TIME TESTED • INDUSTRY TRUSTED

Transmission Report Volume 5, No. 1 March 2014

The Right Kit for the Rebuild

is a Genuine SONNAX Kit
At Sonnax, we’re focused on addressing real-world transmission
challenges. Some rebuilds are easy and require only a few new parts to
get the driver back on the road. Others need a lot of diagnostics and
an overhaul of the entire valve body so the vehicle can roll out the door
under warranty.
Our four flagship kits are designed to tackle different levels of
transmission rebuilds. This makes it fast and easy to order parts with
confidence because these kits are designed to repair the root cause of
valve body problems. No gimmicks, shortcuts or unproven products
come out of our technical research labs or out of our kits!
Quality Engineered
& Manufactured Parts
Rebuilders consistently vote these kits
Exclusive, Matched Reamers
Top Shop Products - try one for your next rebuild!
Patented Holding Fixtures
Sonnax products are part of a
unique system trusted for years Line Pressure Booster Kit
to provide reliable, effective, Big Performance without a Big Price Tag
top-of-the-line transmission repairs. Peace of mind for everyday drivers pushing
vehicles to the limit.
Don’t compromise a rebuild
by going outside the system.
Only SONNAX products deliver Zip Kit®
authentic, Sonnax-quality repairs. The First Step in Correcting Common Shift Problems
No reaming, quick-to-install shift and pressure
repairs for the routine customer.

The Sure Cure®

Comprehensive Kit for Big Problems You Don’t Want Back
Ideal for shops standing behind a three-year/100,000 mile
transmission repair warranty.

Performance Pack
The Best Parts for Performance & Heavy Duty Recalibration
Always ask forGENUINE
Ramping up the performance on a gearhead’s hot rod
Sonnax parts! or toughening up a farm truck for hard daily use.

Contact us 8:30 a.m. to 5 p.m. ET (800) 843-2600 • fax (802) 463-4059 • www.sonnax.com 1
 Choose from FOUR
Transmission Levels of Transmis
Tech Bulletin
Rebuild Level Rebuild Level
Basic Boost Shift Repair

Affordable Parts Install Quickly & Easily Installs Easily with

with No Reaming or Special Tools Required No Reaming or Special Tools Required

Slightly Stronger Spring for a Modest Stops Leaks so the Valve Body Works
Base Line Pressure Increase the Way It’s Supposed To

Larger Boost Valves for Demand-Based In-Depth Tech Booklet for Installation,
Line Rise without Low-Speed Harshness Plus Diagnostics & Repair
Application Sonnax Part No. Application Sonnax Part No.

Ford Aisin AW

E4OD, 4R100 4R100-LB1 60-40LE AW60-40LE-ZIP

AODE, 4R70W, 4R75W 4R70W-LB1 60-41SN AW60-41SN-ZIP

GM Ford
4R44E, 4R55E,
350 350-LB1 4R44E-5R55E-ZIP
5R44E, 5R55E
GM
400 400-LB1
6L45, 6L50, 6L80, 6L90 6L45-6L90-ZIP New
4L60 (700-R4), 200-4R 700R4-LB1
Toyota
4L60-E, 4L65-E, 4L60E-LB1 Early-Style
4L70-E A340E/F, ‘00-Later A340-LATE-ZIP New
4L60E-LB2 Late-Style
A750E/F,
4L80-E, 4L85-E 4L80E-LB1 A750E-A761E-ZIP
A760E/F/H, A761E
U140E/F,
4T65-E 4T65E-LB1 U140E-U241E-ZIP
U240E, U241E
6L45, 6L50, U151E/F, U250E U151E-U250E-ZIP
6L80-LB1
6L80, 6L90

