SONNAX Catalog Transmission PDF

Quality Engineered Products
TRANSMISSION SPECIALTIES
VOLUME 4 2001
SPRING
On-line Action
he Sonnax Transmission
T Specialties site at www.trans-

missionspecialty.com has been
redesigned and is one of eight distinct
and affiliated sites. The main site at
www.sonnax.com serves as a portal
for webpages that focus on the
following product lines: TS
(Transmission Specialties), Torque
Converter, SonnaFlow™, Sonnax
Information, High Performance,
Ring Gears, Manual Clutch, and a
From the main portal site
site for our other products (which hundreds of pages of information can be accessed
includes Allison Replacement Hard with the click of a button.
Parts, Friction Papers and Band
Linings, and Harley Davidson Replacement organized by product line, and listed from the most
Bearings). We will be adding more sites in the future, recent date to the oldest. Each article has a synopsis
including a web site that focuses on technical ques- under the title. Customers have downloaded a num-
tions. ber of these technical articles every day since they
Because of the new site, we will be able to better were placed on the site and over 10,000 times to
serve our customers by providing the information date. Additional articles will also be added to this
pertaining to the Transmission Specialties product page regularly. The Seminar Schedule enables cus-
line and our customers’ area of expertise and inter- tomers to know which shows we will be attending,
est without items not relevant to their business. The where they are being held, and who is sponsoring
site is revised weekly with listings of recent updates. the seminar. The Spanish site contains TS
Our dynamic menu that allows the user to search by announcements and technical articles and is con-
part make (GM, Chrysler, etc.), application (4L60, tinually being developed to mirror our TS site. The
41TE, etc.) and part type (boost valve, front pump New Featured Parts Section includes brief product
bushing, etc.) has been redesigned and is more user- summaries, and links to the announcements and
friendly. We also have on-line instructions for prod- additional information.
ucts, making it easier to install our products if The new site also makes it easier to contact a
instructions are lost. These instructions provide Sonnax Salesperson and receive technical help.
more detailed information, allowing for additional Customers can fill out a form to request catalogs,
helpful information such as Wet Air Test (WAT), our newsletter, or email updates on new TS prod-
wiggle test, additional photos, reaming instructions, ucts. Please be aware that to view the individual
general tips, and other problems to look for as well. parts announcements, a password is required. To
The Information page contains numerous techni- get a password, complete the password request form
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are added regularly. The technical articles are each of your aftermarket product needs!
APPLICATIONS
8 General Motors
52 Ford
100 Chrysler
118 Foreign HONDA TOYOTA MAZDA KM/JATCO ZF
132 High Performance
TECHNICAL DISCUSSIONS
IFC On-line Action
4 Valve and Bore Inspection
50 GM Friction Materials and Applications
60 Transmission Gerotor Pumps
78 Sonnaflow™: Cooler Flow Sensor
98 Bushings Take a Beating
108 Designed for Durability
115 Converter Code Blues?
116 So Where’s the Connection?
124 Restoring the Valve Body: Reamer Technique
150 Sealing the Seals, Bore Prep is More than Elbow Grease and Sandpaper
PRODUCT CHARTS AND LISTINGS

2 Sonnax Valve Family Chart
123 Sonnax Precision Reamers
140 Sonnax Small Parts Program
142 Shims, Allison and Bearings
146 Transmission Replacement Parts Showcase
152 Complete Sonnax Transmission Specialty Product Listing
Symbols used in this catalog:
:Sonnax featured part
:Sonnax part also available

O
TO L
:Tool required for installation

R
E
QUIRE
CH
INI
A
N
M
:Machining required for installation

R
E
QUIRE
:New Sonnax part introduced in this catalog
© 2001 SONNAX INDUSTRIES

:New Sonnax part soon to be available DESIGN BY SONNAX CREATIVE DEPARTMENT
SONNAX FAMILY VALVE CHART
PR BOOST PR VALVE TV BOOST/CONTROL TCC/BYPASS
GENERAL MOTORS
125 75918-01K 8
200, 200C 65754-Series 9
4T60 84754-12K & 17K 42 84754-16K, 22K 41
4T60-E 84754-12K, 17K 42 84754-01K,08K,16K ,22K, 97K, 98K 40-41
4T65-E 84570-30K 44
350
400 34910-03K 11 34910-01K 11, 34910-05K 11
4L60 77917-06 33 77917 Ser. 18, 77968 19, 77966 Ser. 20 77805-K 28
4L60-E 77917-07 33 77898E-K, & 77898E-4K 32 77754-03K, 04K, 29
77898E-3K, & 77898E-6K 32 77805E-K, 77805-K 28
4L80-E 34994-01K 49
FORD
C6
E4OD 36424-01K, 03K 56
A4LD 56947-02K,03K,04K,05K 66 56947-06K 67
4R44-E, 4R55-E 37947-01K 71
AXOD 96201-01K, 08K,12K,13K 87 96201-06K 86
AXOD-E, AX4S 96201-01K, 08K,12K,13K 87 96206-01K 89
AX4N 96201-01K, 08K,12K,13K 87 96206-03K (AX4N), 92 96206-01K 89
AOD 76990K, 03K 73 76989K & 03K, 72 76970 75
AOD-E, 4R70W 76948-02K 81 76948-01 & -09 81 76948-04K 80
ATX 86940-01 & 03 83
CD4E 73480-RK, MK 94 73840-BK, MK 94
CHRYSLER
A904/42RH 12229-01K 109 22771-01K 110 22771A-01 (42RH only) 111
A727/46RH 22229-01K 109 22771-01K 110 22771A-01 (46RH only) 111
47RH 22771-01K 110 22771A-01 111
A404, A413
A470, A670
41TE 92835-07 102 92835-03K, 101 92835-02K, 104
42LE 92835-03K, 101 92836-01K 105
MAZDA
G4A-EL 71846-01K 121
GF4A-EL 74846-01K 121
MITSUBISHI
KM four speeds
JATCO
L4N71B 66942-01K 128 66942-01K 128
RL4F02A(various others) 93990 130
TOYOTA
A130 89010-01 119
A131 89010-01 119
A132(L) 89010-01 119
A540-E 89031-01 119
OTHER
ZF4HP14 85991-01 131
©2001 Sonnax Industries, Inc.
2 sonnax 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com

SONNAX FAMILY VALVE CHART
REVERSE BOOST MANUAL VALVE ACC. PIN KITS ACC. SLEEVE KITS SHIMS
75918-01K 8
84754-14K, 19K 42-43 84573-01K 13 75410-10, 37 84733-10 & 20 36

84754-14K, 19K 42-43 84573-01K 13 75410-10, 37 84733-10 & 20 36
35718-01K 13 35709-01K 10 77406-10 26

34910-01K, 05K 11 34105-01K 13 34500-Z 12
K77898 & K77898A 18 77999 13 77998-01K 34 77406-10, 77409-15 26
77898E-K & 77898E-6K 32 77754-01K 13 77998-01K 34 77406-10, 77409-15 26
77898E-3K & 77898E-4K 32
34200-01K, 03K 46 34989-02K 45 34500-Z 12
36946 Series 53 36428-Z & A-Z 52

36402-Z 64
56947-01 70
96201-01K, 08K, 12K,13K 87 96201-05 90 96511K, 12K, 13K 91

96201-01K, 08K, 12K,13K 87 96201-05 90 96511K, 12K, 13K 91
96201-01K, 08K, 12K,13K 87 96201-05 90
86539-Z5 84
73840-24, -LR & -FWD 97 73251-01K 93
12780-Z 106
22700-Z 112
32539-Z5, 35539-Z5, 100

39539-Z5 100
92834-03K 104 39539-Z5, 100 92965-Z5 106
71400-15 122
41750-03 126
B
Buuyy
G
Geennuu
iinnee SS
oonnnnaa
xx P
Paarrttss
92834-03K 104
Part number Page number
800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com sonnax 3

Valve and Bore Inspection
BY BOB WARNKE
very trade has developed special equipment to screwdrivers. Heat the tip and bend a 45˚ curve into
E do a job quickly, accurately or with greater

safety. The Electrician carries a circuit tester,
a Lineman has rubber safety boots and gloves and the
one and a 90˚ curve into another (Figure 1). Start to
move the valve from the face of a spool, as a circuit
opens, continue with a 45˚ curve, follow using 90˚
Transmission Rebuilder has his pocket screwdriver. curve, until the valve is fully stroked through its trav-
Valve bodies are delicate. Inspection often begins el. Reverse the process slowly, allowing the valve to
with a pocket screwdriver, but ends with a ball peen come back to rest. This identifies rough surfaces and
hammer. After use of the hammer, it is heated, lubed, bad springs. Valves normally spiral slightly during
twisted and tossed while mumbling “bosura”. But the compression of the spring, but should not catch
scrapping the original valve body leads to high parts or coil bind before full stroke.
costs, down time and calibration concerns. Omitting Long stem aluminum valves commonly bend after
the visual inspection can lead to bigger problems. repeated bottoming. The AXOD-E forward control
valve is an example. All valves should be rotated
Visual Inspection: slowly while stroked to identify warpage. Some
Some say “All you have to do is look at aluminum anodized valves flake at the edge or become sharp
valves or bodies, and they will stick.” The point of and rough. Rotate the valve against a fingernail and
this article is that “outside inspection may not find if the edge catches the nail, run a jeweler’s file over
an internal problem.” We are familiar with “picken’ it.
and lookin’” at cast iron
valve bodies, but on alu-
minum, getting anxious
or pushing material
causes it to get ornery
and fight back.
Using a round pick to
stroke raw aluminum or
anodized valves, often
creates valve hang-up.
Most of the new valves
have an anodized hard
coat, which penetrates
into the aluminum by
.001”. The build up is
very hard, yet brittle and
sharp at the edge, which
works as a wiper. Prying
on that edge raises a Figure 1: Varied flat blade angles pry on spool face instead of sharp edge.
slight burr, which causes
the valve to seize in the bore. That burr may only Bores that have raised edges can be resized by
extend .0015", but with aluminum valves and castings, inserting a drill shank, centering pins or a steel valve
the minimum valve to bore clearance (diametrical) is and then lightly tapping on its side. Spinning a shank
.0005" and maximum is .001". In comparison, the tol- with a low speed drill, and running abrasive cleaner
erance with cast iron bodies and steel valves is twice over it, works to quickly polish a bore. Specific bore
that of aluminum, due to steel’s expansion properties. sizing tools, which duplicate the OEM valve, work
To prevent raising a burr, a set of valve stroking well for reforming material. Care must be taken if
tools should be made from two flat blade pocket emery cloth is used to rework bores, as they easily

casting. This is comparable to a heavily traveled road
or stair tread wear. When the valve is removed, look
for worn pockets opposing the fluid entry side of the
bore (Figure 2). A flashlight set over the casting with
or without the valve installed can be a good visual
indicator of wear.
Examine bores closely when one spool separates a
pressure from an exhaust circuit (Figure 3).
Inspect short valves or plugs located between
springs and oil circuits. Short valves and plugs want
Figure 2: 4L60-E AFL limit valve bore wear.
to tip into the bore or round off their edges. This
movement and wear will jam the valve or allow oil to
become out-of-round. Valve and bore finish affects pass around it (Figure 4).
valve seal, stroke and oil loss. Bore surface finish is Examples of this are found in 604 switch valves,
specified to be no rougher than 45 micro-inches. This 4R44E reverse engagement and AOD end plugs.
number represents deviation from an average surface,
where a low number is similar to a polish. The valve fin-
ish should be near 15. Surfaces rougher than this reduce
valve action and increase leakage. These standards
explain why reamers need a slow feed, cutting fluid and
should not be loaded inward. The manual stroking of
valves as mentioned in Figure 1, will not identify a
worn bore. Remove and inspect valves and bores which
are reacted on by duty cycled solenoids
Which and Wear:

