8-ZIP-Booklet ©2017 Sonnax Industries, Inc.
Page 6 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
TIME TESTED • INDUSTRY TRUSTED
ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT® Technical Booklet
OE Exploded View
Upper Valve Body • ZF8HP45 Shown
Upper Valve Body Descriptions
I.D.
No. Description ZF
Valve Name
Chrysler
Valve Name
101 Holding Valve B2 HV-B2 HV-B2
102 Clutch Valve B2 - B Clutch NIC
(Neutral Idle Control) KV-B2 CV-B2
103 Holding Valve A HV-A HV-A
104 Holding Valve D HV-D HV-D
105 Torque Converter Pressure Valve WD-V TC-V
106 Position Valve (Outboard)
Default Position Valve (Inboard)
Pos-V,
PosD-V
Pos-V,
PosD-V
101
102
103
104
105
106
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.
©2017 Sonnax Industries, Inc. ZF8-ZIP-Booklet 11-14-17
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 7
ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT® Technical Booklet
OE Exploded View
Lower Valve Body • ZF8HP45 Shown
Lower Valve Body Descriptions
I.D.
No. Description ZF Valve
Name
Chrysler
Valve Name
201 Main Pressure Regulator
Valve and Sleeve SYS-DR-V LP-V (Inboard)
RED-V (Outboard)
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 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 HV-C
209 Clutch Valve C KV-C CV-C
210 Clutch Valve E KV-E CV-E
211 Holding Valve E HV-E HV-E
212 Clutch Valve D KV-D CV-D
213 Clutch Valve A KV-A CV-A
204
203
202
201
206
205
207 208 211
209 212 213210
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.
11-14-17 ZF8-ZIP-Booklet ©2017 Sonnax Industries, Inc.
Page 8 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
TIME TESTED • INDUSTRY TRUSTED
ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT® Technical Booklet
OE Exploded View • ZF8HP55 Shown
Lower Valve Body Descriptions
I.D. No. Description ZF Valve Name
201 Manual Valve
202 Pressure Regulator Valve SYS-DR-V
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 DR-RED-V
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
Upper Valve Body Descriptions
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
204
203
202
201
206
205
207 208 209 210 211
212
213 214
Lower
Valve Body
101
102
103
104
Upper Valve Body
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.