U660E U660E-ZIP New

Electronic Booster Kits ZF

 for Chrysler computer-controlled ZF6HP19/26/32 (Gen. 1) &
ZF6-6R60-ZIP
line pressure units also are available. Ford 6R60, 6R80
ZF6HP21/28/34
45/545RFE 44957-LB2 ZF6-GEN2-ZIP
(Gen. 2)
68RFE 44957-LB1
Vacuum Test Guides
in Every Zip Kit!
2 Transmission Report • March 2014  ©2014 Sonnax Industries, Inc.
sion Repair Kits Nobody knows transmissions like Sonnax.™

Rebuild Level Rebuild Level

Total Overhaul Major Upgrade

Firmer Shifts Under Load

Restores OE Shift Quality without Low-Speed Harshness
Repairs Biggest Trouble Areas Consistent Recalibration
to Reduce Comebacks Results with Tuning Options
Step-By-Step Manual for Comprehensive Improved Durability
Valve/Pump Body Restoration
No Special Tools Required
Application Sonnax Part No.

Ford Application Sonnax Part No.

AODE, 4R70W, 4R75W SC-AODE

GM
(‘95-Earlier)
4L60-E (‘94-Later),
HP-4L60E-01
AODE, 4R70W (‘96-Later) SC-AODE-1 4L65-E, 4L70-E

AX4N (4F50N) SC-AX4N Tool Required For more radical applications and even greater levels of
performance, combine this Performance Pack with the
AXODE, AX4S SC-AXODE Sonnax 1-2 and 4th super hold servos:
2nd Gear Super Hold Servo Kit 77911-03K
E4OD, 4R100 SC-E4OD
4th Gear Super Hold Servo 77767K
Chrysler
Ford
41TE, 42LE, 42RLE SC-41TE
4R100 SC-4R100HD
42RH, 42RE SC-42RHE
Formerly a popular Sure Cure® option, this heavy-duty kit has
46-47RH/RE SC-46/47RHE been further refined to become a Performance Pack with the
Tool & VB-FIX inclusion of intermediate and direct clutch feed seal parts.
48RE SC-48RE Required

GM
4L60 (700-R4) SC-4L60 Tool Required
Booster Kits, Zip Kits, Sure Cures
4L60-E, 4L65-E, 4L70-E SC-4L60E Tool Required
and Performance Packs are all
4L80-E, 4L85-E SC-4L80E Tool Required Transmission Digest
4T60-E (‘93–‘96)

4T60-E (‘97-Later)
SC-4T60E

SC-4T60E-1
Tool Required

Tool Required Top 10

Product Winners
Tool & VB-FIX
4T65-E SC-4T65E Required

Saturn TAAT SC-TAAT Tool Required

From our team to yours,
VW/Audi
Tool & VB-FIX THANK YOU for consistently
01M/01N/01P SC-01M/01N/01P Required
Tool & VB-FIX
supporting Sonnax products!
096/097/098 SC-096/097/098 Required

©2014 Sonnax Industries, Inc.  Transmission Report • March 2014 3

 Toyota/Lexus
Transmission A340E/F
Tech BulletinValve Body So

A340E/F ‘00-Later, V6 & V8 Identification

1 77741-02K
The parts shown here are designed for 2000-later, V6 and V8 applications
Lockup Relay Control Valve Kit using Type 3- or Type 4-style valve bodies.
Helps cure:
• TCC apply/release complaints Type 3 (Casting I.D. #8935) Type 4 (Casting I.D. #8938)
• Inadequate lubrication V8 applications, V6 or V8 applications, EPC (shown)
EPC style throttle control only. or cable-style throttle control.
TOOL

Upper Valve Body

2 97741-20K E Casting I.D.
R

Q UIRE D

Oversized Lockup Relay

Valve Kit
Helps cure:
Type 3 Type 4
• TCC apply/release complaints
• Converter codes
• Inadequate lubrication
Note: Requires tool kit F-97741-TL20 Contour I.D.
& the VB-FIX reaming fixture. Contour I.D.

3 19741-01K
Lower Valve Body
TCC Control Plunger Valve Kit Separator Plate I.D.
Helps cure: PR Valve (visible)
• Converter apply/release complaints Casting I.D.