RIDGES
The quick stroking of valves will not identify bore wear
unless the area of focus is clear. To begin with, look at Figure 4: Valves with high aspect ratio (length to height) are
proned to toggle.
valves and end plugs, which are reacted on by duty
cycled (pulsed) solenoids (Review the “Complaint, Measuring Bores:
Cause and Correction” information in this catalog). The actual valve to bore clearance can be measured
Since the valve body is designed to control hydraulics, with small dial bore gauges, telescoping gauges and
we can use oil diagrams to identify pulsed or active pin gauges (Figure 5). The measuring equipment
shift solenoid circuits. Find that circuit on paper and must be accurate to tenths of a thousandth or .0001".
transfer it to the oil reacting on the valve, which indi- Measurements should include taper and concentrici-
cates an area of concern. ty to verify the total tolerance. Suggested valve to
bore tolerance of aluminum valve bodies is .0005"
Visual Bore Inspection: minimum and .0012" maximum of total I.D. to O.D.
The scrubbing action from contamination, high cycle
rates and fluid loading on the valve etches away the
AFL
WEAR EXHAUST
Figure 3: Inspect bore which controls exhaust. Figure 5: Measurement Tools

(diametrical) clearance. Inverted Valve:
To translate this for a wig- This refers to inserting a
gle test, .003" will slightly valve backwards and position-
move or push oil from ing the mating spool where it
between the spool and bore. lives in the bore. A close toler-
Beyond those figures leakage ance of the valve to bore will
becomes excessive, and you not allow the valve to “sag”
can feel or wiggle the toler- off-center (Figure 6). This sag
ance and see significant leak- test can be visual, but is best
age during a Wet Air Test defined with a Go-No-Go pin
(WAT). The 4T60-E TCC or drill bit. This procedure
apply valve (inside small works on any valve, but is
spool) visibly moves with .005" best defined with two spool
clearance. The CD4E pressure Figure 6: Sag Test diameters, as the 4T60-E and
regulator bore (small spool) CD4E TCC valves.
will WAT and leak severely with .004" and is often Knowing critical dimensions allows calculating a
worn over .008". measurement or gauge pin. When possible, Sonnax
will define measuring procedures or Go-No-Go gauges
Wiggle Test: for excessive clearance.
If the valve is assembled, prop the valve into the posi-
tion that it regulates or cycles in, “not the at-rest Wet Air Test (WAT) or Captive Air Test:
position.” Place a pocket screwdriver on each side of This is a visual leakage test, similar to air checking a
the valve stem, then “pry it into, and out of the clutch. Sonnax identifies WAT locations whenever
loaded position, simulating the fluid forces.” If it vis- possible, because it educates visually, is a familiar prac-
ibly moves, it is over the maximum tolerance specifi- tice and identifies excessive clearance (Figure 7).
cation. If it toggles easily from side to side of the bore, To isolate problems, the best results include using
the body should be replaced or repaired. regulated air (30-40 psi); a controllable vacuum gun
such as a rubber tipped Vacula, and a small amount
Figure 7: Wet Air Test

of ATF fluid to identify the leak.
A finger, shop rag or small plate is
often used to enclose the circuit
being pressurized. With a good fit
Technical Information/
between the spool and the bore,
little to no leakage will pass
Diagnostic Resources
through the surface area.
Limitations of this test include the
relatively higher viscosity of ATF Sonnax recognizes
used at room temperature and these groups as the
experience to know good vs. bad leaders in transmis-
leakage.
www.atra-gears.com • 805-604-2000 sion technical services
Air Gauges: and publications,
This test requires the predeter- providing rebuilders
mined airflow and pressure values with the necessary
on a sealed working valve circuit. information to keep
The airflow meter can either be up with the complex
pressure or flow sensitive. changes that hit our
www.atra-gears.com • 805-604-2000
Generally these include a tube in www.transbuilder.com • 602-494-6233 industry every day.
which a ball is suspended by air
held within the circuit. A pass-fail
standard is set, and when leakage The days of the
is excessive, the position of the 400 are far behind
www.transmissiondigest.com
ball lowers to indicate the leak. 602-494-6233 us. Transmissions
Remanufacturers use this test cannot be fixed by
because of their high volume; it just replacing the
creates less mess, and once a stan- failed part any
dard is set, limited experience is longer. Learn what it
needed. Drawbacks include each
takes to repair today's
circuit must be isolated so plates www.atsgmiami.com • 800-245-7722
must be developed, as well as transmissions, from

instrument costs. understanding
electronics, to using
www.transonline.com • 888-762-0229
Hydraulic Test Bench: diagnostic tools,
Hydraulic control over a valve changes in compo-
body in a simulator is accurate nent design and
and closely duplicates the vehicle www.iatn.net • 714-257-1335 much more.
operation. As valves wear and
new problems arise, the test proce- ®
dure can be modified to pinpoint If you want to be
the problem. a profitable shop
This material was compiled to and be able to keep
explore different methods of test- up with the latest
ing and service work to valve www.asashop.org • 1-800-272-7466 in transmission
bodies. Rebuilders have likely technology, become
developed their own procedure, a member of these
but I hope this material leads to
groups by joining
improved results and success,
together with a pocket screw-
now!
www.sonnax.com • 1-800-843-2600
driver.

125-C Part No. 75918-01K
Complaint Delayed reverse engagement

Secondary Complaints: T V A N D R E V E R S E B O O S T VA LV E K I T
• Poor line pressure

• Poor upshift quality Reverse Valve
• Burned bands
Sleeve
and clutches
Cause
End Plug
Worn TV and reverse
boost valve sleeve resulting Valve Body
in TV/Reverse oil cross Retaining Ring
TV Valve
leakage or exhausting
Correction SONNAX PART SUMMARY

This replacement TV and
reverse boost assembly C ommon problems with a 125-C transmission are burned clutches or
band, poor line rise response, or delayed reverse engagement. These
problems can frequently be caused by a worn TV and reverse boost valve
eliminates these problems
sleeve. The steel TV and reverse plungers continuously oscillate in the
with four closely toleranced aluminum sleeve, which can cause wear resulting in oil cross leaking or
parts that restore hydraulic exhausting. This oil loss can prevent the pressure regulator valve from reaching
integrity of the circuits to higher line pressure (maximum pump output) positions.
prevent cross leaks and
raise line pressure. The Sonnax replacement TV and reverse boost valve assembly 75918-01K
eliminates these problems with four closely toleranced parts: a hardened steel
TV boost valve, a hardened steel reverse boost valve, a high quality
Part No. 75918-01K aluminum sleeve and an end plug. These parts will restore the hydraulic
1985 and later models
integrity of the circuits to prevent cross leaks and raise line pressure. This kit
1 Sleeve is designed for the late model (1985 and up) valve bodies.
1 TV Valve
1 Reverse Valve
1 End Plug
1 Retaining Ring

200C 200-4R Part Nos. 65754-01K, -02K & -03K
Complaint Soft 1-2 shift, poor detent and up-shift control

Secondary Complaints: T H R O T T L E VA LV E S L E E V E K I T S
Valve Body
• Poor line pressure
• Poor upshift quality
• Burned bands
and clutches
Throttle Valve Plunger
Spring
Cause Part Throttle Orifice
Roll Pin
Shift Throttle
Plunger bore wear creates Annular Grooves
Valve Orifice
TV leaks that get worse as
Detent Orifice
the unit heats up Identification Grooves
(2 Grooves Shown)
Correction Throttle Valve Sleeve
SONNAX PART SUMMARY

These valve sleeve kits have
annular cleaning/centering
grooves added to the valve
P oor line rise, no detent downshifts, and soft 1-2 shifts are common
complaints in vehicles with a 200 transmission. The steel throttle valve
plunger continuously reciprocates within the steel throttle valve plunger sleeve,
and an identification groove wearing the sleeve. This wear allows shift TV oil to leak past the plunger and
added to match OEM. exhaust, resulting in poor line rise. Also, detent feed oil leaks past the plunger
and results in poor shift timing and/or soft shifts.
Part No. 65754-01K
This excessive leakage can be eliminated by installing one of three Sonnax
Part No. 65754-02K
replacement throttle valve plunger and sleeve kits: 65754-01K, 65754-02K, or
Part No. 65754-03K
65754-03K. These three kits have different sized plunger diameters that must
Each includes the following:
be matched to the vehicle's TV valve. Identification grooves have been added
for ease in matching with the OEM TV valve (see chart below). Both the sleeve
1 TV Plunger
and plunger valve have been tightly toleranced to restore the hydraulic integrity
1 TV Sleeve
of the circuit. Annular grooves have been added to the plunger valve for
cleaning and to minimize side loading that creates friction leading to sticky and
erratic operation.
Sonnax P/N TV Valve Groove TV Plunger Dia.

65754-01K no machined grooves .357"
65754-02K 2 machined grooves .390"
65754-03K 1 machined grooves .430"

350 & C Part No. 35709-01K
Complaint Delayed engagement

Secondary Complaints:
Cause Case bore wear and oil loss at the intermediate servo
• No engine braking in
manual 2nd This drop-in sleeve and piston salvages the case, and eliminate the
Correction complaints caused by oil loss.
• Low line pressure
in R, N, D I N T E R M E D I AT E S E R V O P I S T O N A N D S L E E V E K I T
Case
Part No. 35709-01K

Spring
1 Piston, Servo
Spring Seat
1 Sleeve
1 Teflon® Seal Pin
Washer
Repair Sleeve
Piston
with Teflon®
seal installed
4L60-E Part No. 77700-HBK
Complaint Stripped bell housing bolt heads

Standard Torx® bits often fit loose and damage the bell housing
Cause bolts during removal or installation of the bolts
Part No. 77000-HBK
‘98 & Later with 2 Piece Case Correction Use this Torx® Plus bit for removing bell-housing screws.
1 Torx® Plus Bit
T O R X ® P L U S B I T F O R B E L L H O U S I N G B O LT S
Torx® Plus Bit
Bolt

400 Part Nos. 34910-01K, -03K & -05K
Complaint High line pressure, poor line rise

Secondary Complaints: P R E S S U R E R E G U L AT O R A N D B O O S T VA LV E K I T S
PR Valve: Teflon® Seal

• Delayed
converter charge
• Poor reverse
engagement PR Valve
Boost Valve:
• Soft 1-2 and 2-3 shifts O-Ring
End Plug
• Delayed reverse
Modulated Boost Pump Body

(Check for cross leaks with the pump
Cause halves assembled)
Reverse Orifice Modulated

Wearing of the pump body TV Orifice
casting or boost sleeve
Correction Boost Valve
Boost Sleeve
Use of these pressure "Factory style"
regulator valve and reverse
O-Ring
boost valve kits restores
the hydraulic integrity of
the pump.
SONNAX PART SUMMARY
Part No. 34910-01K
1 Boost Valve V ehicles with a 400 transmission will often exhibit wear in the pressure
regulator and reverse boost valve circuits. Wear in the pressure regulator
area creates high and uncontrollable line pressure, delayed converter charge or
1 Boost Sleeve
poor reverse engagement. This may also result in high cooler pressure causing
2 O-Rings
converter, crankshaft and/or friction element failure. Wear in the reverse
boost sleeve results in poor line rise, soft 1-2 and 2-3 shifts and/or reverse
Part No. 34910-05K engagement or shudder.
1 Boost Valve The Sonnax replacement kits 34910-01K & 34910-05K reverse boost valve
1 “Factory style” Boost Sleeve assemblies, and 34910-03K pressure regulator valve kit, restore the hydraulic
integrity of the unit and salvage hard to find cores. The boost valve and sleeve
Part No. 34910-03K kit is manufactured from high-quality heat-treated steel and the sleeve is available
1 Pressure Regulator Valve with or without (“Factory style”) o-rings.
2 Teflon® Seals The pressure regulator valve incorporates a solid Teflon® seal to prevent cross
1 End Plug leakage between orificed line pressure and pump suction. The kit also includes
1 O-Ring an o-ringed end plug to assure proper back pressure to the pressure regulator valve.

4L80-E 400 Part No. 34500-Z
Complaint Burned forward clutches

Secondary Complaints: Normal component wear allowing forward & direct drum travel,
Cause resulting in excessive unit endplay
• Front/rear unit
excessive endplay This unit endplay shim allows for proper setting of front unit
Correction endplay and supports the direct drum by supporting the sun gear.
• Premature seal
ring failure U N I T E N D P L AY S H I M
Reaction Drum & Output
Carrier Assembly Carrier Assembly
Part No. 34500-Z

Rear Internal Gear
10 Shims (.010" Thick)
Sun Gear
Application Note: Not for use in ‘97-up
4L80-E “centerlube” units. Use of shim
in these units will restrict lube.
Sun Gear Thrust Bearing

Shim
4L80-E 400 Part No. 34006-SP
Complaint Bushing “walks out”

Cause Lack of flange or “stop” surface on the case bushing
• Output shaft and
case damage This no walk-out case bushing is flanged to prevent movement
Correction in either direction.
• Metal contamination
NO WALK-OUT CASE BUSHING
Part No. 34006-SP

Case Bushing
1 Case Bushing case bushing has oil grooves
Thrust Washer
Transmission Case
Selective Washer
Lip prevents bushing from

traveling toward front or back

VARIOUS GM
Complaint Burned forward clutches/band
Secondary Complaint: O V E R S I Z E D A C C U M U L AT O R P I N S A N D R E A M E R S
• 2nd & 4th clutch
failure (84573-01K
& -02K only)
Part No. 77754-01K Part No. 77999
4L60-E 4L60, 200-4R & 325-4L
4 Accumulator Pins 4 Accumulator Pins
Note: For use with accumulators Note: For use with accumulators
having an original pin diameter of having an original pin diameter of
0.235". 0.309".
Part No. 77754-02K Part No. 77999-02K

4L60-E 4L60, 200-4R & 325-4L
1 Reamer 1 Reamer
Part No. 35718-01K Part No. 34105-01K

350 400
8 Retaining Rings (4sml, 4med) 4 Retaining Rings
Part No. 35718-02K Part No. 34105-02K

350 400
20 Retaining Rings (10sml, 10med) 10 Retaining Rings
1 Reamer 1 Reamer
Part No. 84573-01K

4T60 & E
4 Accumulator Pins
Part No. 84573-02K

4T60 & E
10 Accumulator Pins
1 Reamer
SONNAX PART SUMMARY
I t is very common in GM units to find worn accumulator piston bores. This wear allows oil to cross leak into
other circuits causing various complaints such as burned forward clutches, direct clutch/band failure and
poor shift quality. Rather than replacing hard to find or expensive pistons, Sonnax offers oversized accumulator
pins to restore hydraulic integrity of the piston. Each package contains four pins; a starter kit with 10 pins and
1 reamer is available on all applications.

SONNAX TRANSMISSION SPECIALTIES
Improvements NOT JUST REPLACEMENTS

Innovation:
Sonnax utilizes a unique professional network of design engineers, technical
experts, and shop technicians to analyze mechanical problems in existing
units. Each new Transmission Specialties product starts as a request to address
a specific problem. Sonnax depends on input from professional rebuilders and
our TASC Force Members. These problems are then turned into the highest
quality, innovative, durable, cost-effective solutions.
Engineering:
A talented team of Sonnax engineers, whose combined experience totals over
200 years, diagnose the causes, specify the materials, and design our
Transmission Specialties parts using the latest and most appropriate technologies
available in the industry. Our Sonnax Technical Center works closely with our
engineers in the design and proving of prototypes.
Testing:
Thorough and extensive testing is a critical part of our process. Before our parts
are approved and offered for sale, careful testing is done at the Sonnax Technical
Center and at TASC Force and associated transmission shops both on the bench
and on the road. Proving of our Transmission Specialty parts is a joint effort
between the Technical Center and the Sonnax-sponsored TASC Force (Technical
Automotive Specialties Committee), a collaborative group of highly skilled and
talented transmission experts.
For further information on Sonnax Transmission Specialty parts, please visit us at:
www.sonnax.com
Contact your Transmission Specialty distributor and ask for genuine Sonnax quality parts.

VARIOUS GM Part No. 6578-01
Complaint Soft 1-2 upshifts

I N T E R M E D I AT E S E R V O P I S T O N B U S H I N G
Part No. 6578-01 INI
CH
200, 200-4R & 325-4L A
N
M
G
5 Nylon Bushings R
D
E
QUIRE
Intermediate Servo
Note: This repair requires machining. Piston Bushing
SONNAX PART SUMMARY
C ommon complaints of vehicles with 200, 200-4R & 325-4L transmissions are soft 1-2 upshifts, a flare on 2-3
shifts, and premature band failure. The Sonnax intermediate servo piston bushing 6578-01 restores the OEM
bore size, reducing oil leakage past the pin, and eliminating the replacement of the costly OEM servo piston.
Part No. 35410-T
Complaint Governor circuit oil loss, worn case bores, sticking shift valves
Part No. 35410-T GOVERNOR CIRCUIT TEST TOOL
350, 400 & 4L60
1 Governor Circuit Test Tool
Note: Diagnostic tool can be used at
rebuild bench or in vehicle. Governor Circuit Test Tool
SONNAX PART SUMMARY
T his Sonnax governor circuit test tool is specifically designed to test the governor circuit of 350, 400 &
4L60 transmissions for a worn bore, obstructions in the circuit, misalignment of the assembly, circuit
leakage, or incorrect shift points due to oil loss or hanging valves.
Part No. 35012S
Complaint Bushing spin-out and case damage

Part No. 35012S OVERSIZED REAR CASE BUSHING
INI
CH
4L60 & E A
N
M
5 Rear Case Bushings

R
E
QUIRE
Note: This repair requires Rear Case Bushing

machining. steel-backed bronze lining
SONNAX PART SUMMARY
T he OEM rear case bushing in the 4L60 & E transmissions spin out causing case damage. After the damage,
it's impossible to reinstall a standard bushing. Bushing spin out may be due to lack of lubrication or too
much load for the bearing area. Replace with Sonnax's oversized rear case bushing 35012S.

4L60 & E Part No. 77911-01
Complaint Poor 1-2 shift

Part No. 77911-01 2 N D A P P LY S E R V O S A V E R S L E E V E
INI
CH
5 Servo Saver Sleeves A
N
M
G
Note: The Sonnax sleeve allows E Q E
D
UIR
the #554 inner sleeve to fit a
#553 piston. With a minimal amount Servo Saver Sleeve
of machining the #554 piston can
convert to a #553 piston.
SONNAX PART SUMMARY
I n vehicles with a 4L60 & E transmission, servo apply areas often need to be increased to improve 1-2 shift.
This is often done by replacing the 2nd servo piston assembly, typically with the #553 version. This practice
has caused an overabundance of used #554 servo assemblies and poor availability of quality #553 assemblies.
Part No. 77911-02
Complaint Burnt 2-4 band

Part No. 77911-02 PISTON BORE SEAL
INI
5 Metal Clad Viton Seals ®
A
CH
N
M
Note: Slight machining of

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QUIRE
servo piston is necessary Metal Clad Viton® Seal
to accommodate the seal.
SONNAX PART SUMMARY

omplaints of no 3rd gear, 2-4 band applying in 3rd gear, and burned clutches/bands can be caused by wear
C at 2nd apply servo piston. This metal clad Viton® seal 77911-02 will restore the hydraulic integrity of pis-
ton/pin interface. This prevents 3rd accumulator oil from exhausting past a worn piston.
Part Nos. 77731-01, 02K, -03, -04, -05, -08 & -RK
Complaint Planetary wear or failure

R E A R P L A N E TA RY R E B U I L D PA R T S
Part No. 77731-RK
Complete Planetary
Part No. 77731-02K

4 Pinion Pins
Note: Pinion endplay factory specifi-
cation of between .008" to .024". Part No. 77731-03 Part No. 77731-05
80 Needle Rollers 1 Batwing Washer
Part No. 77731-01
1 Pinion Gear Part No. 77731-04 Part No. 77731-08
1 Round Washer 1 Oil Deflector (not shown)

4L60 200-4R Part Nos. K77898, K77898A & 77917-01K,
-02K, -03K, -04K, -471, -500
Complaint Poor line rise, burnt clutches and band

Secondary Complaints: R E V E R S E & T H R O T T L E B O O S T VA LV E S & S L E E V E S
• Delayed reverse Pump Body
• Soft slide shifts
Cause D2
test with oil here
Worn reverse boost valve

sleeve or wear at pump body Pressure Regulator Valve
and worn TV boost sleeve
Spring
Correction Reverse Boost

Valve & Sleeve
TV Boost Valve Retaining Ring
These reverse & throttle & Sleeve
boost valve kits, are made
from hardened steel, with
optional o-rings.
“Factory style” Sleeves
Throttle Boost Valve
(O-ring Style)
Part No. 77917-01K SONNAX PART SUMMARY

.423" diameter
Part No. 77917-471

.471" diameter A common problem with the 4L60 and 200-4R transmissions is a burned
band and/or clutches. This failure can be reduced by eliminating boost
oil leakage. The Sonnax Factory style replacement assemblies 77917-02K,
Part No. 77917-500
.500" diameter
77917-03K, and 77917-04K eliminate these problems with two closely
toleranced, hardened steel parts: a throttle valve boost valve and a throttle
valve boost sleeve. The three kit numbers are used for different applications.
In addition, Sonnax offers the same replacement assemblies with o-rings on
Part No. 77917-02K the throttle boost sleeve for extra protection: 77917-01K, 77917-471, and
.423" diameter “Factory style” 77917-500. The o-rings on the sleeve separate the throttle pressure and
Part No. 77917-03K reverse boost circuits, thus providing additional protection against cross leaks
.471" diameter “Factory style” by preventing oil loss between the outside diameter of the throttle valve sleeve
Part No. 77917-04K and the pump body.
.500" diameter “Factory style”
Complaints of poor reverse, delayed reverse or shudder in reverse can be
traced to a worn reverse boost sleeve or pump bore. The Sonnax “Factory
Each kit above and to the style” K77898A and o-ring style K77898 boost valve kits address this wear,
right includes the following: while the o-ring style K77898 will also salvage pumps with a worn bore.
1 Boost Valve
1 Boost Sleeve
2 O-Rings (O-ring style only) Part No. K77898 Part No. K77898A
(“Factory style”)
Reverse Boost Valve
(O-ring Style)