• Converter slip codes

• Overheated fluid TC Control Valve
(visible here if used)
Type 3 Type 4
TOOL

4 97741-18K E
R

Q UIRE

Oversized Secondary
Pressure Regulator Valve Kit
Helps cure: Contour I.D.
Contour I.D.
• Converter complaints Accumulator
Piston Assembly*
• Overheated transmission Pressure Relief
• Bushing wear & lube failure Check Valve*

Note: Requires tool kit F-97741-TL18 *Alternate Configuration: May have same
& the VB-FIX reaming fixture. lineup as Type 3 lower valve body.

A340-LATE-ZIP Parts Not Shown

Zip Kit ®
Kit includes: Helps cure:
• Accumulator Control Valve O-Ringed End Plug • Burnt brake clutches
• Secondary Regulator Valve & Reverse Control • Burnt clutches
Valve O-Ringed End Plugs • Delayed engagement
• 1-2, 2-3, & 3-4 Shift Valves O-Ringed End Plugs • Inadequate lubrication
• 2nd Coast Modulator Valve O-Ringed End Plug • Low pressure
• Slips & flares
• Lockup Relay Control Valve & Sleeve
• Soft shifts
• Checkballs • TCC apply & release complaints
• Dual Ratio Boost Valve Kit • TCC codes

4 Transmission Report • March 2014  ©2014 Sonnax Industries, Inc.

lutions Nobody knows transmissions like Sonnax.™

5 97741-01K  Patent Pending

Dual-Ratio Boost Valve Kit

Upper Valve Body
Helps cure:
7
• Soft upshifts
• Delayed reverse/forward
• Burnt brakes/clutches
4
97741-10K .353" EPC boost valve spool
6
97741-06K .426" EPC boost valve spool
7 Oversized Pressure TOOL

Regulator Valve Kit E

D
Q UIRE

Helps cure:
• Poor shift quality
• Low/High line pressure
• Converter complaints
Note: Requires tool kit F-97741-TL6
7 2 & the VB-FIX reaming fixture.

7 97741-19K Includes 7 End Plugs

O-Ringed End Plug Kit

Helps cure:
• Shift complaints
7 • Burnt clutches
Note: Includes seven end plugs in various sizes.
Follow usage chart on website or in packaging to
determine correct location and size correlation.

3
Lower Valve Body

A340E/F Vacuum Test Guide

6
TheA340E/F guide is available FREE ONLINE
as a tech resource at www.sonnax.com.

©2014 Sonnax Industries, Inc.  Transmission Report • March 2014 5

 Transmission Tech Bulletin

Tech
Component SC-46/47RHE Kit SC-48RE Kit
1. Manual Valve  

Tip
2. Throttle Valve Kit  Standard  Oversized
3. 4-Spool Switch Valve  Standard  Oversized
Choosing the Right Chrysler Kit 4. Lube Regulated PR Valve  Standard  Oversized
The new Sure Cure Kit SC-48RE addresses  Fits  Fits
5. Line Pressure Plug & Sleeve Kit
the same symptoms as the SC-46/47RHE, 46-47/RHE Only 48RE Only
with many of the same great Sonnax 6. 3-4 Accumulator Spring  
products. 7. Output Pilot Bushing  
While these kits can be interchanged to a 8. 4 Accum. Piston Seal & D-Ring
th
 
certain degree, there are some parts which
can only be used in specific units, as well 9. Intermediate Shaft Plug & Pilot Kit  
as some locations addressed only by the 10. Turbine Shaft Seals  
48RE kit (see chart). 11. Plastic Checkball  
The SC-46/47RHE kit can be used in a
12. Shift Linkage E-Clip  
48RE, but the following two items from
the kit cannot be used: line pressure plug 13. Endplay Shims 
and sleeve kit 22229-01K and endplay 14. Rear Planet Thrust Washer 
shims 22700-Z.
15. Detent Ball & Sleeve Kit 
Sonnax recommends selecting the kit
16. Boost Valve Spring Retainer 
that best addresses your application.