4L60 Part Nos. 77968 & -RM
Complaint Poor line rise

Secondary Complaint: O V E R S I Z E D T H R O T T L E VA LV E
• 3-4 clutch and

band failure
Cause
Valve Body
A low throttle boost
oil condition
Correction Reamer
Oversized Throttle Valve

Stop the excessive leakage
by installing this oversized
replacement throttle valve
that has slightly larger
spool diameters. The valve
SONNAX PART SUMMARY
body bore can be made
larger with the special
reamer. The oversized
A low throttle boost condition is a common complaint in vehicles with a
4L60 transmission. This loss of throttle boost oil creates poor line rise and
accelerates 3-4 clutch and band failure.
valve will fit the newly
reamed bore. In late model transmissions, the hardened steel throttle valve continuously
oscillates in the cast iron valve body bore and eventually wears the three bore
diameters. This wear allows throttle valve feed oil to leak past the valve spool
Part No. 77968
and exhaust, resulting in a low throttle boost condition.
1 Oversized Throttle Valve
O
TO L
This excessive leakage can be eliminated by installing the oversized Sonnax

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QUIRE
Part No. 77968-RM replacement throttle valve 77968. The three spool diameters on this valve are
1 Reamer slightly larger than the late model OEM valve, allowing the valve body bore to
be modified to restore the hydraulic integrity of the assembly. The valve body
Note: It is necessary to use Sonnax
Reamer 77968-RM to re-size the bore can be made large enough to accept this replacement valve by reaming it
worn valve body bore. with the specially designed reamer 77968-RM. This hand reamer has three
tightly-toleranced cutting diameters that will slightly enlarge the valve body
bore in the area of the throttle valve. The reamer is piloted by the bore of the
throttle valve plunger sleeve. This is much less expensive than replacing the
worn valve body. It eliminates mis-calibration or similar wear when exchanging
with another used valve body.

4L60 Part Nos. 77966-93K, -94K & -94MK

Secondary Complaints: The steel TV plunger wears the TV plunger sleeve, allowing TV feed
Cause oil to leak past the plunger and exhaust
• No detent downshift
These sleeves are made with high quality aircraft aluminum; the sleeve and
• Poor throttle control Correction plunger have been tightly toleranced to restore hydraulic integrity.
T H R O T T L E VA LV E S L E E V E A N D P L U N G E R
Part No. 77966-93K
Part No. 77966-94K
Part No. 77966-94MK
Each kit contains the following:
1 Plunger
1 Sleeve
Valve Body OEM identification
Notes: numbers “93” or
1. 77966-93K (OEM “93”) “94” located here
77966-94K (OEM “94”)
77966-94MK (High Performance)
2. The 77966-94MK is a high
Throttle Valve Plunger
performance sleeve that allows
full throttle upshifts from 3rd
gear to overdrive. Roll Pin
Throttle Valve Plunger Sleeve
4L60 Part No. 77872-01
Complaint 3-4 clutch/band failure

Cause Insufficient TV linkage travel
• Poor line rise
This shorter TV link insures re-adjustment of the throttle cable
• Soft shifts Correction and was designed with the carry-out unit in mind.
SHORTENED TV LINK
Part No. 77872-01
5 TV Links
TV Link
Valve Body

4L60 & E Part No. 77918S-K
Complaint Delayed reverse, code 1870

Secondary Complaints: Overheating and manufacturing flaws cause sleeve rotation and
Cause block oil flow which leads to transmission failure
• No 3rd gear
Replace the shaft with this support shaft. The sleeve in the shaft is
• 3-4 clutch failure Correction secured with Loctite® and a set screw to prevent rotating in use.
• Converter overheat U N I V E R S A L S TAT O R S U P P O R T S H A F T K I T
100% Leak Tested
Stator Support Shaft
Part No. 77918S-K
1 Stator Support Shaft
Universal Bolt
3 Bushings Slot Indexing
Note: Bushings are provided to
allow use with 4L60 units and late
PWM 4L60-E units (except w/ 300
mm converter).
Set Screw To Mechanically
Lock In Sleeve
Bushing
35007B
Bushing
77002B
Bushing
35007A
4L60 & E Part No. 77701-076
Complaint Reduced 3-4 clutch life

Secondary Complaint:
Cause Inadequate metering of the 2nd band servo release oil
• Poor 2-3 shift feel
This solution meters servo release oil for a shorter 2-3 shift while
Correction providing proper exhaust for a smooth 3-2 down shift.
Part No. 77701-076
1 Check Valve S E R V O R E L E A S E “ C H E C K VA LV E ”
Notes:
1. Sonnax P/N 77701-076 has U.S.
patent number 5,536,221. Patent
infringement will not be tolerated
2. Installs over and together with Transmission Case
3rd accumulator check-ball
capsule. Can be used with
either OEM capsule or field
fix of cup plug.
Check Valve™
allows 3-4 clutch feed orifice
calibration without creating
2-3, 3-2 concerns

Innovation
IDEAS, METHODS & PRODUCTS
Reaming to repair bores & specialized tools to match repair market needs
•
Wear-resistant hard-coated aluminum and hardened steel valves
•
O-ringed valve sleeves: for added protection against cross leakage
•
Designs made specifically for use with remanufactured parts
•
Annular grooves & built-in reliefs to prevent sticking
•
“Factory style” valve sleeves: for ease of installation
•
E4OD pump gears with improved drive surfaces
•
Diagnostic procedure: Wet Air Test (WAT)
•
SonnaFlow : unique diagnostic tool
TM
•
Longer servo-pins with o-ring seals
•
Sleeving of the accumulator bores
•
Case and valve body savers
www.sonnax.com

4L60 & E 200-4R Part Nos. 77777M-K, L-K & K-K
Complaint 1-2 bang (light throttle) or slide bump shift

Secondary Complaint: A C C U M U L A T O R V A LV E T R A I N A S S E M B LY
Valve Body
• Shortened band life
Cause Accumulator Plug

Accumulator
Valve Spring
Accumulator control
incorrect for vehicle
application
Correction Accumulator Sleeve
Using one of these three

assemblies will maintain
holding power and proper Accumulator Valve
shift feel. The sleeve is SONNAX PART SUMMARY

made from high quality
aluminum and each kit
contains three springs of
V ehicles with 200-4R or 4L60 & E transmissions can experience 1-2 light
throttle abrupt or “bang” shifts, or a slide-bump on the 1-2 shift, based
on a mismatch of accumulator control valve for the application. This valve
varying spring rates. train has 7 different OEM size variations: B, A, N, M, L, K, and F. They
range from the largest valve diameter giving the firmest shift (B) to the
smallest valve diameter giving the softest shift (F), respectively. The size
Part No. 77777M-K variations are clearly stamped with the letter on the aluminum sleeve. Most
(.341")
vehicles, depending upon the transmission/engine combination, can use
Part No. 77777L-K either the M, L, or K version. However, these are not available unless scavenged
(.330")
from other valve bodies.
Part No. 77777K-K
(.315") Sonnax has designed a replacement accumulator valve train assembly for the
Each includes the following: M (.341" valve diameter) 77777M-K, L (.330" valve diameter) 77777L-K
and K (.315" valve diameter) 77777K-K versions. Using one of these three
assemblies will maintain proper shift feel. The sleeve is manufactured from
1 Accumulator Valve high quality aluminum that is designed to prevent excessive wear due to the
1 Accumulator Sleeve reciprocating motion of the steel valve. Each accumulator valve kit contains
1 Accumulator Plug three springs of varying spring rates to choose from.
3 Accumulator Springs
Vehicle Type Accumulator Yellow White Pink
Note: The Sonnax sleeves are not
Valve Assembly 3 lb. 5 lb. 7 lb.
stamped with the letter I.D.
The diameter listed with the part Heavy Cars & Trucks “M” Version Light Shift Medium Shift Firm Shift
with High Axle Ratio (3.08-3.23-3.42)
numbers above is of the smallest
land on the valve. Medium Weight Cars “L” Version Light Shift Medium Shift Firm Shift
(such as Camaro & Firebird) with Mid Axle Ratio (3.42-3.55-3.73)
Lighter Weight Cars “K” Version Light Shift Medium Shift Firm Shift
(under 3,200 lbs) with Mid to Low Axle Ratio (3.73-4.11-4.33)

4L60 & E 200-4R Part No. 65797
Complaint High line pressure at an idle

Cause A worn pump slide pivot pin
Part No. 65797 This hardened pump slide pivot pin is a direct replacement and
5 Pivot Pins Correction helps restore hydraulic integrity.
PUMP SLIDE PIVOT PIN
Pivot Pin
Pump
4L60 & E Part Nos. 77704S & 74926
Complaint 1-2 slide bump shift

Secondary Complaint: The OEM spring is broken or a stronger spring is needed for high
Cause performance applications
• Soft 1-2 shift
Use the purple accumulator spring for stock and the enhanced for
Correction performance and firmer 1-2 shifts.
Part No. 77704S
Enhanced Performance 1 - 2 A C C U M U L AT O R S P R I N G
5 Springs
Purple
Spring
Part No. 74926 Enhanced

“Purple” 1-2 Accumulator Spring Performance Spring
5 Springs
1-2 Accumulator Piston

Housing

4L60 & E Part Nos. 77767K & -SK
Complaint Soft 3-4 shift

Part No. 77767K Cause Insufficient holding power of the 4th gear servo piston
1 Dual Piston Assembly
1 Steel Washer The apply surface of the new piston has been increased by 40% to
Correction increase holding power on heavy-duty and performance applications.
Note: Sonnax Part 77767K has U. S.
Patent Number 5,944,627. Patent
infringement will not be tolerated.
4 T H G E A R " S U P E R - H O L D " S E R V O P I S T O N TM
Part No. 77767K-SK

4 Replacement Seals (see below)
Blue PTFE
Coated,
Viton® Steel Washer
O-Ring
Scarf Cut
PTFE Seal
Scarf
Cut
PTFE
Seal Viton® Case Section
Dual Piston Assembly
O-Ring offers 40% more holding
power due to greater apply area
4L60 & E 350/C Part Nos. 77406-10 & 77409-15
Complaint Excessive unit endplay

Cause Normal wear of drivetrain components
• Drivetrain noise
These endplay shims allow for proper adjustment of front and rear
Correction unit endplay.
Part No. 77406-10
10 Rear Unit Endplay Shims R E A R & F R O N T U N I T E N D P L AY S H I M S
Output Shaft Assembly
Input Drum
Part No. 77409-15
10 Front Unit Endplay Shims Shim
Shim
Shim
place against drum pocket

4L60-E Part Nos. 77754-09K & -TL
Complaint Wrong gear starts, solenoid codes, clutch/band failure

Secondary Complaints: A C T U AT O R F E E D L I M I T VA LV E K I T
• 2nd starts
• Soft shifts
• 3-4 clutch failure
• No 4th gear
• 1870, slip-ratio codes Sleeve
with retaining
ring installed
Cause Valve
Actuator feed limit bore

wear results in low pressure
at shift and EPC solenoids
End Plug
Correction
Spring
This kit salvages 4L60-E
valve bodies. The kit
includes a re-designed,
anodized AFL valve that
regulates pressure and a SONNAX PART SUMMARY
wear resistant sleeve to re-
establish hydraulic integrity. T he OEM actuator feed limit (AFL) valve design has a large reaction area
and is highly affected by side loading, which wears the valve body bore.
The EPC solenoid oscillates the torque signal and AFL oil which increases valve
action. As the bore wear increases, oil pressure is reduced to the shift solenoids
Part No. 77754-09K which causes solenoid and ratio codes. The same AFL oil loss results in lower
1 Valve Sleeve Assembly line pressure.
O
TO L
1 Spring
The improved Sonnax kit 77754-09K (4L60-E) includes an anodized valve
1 Retaining Ring and wear resistant sleeve. The valve has annular grooves to prevent side load-
R
E
QUIRE
ing and has 54% more support by operating in the full contact sleeve. Due to
the valve diameter and sleeve, this repair requires a reamer and reamer guide
Part No. 77754-TL tool kit, Sonnax part number 77754-TL, which services both the 4L60-E and
1 Twist Drill 4L80-E (see page 47 or information on the 4L80-E).
1 Reamer
3 Guides
1 Collar

4L60 & E Part Nos. 77805-K & 77805E-K
Complaint No lock-up condition, code 1870

Secondary Complaints: T C C A P P LY V A LV E S
• Falling out of
lock-up when hot
• Fluid blowing out
the fill tube Pump
• Lock-up immediately
after 2nd gear (no
TCC Apply Valve
power complaint) 77805E-K
• Blued/overheated No leakage here

during WAT
converters
TCC Apply Valve
77805-K
Cause
Retaining Clip
Excessive pump bore to
valve clearance
Valve Stop
Correction Teflon Seal

®
SONNAX PART SUMMARY

These TCC apply valves
will eliminate bore cross
leakage with a
V ehicles with a 4L60 or 4L60-E transmission have numerous converter
overheat and lock-up complaints related to TCC apply valve bore wear.
These include no lock-up or lock-up immediately after 2nd gear when fluid
Teflon® seal. warms up. Frequently the solenoid will have no control over the valve’s position.
These complaints are usually created by excessive pump bore to valve clearance.
Part No. 77805-K Often converter feed oil will leak past the spool, which added together with
4L60 & 4L60-E Non-PWM orificed signal oil, will be more than the solenoid can exhaust. This may com-
Part No. 77805E-K pletely stroke the valve into the lock-up position and create a “no power” or
4L60-E PWM only “no brake cancel” condition. Oil cross leaks may float the valve into a
Each includes the following: midway position and restrict cooler flow, which burns up the converter.
Sonnax has developed a hardened steel TCC apply valve 77805-K for the
1 Valve
4L60 and 4L60-E non-PWM units and an anodized aluminum valve
1 Teflon® Seal 77805E-K for the 4L60-E PWM units, that will eliminate the bore cross
leakage. These precision valves have a Teflon® seal to prevent the cross leaking
of converter signal oil and converter feed oil.

4L60-E PWM & NON-PWM Part Nos. 77754-03K, -04K & -R2
Complaint Code 1870, harsh 1-2

Secondary Complaint: T C C R E G U L AT O R VA LV E K I T S
• Overheated or blued
converters
Isolator Valve
Cause Spring
Retaining Clip
Severe wear of the TCC Regulator Valve
regulator valve bore allows Valve Body
regulated converter apply

pressure to exhaust
Reamer
Correction Sleeve
These kits have a longer

SONNAX PART SUMMARY
spool diameter to prevent
leakage. A wear resistant
sleeve restores hydraulic S onnax now offers two kits for this assembly: 77754-03K and 77754-04K.
The isolator valve is the same in both kits and has a .560" longer spool
diameter to ride in the unworn portions of the valve body bore and prevent
integrity of the apply circuit
leakage. Annular grooves have also been added for better valve centering. A
and gives full support to the wear resistant sleeve has been added to the regulator apply valve to restore the
valve to prevent side loading. hydraulic integrity of the apply circuit and to give full support to the valve to
prevent side loading. Part number 77754-04K offers the same converter apply
Part No. 77754-03K pressure as the OEM design and can be used with all model years (including
Offers an increased TCC apply rate non-PWM versions). Part number 77754-03K offers an increase in TCC apply
O
TO L
pressure, where additional converter clutch holding capabilities are needed.
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An annular groove on the regulator apply valve spool gives added insurance
Part No. 77754-04K against side loading. Reaming of the valve body bore is necessary for the
Offers OEM TCC apply rate installation of both sleeves. The OEM retaining clip is re-used. The kit includes
Recommended for EC3 units. O
TO L
a spring for use in PWM units. Since the valve body castings for PWM and
non-PWM units are identical, kit 77754-03K can be used in converting
R
E
QUIRE
Each includes the following: non-PWM valve bodies for use in PWM units and converting PWM valve bodies
for use in non-PWM units.
1 Isolator Valve Note: EC3 is short for electronically controlled capacity clutch.
1 Sleeve
1 Regulator Valve
1 Spring
Part No. 77754-R2

1 Reamer (required for use
with above part #’s)

Engineering
MEETING OR EXCEEDING OEM PERFORMANCE
Diagnosis of root cause

•
Proper geometry-exacting tolerances
•
Optimum selection of materials based on application
•
Quality assured with instrumentation & manufacturing technology
•
Designed with rebuilder needs in mind
•
Process & manufacturing engineering
•
Uncompromising standards
www.sonnax.com

4L60-E Part Nos. 77898E-K, 77898E-3K, 77898E-4K & 77898E-6K
Complaint Insufficient line rise, 3-4 clutch failure

Secondary Complaint: R E V E R S E B O O S T VA LV E & S L E E V E K I T S
• Poor shift quality
Cause
A worn boost sleeve can
allow torque signal and Boost Valve
reverse oil cross leakage
or leakage to sump Boost Sleeve
Valve Body
Correction ”Factory style”
The closely toleranced

valve and sleeve kits O-Rings
restore hydraulic integrity identification

and prevent leakage. Kits groove on .470" ratio
are available in the .470" SONNAX PART SUMMARY

stock replacement or .490"
increased boost ratio sizes,
with or without o-rings.
V ehicles with a 4L60-E transmission frequently have poor line rise, which
can result in 3-4 clutch, 2-4 band failure or poor shift quality. The duty
cycle of the EPC solenoid causes the boost sleeve to wear quickly. Oil enters
the torque signal orifice, leaks past the boost valve, and exhausts through the
reverse orifice, resulting in poor line rise. Reverse oil can exhaust both to the
Part No. 77898E-K
Oversized .490" EPC Spool Diameter
sump and back through the torque signal orifice. The outside diameter of the
boost sleeve also allows some leakage through the pump body, which decreas-
Part No. 77898E-4K es pressure rise.
OEM Ratio .470" EPC Spool Diameter
Each includes the following: Sonnax offers two replacement boost valve kits that will prevent the problems
mentioned above by matching a closely toleranced valve and sleeve. OEM
1 Boost Valve boost ratio (.470" EPC spool diameter) kits are offered 77898E-4K and
1 Boost Sleeve 77898E-6K as well as increased spool diameter kits (.490" EPC spool diameter)
2 O-Rings 77898E-K, and 77898E-3K which will result in a higher boost ratio to raise
line pressure and provide firmer shifts.
The boost valves have been specially hard coated to eliminate excessive wear
Part No. 77898E-3K
“Factory style” .490" EPC Spool Dia.
from occurring on the inside diameter of the sleeves. These boost sleeves have
been manufactured from Deltalloy® 4032 high quality aluminum specifically
designed to resist wear. On o-ring type sleeves, the two o-rings provide
Part No. 77898E-6K additional protection against leakage through the pump body and assist in
“Factory style” .470" EPC Spool Dia. maintaining pressure in the circuits that supply the boost valve.
1 Boost Valve
1 Boost Sleeve

4L60 & E Part Nos. 77917-06, -07 & -TL
Complaint Insufficient line rise, 3-4 clutch failure

Secondary Complaints: P R E S S U R E R E G U L AT O R VA LV E K I T S
• Limited maximum Pump Body
pressure
Pressure Regulator Valve
• Reverse chatter 4L60-E
Spring Boost Assembly
Cause valve
Boost Assembly
sleeve
Pressure regulator valve 4L60
bore wear allowing leakage
Spring
and contributing to erratic
pump slide movement
Reverse Boost
Valve & Sleeve
Correction TV Boost Valve

& Sleeve
Retaining Ring
Drill Jig
Repair the valve bore and
restore pressure control Reamer
to the system with these
oversized pressure regulator
SONNAX PART SUMMARY
valve and reamer kits.
Part No. 77917-06 O

S onnax offers an oversized pressure regulator valve for the 4L60,
77917-06 and the 4L60-E, 77917-07. The Sonnax valve permits pump
covers to be restored to OEM specifications despite wear and leakage at the
TO L
4L60 pressure regulator valve. The pump cover is reworked using the Sonnax Reamer
and Guide Kit 77917-TL which refinishes and prepares the valve bore to accept
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Part No. 77917-07 the oversized PR valve.

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4L60-E
Wear usually occurs at 3 locations. The most common wear areas are on either
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side of the decrease circuit where the double spool constantly oscillates. With
Each includes the following: these areas worn there is leakage of line pressure in boost conditions and leakage
of decrease pressure during non-boost conditions. The result is twofold. First,
1 Pressure Regulator Valve line pressure is too low when high line holding power is needed during boost
conditions (pressure can be 50-100 psi low in reverse). Second, the decrease circuit
fails to effectively adjust pump output. The pump slide movement is erratic
Part No. 77917-TL causing excess pump noise and wear. Also, line pressure is too high and
1 Reamer & Drill Jig uncontrollable during non-boost conditions. The last wear area is at the
Note: Reamer and drill jig are the balance end of the pressure regulator. The result is balance oil leakage which
same for both the 4L60 & 4L60-E. locates the valve in a high line position. The Sonnax PR valve helps restore
Wiggle Test
control over the pressure regulating circuit by eliminating leakage.