46-47RE/RH Kit 48RE Kit

TOOL

E
R

Q UIRE

2 2 12

5 3 11 1 11 16
Fits 46-47RH/RHE Only
3
1 4 12
4
Fits 48RE Only

8 6 15
8
6

13
10 14
9 7
7 10
9

Part No. SC-46/47RHE Part No. SC-48RE

Helps cure: • Overheated converter Helps cure: • Poor cooler charge at idle
• 2-3 Late • Poor cooler charge at idle • Build up of release pressure • Poor cooler flow
• 2-3 Oversensitive • Poor Forward & Reverse during lockup • Poor detent & upshift control
engagement • Converter bushing failure • Poor Forward
• Build up of release pressure
during lockup • Poor kickdown • Delayed engagement & Reverse engagement
• Converter bushing failure • Poor line pressure control • Lockup shudder • PR valve buzz
• Delayed engagement • PR valve buzz • Lube failures • Slips in Reverse
• Lockup shudder • Shift timing complaints • Overheated converter • Soft TCC apply
& throttle buzz • Throttle buzz
• Low cooler flow
• Slips in Reverse Note: SC-48RE requires the VB-FIX reaming fixture and tool kits
• Lube failures
• Soft TCC apply 22771-TL12, F-22771-TL, 22771A-TL13 and F-22771A-TL7.

6 Transmission Report • March 2014  ©2014 Sonnax Industries, Inc.

 Nobody knows transmissions like Sonnax.™

New & Improved Vacuum Test Guides

• LEARN Vacuum Test Locations Aisin AW Mercedes
• IDENTIFY Common Transmission Problems 60-40LE 722.6 New
60-41SN
• FIND Recommended Sonnax Parts for Quality Repairs Toyota
Ford A340E/F, ‘00-Later
Tool Details on Every Guide V6 & V8
4/5R44E, 4/5R55E
By popular demand, our vacuum test guides were recently
5R55W/S A750E/F, New
updated with required tool information for Sonnax parts. A760E/F/H, A761E
This makes it easy to see all the products required for repairs. GM U140E/F, U240E,U241E
4L60-E U151E/F, U250E
Mercedes 722.6 Your “Most Wanted” Guide
4L80-E U660E
Our fall survey asked rebuilders what unit they most wanted a
vacuum testing guide for, and the 722.6 was the overwhelming 4T65-E
ZF
favorite. It’s one of two new guides available online right now, 6L45, 6L50, 6L80, 6L90
ZF6HP19/26/32 (Gen. 1)/
with more coming soon for other units. Check our website for Ford 6R60, 6R80
updates, or sign up for Sonnax e-news and be the first to know
ZF6HP21/28/34 (Gen. 2)
about all our new parts and tech resources.

visit www.sonnax.com to view, print or Scan code with

smartphone to view
download these guides and check out the latest units! vacuum test guides.

4R70W Forward Clutch Drum

• Increased groove depth for additional ring support
• One-piece forged material provides increased strength
and durability over the OE stamped drum
A common failure of the Ford 4R70W/E, 4R75W/E is the separation
of the forward drum at the snap ring groove. The manufacturing
process of the OE snap ring groove creates high-stress points around
the circumference of the drum. The forward drum is active in 1st,
2nd and 3rd gear ranges and suffers the most abuse on a forced 4-3
kick down, especially in heavy duty applications.
The concurrent pressure from the forward clutch piston combined
with the high stress at the snap ring groove causes the upper portion
of the drum to split and separate at the groove. Depending on
severity of breach, this can result in no forward engagement or
slipping in 1st, 2nd and 3rd gear.

The forged, one-piece construction of the Sonnax forward clutch

drum construction eliminates these stress points.
Part No. 76654-01K Patent Pending

©2014 Sonnax Industries, Inc.  Transmission Report • March 2014 7