4L60 & E Part No. 77998-01K
Complaint Worn or scored accumulator bores

Secondary Complaint: Repeated oscillation of the accumulator piston scores the 3-4
Cause accumulator bore during normal operation
• Damaged cases
This simple drop-in solution saves cases with an aluminum sleeve, a
Correction replacement piston with an o-ring seal, and a new accumulator pin.
Part No. 77998-01K
1 Repair Sleeve 3 - 4 A C C U M U L AT O R S L E E V E K I T
1 Piston with O-Ring
1 Accumulator Pin
Accumulator Pin
Repair Sleeve
Piston with O-Ring

made of high quality
fluorocarbon material
4T60-E Part No. K84956-SP
Complaint No movement, rattle noise in park

Cause 1-2 roller failure or insufficient spring loading on 1-2 rollers
Part No. K84956-SP
16 Springs
These heavy duty roller clutch springs outperform OEM springs and
Note: Not compatible with 1996-up Correction insure rebuild durability.
black plastic roller clutch update.
1-2 ROLLER CLUTCH SPRING KIT
Roller Clutch
Springs

4T60 & E Part No. 84754-23K
Complaint 1-2 shuttle shift

Cause A worn OEM valve
• 2nd gear start with
light throttle bump This drop-in replacement valve is hard anodized with annular
Correction grooves to reduce sticking and does not require a reamer.
back to 1st
• Failure to shift to 2nd 1 - 2 S H I F T VA LV E
Part No. 84754-23K

1 (1-2) Shift Valve
Spring
1-2 Shift Valve
Valve Body Annular Grooves
4T60 & E Part Nos. 84881 & 84881A
Complaint Low or high line pressure

Cause Normal wear of the pin due to continuous motion of the pump slide
• Low or high
line pressure due to These direct replacement thru-hardened steel pins come in both
pivot pin mismatch Correction solid and grooved designs.
• High pressure caused PUMP SLIDE PIVOT PINS
by a worn out pin
Pump Body
Part No. 84881

Solid Version
Part No. 84881A Pivot Pin

Grooved Version 84881A
5 Pump Slide Pins

4T60 & E Part Nos. 84733-10 & -20
Complaint Rapid sealing ring wear, drive line engagement clunk

Cause Excessive input clutch endplay and drum travel
• Loss of lube
oil control These shims are designed for precise and accurate reduction of input
Correction clutch endplay and to adjust for component wear.
• Reduced bearing life
INPUT CLUTCH HUB SHIMS
Part No. 84733-10 Input Clutch Hub

10 Shims (.010")
Part No. 84733-20

10 Shims (.020")
Shim
Bearing
Shim
4T60 & E Part No. 84995-01
Complaint Leakage of oil at side cover to channel plate inner gasket

4th clutch heat, side cover corrosion, crushing or splitting of the
Cause gasket when the side cover pan nuts are torqued
Part No. 84995-01
1 Leak Repair Plate Fix the leak without removing the side cover or replacing the failed
Note: For use with stamped steel Correction gasket with this leak repair plate.
side cover.
A X L E / S I D E C O V E R L E A K R E PA I R P L AT E
Side Cover
Axle/Side Cover
Repair Plate

4T60 & E Part No. 75890-30
Complaint Differential side gear thrust washer failure

Secondary Complaints: Worn side gear thrust washers allow the gears to move away from
Cause pinions causing backlash and clunk
• Washers not
serviced separately
Correction Hardened thrust washers allow differential salvage and correct set-up.
• Excess differential/axle
backlash THRUST WASHER
Part No. 75890-30

4 Thrust Washers
Differential
Thrust Washer Side Gears
4T60 & E Part No. 75410-10
Complaint Driveline noise, backlash

Cause Excessive endplay
• Reduced differential
bearing life This differential carrier to case shim is used with OEM shims
Correction to accurately adjust endplay and improve planetary life.
Part No. 75410-10 DIFFERENTIAL CARRIER TO CASE SHIM

10 Shims (.010")
Shim
Thrust Bearing
Differential Carrier Assembly

Thrust Washer

Testing
100% TESTED PRIOR TO RELEASE
Dyno-tested & road-tested at Sonnax Technical Center

•
Tested for compatibility with different model years
•
Tested for complete and explicit instructions
•
Tested in various conditions & climates
•
Tested in shops by TASC Force members
•
TASC Force Approved
www.sonnax.com

4T60-E (PWM ONLY) Part Nos. 84754-01K, -08K & -RM
Complaint Code 39 / 740 / 1870, converter shudder

Secondary Complaints: T C C R E G U L AT O R VA LV E & I S O L AT O R VA LV E
Valve Body
• Converter overheat
• Low converter
apply pressure
• Falling out of Spring
lock-up hot
Reamer
Cause Isolator Valve
TCC Regulator Valve

Low converter apply
pressure, a worn regulator
valve bore, and insufficient Isolator Valve TCC Regulator Sleeve
‘91 & ‘92 Applications
isolator boost/PWM oil
TCC Regulator Valve
Correction
‘93 & Up Applications
Restore the hydraulic TCC Regulator Sleeve
integrity of the TCC
SONNAX PART SUMMARY
regulator circuit by
replacing with these
TCC regulator kits.
C ommon complaints of PWM 4T60-E transmissions are codes 39, 740,
1870, converter shudder, converter overheat and excessive converter
clutch slippage. These complaints are typically caused by a worn valve body
bore or sleeve at the TCC regulator valve and/or isolator valve area. In '91
Part No. 84754-01K and '92 designs, the steel TCC regulator and isolator valve operates in the
‘93 & Up PWM Units valve body bore. This motion eventually wears the bore and allows converter
1 Isolator Valve clutch apply oil (regulated line pressure) to exhaust to the sump. Wear at the
1 TCC Regulator Valve isolator valve bore allows leakage of converter charge oil and PWM boost oil.
1 TCC Regulator Sleeve
In 1993 and up units, GM changed the design of the TCC regulator to oscil-
Note: No Reaming Required.
late in an aluminum sleeve. This sleeve also wears, allowing critical TCC
apply to exhaust to the sump.
Part No. 84754-08K To overcome these complaints, Sonnax has developed two TCC regulator
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‘91 & ‘92 PWM Units valve kits. 84754-08K and required reamer 84754-RM are used with '91
1 TCC Regulator Valve and '92 units, while 84754-01K is used with all '93 and up PWM units. The
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1 TCC Regulator Sleeve two kits restore the hydraulic integrity of the circuit. The regulator valves are
1 Spring made with anodized aluminum and the sleeves are made of wear resistant
1 Isolator Valve ALCOA Deltalloy® aluminum. The isolator valves are made from hardened steel
and feature additional length and annular grooves for better valve centering
Part No. 84754-RM and stability. The 84754-01K for '93 and up units does not require a reamer.
1 Reamer Note: See page 41 for additional information on this subject.

4T60 & E Part Nos. 84754-16K, -22K, -TL, -97K, -98K & -DJ2
Complaint Code 1870, falling out of lock-up hot

Secondary Complaint: T C C A P P LY V A LV E K I T S
• No lock-up
A
Cause
Wear of TCC apply valve
bore allows leakage of OEM Stock Size Valve
84754-22K Teflon® Seal
TCC signal oil to exhaust
A
and apply valve to move Valve Body
into TCC release position B
Spring
Valve Body Bore wear
Correction here, requires Reamer and

Oversized Valve 84754-16K
Replace with these TCC Reamer

required for 84754-16K
apply valves to restore
circuit integrity. Drill Jig
Part No. 84754-16K O

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SONNAX PART SUMMARY
Up to '96 (oversized diameter)
I solating converter codes which are valve related is difficult. The TCC apply
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Part No. 84754-22K valve should be considered as the switch for converter apply and release oil,
Up to '96 (standard diameter) where the regulator valve 84754-01K controls the apply pressure and TCC
piston slippage. The apply valve and its bore wear (indicated above) can be
isolated with either the SonnaFlow™ or a scanner.
Part No. 84754-97K O
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'97 and up (oversized diameter) On the Sonnaflow™, the TCC valve stroke will be evident as a .2 gpm increase
in flow as the valve strokes. If the valve strokes off or releases hydraulically, the
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flowmeter will indicate the same reduction. When the bore is worn, the solenoid
Part No. 84754-98K has no control over the valve as heat rises and the oil thins.
'97 and up (standard diameter)
Each includes the following: Electronically, look for TCC slip RPM to be 10% of engine RPM. The scanner
1 Apply Valve will indicate the TCC is enabled, indicating the TCC has not locked up as the
1 Teflon® Seal valve has stroked to the un-apply position.
1 Spring There are two wear points in the TCC apply valve bore. The most common is
at the largest end spool closest to the solenoid (see ref. B above). TCC Signal
Part No. 84754-TL oil is allowed to leak past the spool to exhaust. The second is at the small end
for 84754-16K & 84754-97K of the valve where line pressure enters (see ref. A above).
Reamer and Drill Jig
For units with wear at the large (B) spool only, use 84754-22K (4T60 and up
to '96 4T60-E) or 84754-98K for '97 and up units. For units with wear at
Part No. 84754-DJ2 both diameters (A & B) use 84754-16K (4T60 and up to '96 4T60-E) or
Drill Jig for 84754-98K only 84754-97K for '97 and up units. For 84754-16K only the 84754-TL is
required. For 84754-97K, both the 84754-TL and 84754-DJ2 are required.

4T60 & E
Complaint Soft shifts, poor line rise
Secondary Complaints: MODULATED LINE BOOST VALVE & REVERSE BOOST VALVE KITS
Valve Body
• Poor reverse boost
• 2nd and /or 3rd
clutch distress
Cause
OEM Spring
Worn and leaking Spring

boost sleeves Pressure Regulator Valve
Identifier
(See øA in
Charts Below)
Correction Spring
Reverse Boost Valve & Sleeve

These four replacement w/OEM spring and retaining clip
boost valve kits provide
more sealing area with Modulated Boost Valve & Sleeve
sleeves and valves made
from high quality, SONNAX PART SUMMARY
hardened steel to
prevent exessive wear. V ehicles with 4T60 or 4T60-E transmissions often have complaints of
poor line rise, soft shifts, poor reverse boost, and/or 2nd & 3rd clutch
distress which can be caused by worn/leaking boost sleeves. The OEM boost
Part No. 84754-12K valve spools have very narrow contact surfaces which contribute to the leakage.
Mod. Line Boost Valve Kit (Low Ratio)
Sonnax has developed four replacement valve kits: 84754-12K (low ratio) &
Part No. 84754-17K 84754-17K (high ratio) for the mod. line boost valve and sleeve, and
Mod. Line Boost Valve Kit (High Ratio)
84754-14K (low ratio) & 84754-19K (high ratio) for the reverse boost
Each includes the following: valve & sleeve. The sleeves and valves are made from high quality, hardened
steel to prevent premature wear and the valve spools have been lengthened to
1 Mod. Line Boost Valve provide more sealing area within the sleeves. Both kits include a replacement
1 Mod. Line Boost Sleeve spring to provide proper calibrations for the lengthened valve spools.
1 Mod. Line Boost Spring
MTV BOOST VALVE REVERSE BOOST VALVE
Note: See Figure to the right for use. OEM DESIGN OEM DESIGN
Part No. 84754-14K

Reverse Boost Valve Kit (Low Ratio)
øA øB øC øD
Part No. 84754-19K
Reverse Boost Valve Kit (High Ratio)
Low Boost Ratio High Boost Ratio
øA .276" øA .199"
1 Reverse Boost Valve Sonnax Kit No. 84754-12K Sonnax Kit No. 84754-17K
øB .567" øB .567"
1 Reverse Boost Sleeve
øC .273" øC .293"
1 Reverse Boost Spring Sonnax Kit No. 84754-14K Sonnax Kit No. 84754-19K
øD .328" øD .348"
Note: See Figure to the right for use.
Note: MTV & reverse boost assemblies can be swapped to achieve varied boost rates.

Part Nos. 84754-12K, -14K, -17K, -19K, -24K & -25K
REVERSE BOOST WET AIR TEST INFORMATION

Part No. 84754-24K
Line (PRN) Reverse & Mod. Line
Boost Valve Kit (Low Ratio)
Low/1st Each includes the following:

No Leakage Part No. 84754-12K
Part No. 84754-14K
Mod TV
Part No. 84754-25K

Reverse & Mod. Line
Boost Valve Kit (High Ratio)
End of Sleeve/No Leakage Each includes the following:
Part No. 84754-17K
Part No. 84754-19K
Identifier
(See øA in Charts
Below)
Perform a Wet Air Test on the reverse boost valve assembly for leakage by placing a small amount of oil into
the line (PRN) circuit. Follow with low air pressure. There should be little or no air/oil leakage through the
low-1st orifice or exhaust at spring.
#312 New Sonnax Spring,
#307 Original OEM Spring, stout inner
inner clipped to valve
Low 1st Orifice
No Leakage Here Line (PRN)
Modulated
TV Circuit Circuit
No
Leakage
Here
Diameter of
#305 Reverse
spool “B” identifies New #311 Original OEM
application Modulated Boost
Boost Valve Sonnax Valve & Spring, Outer
(See chart at left) & Sleeve Spring, Sleeve Exhaust
outer
Note: The #311 spring can be changed to set idle pressure, which will not affect the Sonnax parts.
Sonnax No. Stem Description Application

84754-12K øA= .276" Mod. Line Boost (Low Ratio) Common in 3.1, 3.4, 4.1, 4.5 L Engines
84754-14K øC= .273" Reverse Boost (Low Ratio) Paired with -12K
84754-17K øA= .199" Mod. Line Boost (High Ratio) Common to 2.3 Quad., 3.8
84754-19K øC= .293" Reverse Boost (High Ratio) Paired with -17K

4T65-E Part No. 84754-30K
Complaint Harsh reverse engagement

Secondary Complaints: B O O S T VA LV E & S L E E V E K I T
• Soft up-shifts
(especially 1-2)
• Low line rise,
forward or reverse
Springs
Cause
Bore wear near the small
valve causes harsh or delayed
reverse depending on the
location and severity of the
leak, and the temperature;
wear near the end plug Boost Sleeve Assembly
causes soft shift quality
and low line rise SONNAX PART SUMMARY
Correction V ehicles with a 4T65-E transmission often have complaints of soft

up-shifts (especially 1-2), delayed reverse and low line rise. This can be
traced to the OEM boost sleeve assembly wearing. The OEM boost sleeve
assembly consists of 2 steel valves and a steel plug that reside in the boost
sleeve. The steel valves wear the aluminum sleeve and allow leakage of boost
The replacement boost
pressure. The OEM boost assembly is not serviceable separately from OEM,
sleeve delivers oil 360˚ which forces the purchase of a new and expensive valve body.
around the valve,
reducing side load. Also Sonnax now offers an upgraded OEM Valve Assembly
the surface contact of the boost sleeve assembly 84754-30K to
spools is greater which replace the worn OEM parts, allow
the OEM valve body to be used, and
improves durability and
restore the hydraulic integrity of the
reduces oil loss.
circuit. The Sonnax valves are made
of hard-anodized aluminum and have
Sonnax Valve Assembly
Part No. 84754-30K been designed to increase oil lubricity,
1 Boost Sleeve Assembly center the valves and increase
longevity. The line boost valve is also
longer than the OEM valve to
increase wear surface area. The sleeve
is made of aircraft quality aluminum
and has been designed with oil channels
to evenly distribute boost valve oil. The Sonnax kit 84754-30K is a drop-in
replacement and requires no machining.

4L80-E Part No. 34989-02K
Complaint Delayed engagement, low line pressure

Secondary Complaints: The piston seal wears away aluminum at the 2-1 servo bore; clearance
Cause and oil loss reduces pressure in all ranges except 2nd
• Case replacement due
to 2-1 servo bore wear Drop-in steel sleeve with o-rings, eliminates the oil loss at I.D. and
Correction O.D. case can be salvaged even with severe bore wear.
• Low line pressure
in all ranges but FRONT SERVO PISTON AND SLEEVE
manual 2nd
• No engine braking in Sleeve
manual 2nd with o-rings
Part No. 34989-02K Retaining Ring

Piston goes onto pin,
1 Sleeve and the retainer follows
OEM piston seal (only 1 retainer used).
1 Piston can be tested here
for leakage (WAT)
1 Spring
1 Teflon® Seal Spring
2 Retaining Rings (Lrg & Sml)
Servo Piston
with Teflon® seal
4L80-E 400 Part Nos. 34301-078 & 34301-094
Complaint Forward clutch & sealing ring failure

Cause Worn components, machined hard parts, excess ring travel
• Excess front endplay
This pump washer takes up play between the forward clutch hub and
• Reduced bearing, Correction direct clutch housing, reducing wear and salvaging valuable hard parts.
thrust washer, and
sealing ring life FORWARD CLUTCH DRUM WASHERS
Part No. 34301-078

.078" Thick Washer
Part No. 34301-094

.094" Thick
5 Washers
Drum

4L80-E Part Nos. 34200-01K & 34200-03K
Complaint High line pressure, broken parts

Secondary Complaint: R E V E R S E B O O S T VA LV E & S L E E V E K I T S
• Buzzing noise
Pump Body
Cause O-rings
Reverse Boost Valve

Worn boost valve/sleeve
allows reverse oil leakage
and imbalance of the
pressure regulator valve
Correction Balance Oil Plug

w/O-Ring Reverse Boost Sleeve
Insure proper regulator

valve control with the o- "Factory style"
ringed balanced oil plug
SONNAX PART SUMMARY
that comes along with the
boost valve and sleeve kit.
C ommon problems in vehicles with a 4L80-E transmission are uncon-
trollable line rise (upwards of 500 – 600 psi), high line pressure in
reverse, buzzing noise, broken direct clutch drums and/or broken cases.
These problems are usually caused due to a cross leak at the sleeve. High line
Part No. 34200-01K pressure and buzz is created by oil leakage past the aluminum balance plug.
1 Boost valve
1 Boost sleeve The Sonnax replacement assemblies 34200-01K & 34200-03K eliminate
2 O-rings (sleeve) these problems with two closely toleranced, hardened steel parts: a reverse
boost valve and a reverse boost sleeve. The kit also includes a replacement
1 Balance plug & O-ring
aluminum balance oil plug with an o-ring to insure proper sealing and
adequate back-pressure on the pressure regulator valve. Although the sleeve
Part No. 34200-03K and valve are sold separately by OEM dealers, we recommend replacing both
“Factory style” parts as a kit due to potential wear of the sleeve and valve. This kit includes
1 Boost valve instructions to retrofit parts dating back to ’89. In addition, the Sonnax
1 Boost sleeve replacement assembly 34200-01K has o-rings on the sleeve to separate the
1 Balance plug & O-ring torque signal and reverse boost circuits, providing additional protection
against cross leaks and the salvage of pumps with worn bores.

4L80-E Part No. 34200-16K
Complaint Wrong gear starts, solenoid codes, clutch/band failure

Secondary Complaints: A C T U AT O R F E E D L I M I T VA LV E
• 3-neutral condition
• No 4th gear
• 2nd gear start
• Ratio codes 85,86,68
Sleeve
with retaining
ring installed
Cause
AFL Valve
Actuator feed limit bore

wear results in low pres-
sure at shift and EPC
solenoids
End Plug
Correction
Spring
This kit salvages 4L80-E
valve bodies. It includes a
re-designed, anodized
AFL valve that regulates SONNAX PART SUMMARY
pressure and a wear resist-
ant sleeve to re-establish
hydraulic integrity.
T he OEM actuator feed limit (AFL) valve design has a large reaction area
and is highly affected by side loading, which wears the valve body bore.
The EPC solenoid oscillates the torque signal and AFL oil which increases valve
action. As the bore wear increases, oil pressure is reduced to the shift solenoids
which causes solenoid and ratio codes. The same AFL oil loss results in lower
Part No. 34200-16K line pressure.
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1 AFL Valve/Sleeve Assembly The improved Sonnax kit 34200-16K (4L80-E) includes an anodized valve
2 Springs (Long & Short) and wear resistant sleeve. The valve has annular grooves to prevent side load-
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1 Retaining Ring ing and has 54% more support by operating in the full contact sleeve. Due to
the valve diameter and sleeve, this repair requires a reamer and reamer guide
tool kit, Sonnax part number 77754-TL, which services both the 4L60-E and
4L80-E (see page 27 also).
Part No. 77754-TL
1 Twist Drill
1 Reamer
3 Guides
1 Collar
Note: Tool also services 4L60-E
AFL kit 77754-09K.

4L80-E Part No. 34994-02K
Complaint 2nd gear starts

Cause Low signal pressure to shift solenoids A and B
• Shifts 1-2-3-neutral
• No 3rd or 4th gear Correction 1-2 and 2-3 shift valve spring recalibration.
1 - 2 S H I F T VA LV E S P R I N G
Part No. 34994-02K
1 Spring
Valve Body Spring
4L80-E Part No. 34016-W
Complaint No lock-up, code 68

Cause TCC apply oil leaks past the front stator support bushing
• No Overdrive
This wide front stator support bushing fills the entire stator support
• Overheated fluid Correction shaft bore.
W I D E F R O N T S TAT O R S U P P O R T B U S H I N G
Part No. 34016-W
4 Bushings
Installation Tip:
For best performance, install bush- Stator Support
ing and hone I.D. to .001" overall
clearance with input shaft.
Bushing
wider, fills entire stator groove

4L80-E Part No. 34994-01K
Complaint Converter shudder, code 68

Secondary Complaints: TCC regulator apply valve wearing the aluminum bore, and causing
Cause a loss of converter apply pressure oil
• TCC apply/release
problems This TCC regulator apply valve kit restores converter apply pressure
Correction and includes a spring for increasing apply pressure.
• Burned converters
T C C R E G U L AT O R VA LV E K I T
Part No. 34994-01K

1 TCC Regulator Valve
1 Scarf Cut Seal
2 Springs Springs
Solenoid
TCC Regulator Valve
Scarf Cut Seal
Roll Pin
SATURN -TAAT Part No. 95200-01
Complaint Erratic line pressure

Cause Broken line pressure regulator valve cushion spring
Part No. 95200-01 This improved spring eliminates the need to replace the upper
1 Cushion Spring Correction valve body; simply replace the broken spring.
Note: The PR cushion spring is
not available from OEM as a L P R VA LV E C U S H I O N S P R I N G - O R A N G E
separate part.
Line Control Plunger
Pressure Regulator
Boost Sleeve
Line Pressure
Regulator Valve
Washer not in all applications
Cushion Spring
Orange
Line Pressure Regulator Spring

GM Friction Material & Applications
BY BOB WARNKE
I
ncreased fuel economy has led to systems that verters, as they may fail prematurely. For example, a
apply the converter clutch during a wider range paper lining will quickly overheat in an EC3 system,
of driving conditions, including low speeds and and should never be used in these applications.
while decelerating. To avoid driveability concerns,
engineers have had to develop materials that could be Identifying Friction Materials in Use:
slipped during low speeds and deceleration. Can you tell what type of lining is inside a converter?
There are two main factors an engineer needs to Converter ID Tag: There “may be” a tag on the cover
consider: the coefficient of friction and heat toler- identifying the friction material (Figure 3), but it
ance. Materials with a high coefficient of friction often burns off.
apply more aggressively than those with a lower coef- Conductor vs Insulator: IF the lining has no metal
ficient. The material’s heat tolerance is determined contamination, and IF the parts are centered proper-
in part by whether it is a thermal insulator or con- ly, a resistance check between the cover and turbine
ductor. Conductive materials transfer heat better will identify a conductive (carbon) or non-conduc-
than insulators. The chart in Figure 1 shows four tive lining. To do this, lift the turbine off the cover
common friction materials used for converter clutch- with snap ring pliers, place an ohmmeter lead on pli-
es and their properties. ers, cover and measure resistance.
These materials offer a wide range of properties. Determining EC 3 or Not: The practical method of
The paper material, for example, has a high friction identifying the control system is to install a scanner
coefficient, but has a low tolerance to heat. Kevlar® during an initial road test. On the PWM system, the
TCC enable will
Figure 1
indicate "Yes" after
CONVERTER CLUTCH FRICTION MATERIAL COMPARISON: a 2-3 shift, as the
CELLULOSE/PAPER COMPOSITION CARBON WOVEN CARBON KEVLAR®
TCC duty % brings
Coefficient High Moderate-High Moderate Low
TCC slip near -0-.
Temp. Rate Low Very High Very High High
Conduct Heat Insulator Conductor-Moderate Conductor-High Insulator With EC3 some
Availability Yes Yes Cores Only/ Yes applications enable
Patented Material after the shift to 2nd
(reprogrammed and
has a low coefficient of friction but a high tolerance to later versions often 3rd), as the duty % lingers at the
heat. Generally a mix or composition of materials is 30-40%. The EC3 system maintains a converter
used for Pulse Width Modulated (PWM) designs, and clutch slip until highway speeds, where duty %
woven carbon (Figure 2) is used in Electronically brings slip to -0-. TCC enable will remain “yes” dur-
Controlled Capacity Clutch (EC3) designs. Carbon ing the shifts and deceleration.
conducts heat or carries it away from the surface, Generally, EC3 applications should use woven car-
where other materials do not. Dissipating heat is crit- bon, PWM should use composition carbon or Kevlar®,
ical to a clutch which is allowed to slip. and On/Off systems should use paper or Kevlar®.
Because of variations in friction
material, many durability and Controlling TCC Slip:
drive-ability concerns exist. Effects of Altering Hydraulic Controls:
Friction materials with properties Blocking the converter regulator
different than that designed for a valve increases the apply pressure
given application should not be to match line pressure. In most
Figure 2: The material on the left is woven carbon.
used when rebuilding torque con- The material on the right is composition carbon. applications, this will result in a

Figure 3
OBSERVED FRICTION APPLICATION AND CONTROL:

TRANS. CONTROL FRICTION MATERIAL CONVERTER
TAG,3RD DIgit
rapid or slight bump on apply, but does 4L30-E
eliminate most TCC slippage. Blocking All years PWM Composition 9,H
the valve will place higher loads on the 4L60
converter. Depending on the type of ‘82-’89 on-off paper
converter regulator modification, the ‘90-’92 on-off paper with low carbon
leakage of AFL and PWM solenoid oil 4L60-E

‘93-’94 on-off paper with carbon
may not be fixed. These leaks can ‘95-’96 PWM composition carbon G,H,L
reduce line rise and shift solenoid oil. ’97 W cars 3.4 EC3 woven carbon N,P
The EC3 system is not as forgiving to ‘97 (298 trucks) PWM composition carbon G,H,L
’98 all EC3 woven carbon N,P
hydraulic control alterations. The OEM ’98-’00 (300mm) EC3 woven carbon B,A
woven carbon friction material is not 4L80-E
designed for an agressive application. ‘91-’98 PWM paper with carbon
Because the computer brings on the ‘99-’00 PWM composition carbon tag# 0829
converter earlier, a bumpy premature 4T40-E

245mm EC3 composition carbon G,L
lock-up and trailer-hitching can occur.
4T60
’86-’89 on-off paper
Road Test and Diagnostics: ‘90 on-off paper with carbon
Determining which valve or component 4T60-E
is causing a slip code is not as difficult ‘91-’95 PWM paper with carbon
as it may seem. The tool to use is a scan- ’96 3.4 DOHC EC3 woven carbon F,P,H
‘96 others PWM composition carbon G,Q
ner that can identify the type of system, ‘96-’98 4 cyl EC3 composition carbon G,Q
amount of converter slip and calculated ’97 3.8L EC3 woven carbon F,P,H
‘97 others EC3 composition carbon G,Q
gear ratio. ’98-‘00 EC3 woven carbon F,P,H
When the TCC is not applied, there
4T65-E
will be a 10% higher engine rpm than ’96- 3.4DOHC EC3 composition carbon G,Q,H
turbine and output rpm. In 3rd gear, ’97 & later EC3 woven carbon F
w/258mm
with TCC fully applied, engine, turbine
and output rpm will be the same. 4T80-E
’95 & later PWM composition carbon
Note: Early carbon formulations included a small percentage of carbon with the
Example: cellulose /paper.
3rd gear -TCC enable: no (off)
-Engine rpm 1850 cates the control valve has not stroked.
-Output rpm 1665 = 10% Slip of 140-180 on a PWM or EC3 system during full
apply/high duty %, equates to low apply pressure
3rd gear -TCC enable: yes (applied) from a worn regulator valve or spun stator sleeve.
–Engine rpm 1850 Slip of 250+ with engine rpm of 1850 would indi-
–Output rpm 1850 = 0 slip cate an output gear ratio problem. This can be creat-
ed by outside signal interference with DRAC, turbine
Slip of 4 to 60 rpm is normal for PWM control sensors, mismatched controller/PROM, or computer
under load and deceleration. not recognizing the inputs. The Sonnaflow™ also can
Slip of 4 to 250 rpm+ is normal for EC3 under slip be used to indicate control valve action, pump output,
mode, reducing to 0 at cruise. filter aeration, and cooler flow which all can influence
Slip of 10%, with TCC enable yes (applied), indi- TCC apply.

C6 Part No. 36414-01K
Complaint Driveline slack and engagement noise

Cause Severely worn sunshells at the sungear contact area
Part No. 36414-01K
5 Shims (.044") The shim prevents contact between the forward planet and sunshell
Correction by raising the sun gear to its original position.
SUNSHELL SAVER SHIM

Sunshell
Sunshell Saver Shims

place between the inner snap
ring and sunshell ledge
C6 Part No. 36428-Z & 36428A-Z
Complaint Rear component drive line wear, clunk

Secondary Complaint: Cause Excessive total unit endplay
• Reduced seal ring life
This shim allows for proper setting of unit endplay. The shim fits
Part No. 36428-Z Correction between the OEM washer and planet.
10 Shims (6-slots - .010" thick)
U N I T E N D P L AY S H I M S
Part No. 36428A-Z Input Shell with
Sun Gear Assembly
10 Shims (4-slots - .010" thick)
Ring Gear
Reverse Planetary
3 or 4 pinion
Thrust Washer
3 tanged
Shim
Thrust Washer 4 slots
4 tanged
Shim
6 slots

C6 Part Nos. 36946-01K, -02K, -03K & -04K
Complaint Direct clutch failure

Secondary Complaints: R E V E R S E B O O S T VA LV E & S L E E V E K I T S
• Poor line rise

• Reverse shudder
Valve Body
Cause Boost Valve
Boost valve wearing the

inside diameter of the
boost sleeve causes oil
to leak past boost valve
and exhaust through
“Factory style”
reverse orifice Springs
Correction
O-Rings Boost Sleeve
These wear resistant • Kits -01K & -02K only. • LP Coasting Regulator Orifice
• Kits -03K & -04K do • Reverse Boost Orifice
replacement assemblies not have o-rings • Modulated Line Pressure Orifice
eliminate the problems
with closely toleranced
boost valves and sleeves.
SONNAX PART SUMMARY
Gas ratio:
Part No. 36946-01K
V ehicles with a C6 transmission often have poor line rise, which results in
erratic shift timing, reverse shudder, or direct clutch failure. This can be
caused by the reciprocating boost valve wearing the inside diameter of the boost
O-rings
sleeve. When this occurs, oil that enters the modulated line pressure orifice leaks
Part No. 36946-04K
“Factory style” past the boost valve and exhausts through the reverse orifice, resulting in poor
or no line rise. The outside diameter of the boost sleeve may allow some leak-
Diesel ratio: age through the valve body, which can result in insufficient line rise. The
Part No. 36946-02K Sonnax replacement assemblies 36946-01K and 36946-02K eliminate the
O-rings above problems with closely toleranced boost valves and o-ringed sleeves. The
Part No. 36946-03K four o-rings provide additional protection against both cross-leakage and oil
“Factory style” exhausting through the valve body bore. “Factory style” replacement assemblies
Each includes the following: 36946-03K and 36946-04K eliminate the above problems, but do not have
o-rings. The sleeve is manufactured from Alcoa Deltalloy® 4032 aluminum,
1 Boost Valve
which is specially designed to resist wear. The boost valve is manufactured from
1 Boost Sleeve
high quality anodized aluminum to prevent excessive wear on the inside diameter
4 O-Rings (In kits -01K & -02K only)
of the boost sleeve. The 36946-01K and -04K provide normal line pressure
Note: This does not recalibrate
shift timing, or allow gas and boost (gas ratio), while the 36946-02K and -03K provide increased line
diesel valve body interchange! pressure boost (diesel ratio).

C6 Part Nos. 36833-01K & 36833-TL
Complaint Direct clutch failure, stacked upshifts

Secondary Complaint: Severe wear of the transmission case at the modulator valve bore
Cause due to continuous valve oscillation
• Poor line rise,
no “kickdown” This slightly oversized modulator valve restores the hydraulic
Correction integrity of the circuit.
Part No. 36833-01K O V E R S I Z E D M O D U L A T O R V A LV E & R E A M E R S Y S T E M

O
TO L
1 Modulator Valve
2 Springs
R
E
QUIRE
Part No. 36833-TL

1 Reamer Springs
1 Drill Jig
Modulator Valve
Drill Jig
Reamer
E4OD C6 Part No. 36440-01
Complaint Damaged or excessively worn pilot journal

Cause Insufficient lubrication, poor alignment, or excessive loading
Part No. 36440-01
INI
CH
1 Repair Sleeve A
N
This forward planetary repair sleeve allows worn carriers to be

M
1 Spring Pin Correction repaired with a minimal amount of machining.

R
E
QUIRE
F O R W A R D P L A N E TA RY R E PA I R S L E E V E
Planetary
Oil Groove
Pin
Forward Planetary Repair Sleeve

pin added to prevent rotation

E4OD C6 Part Nos. 36008A, B, C & D, T36605-03, -04 & T36008A
Complaint Spun-out bushings and case damage

Secondary Complaint: OVERSIZED & STANDARD REAR CASE BUSHING INSTALLATION SYSTEM
• Bushing failure Reamer Fixture Flange
Cause Reamer Fixture
Lack of lubrication,
excessive journal clearance,
or too much load for the
bearing area
Correction 1-5/8" Reamer
This one piece, oversized

rear case bushing installa-
tion system can replace a
One-Piece Bushing
spun-out bushing and save hardened, steel-backed
expensive cases from being
replaced.
Part No. 36008A
O
TO L
4 Oversized Bushings
Note: 3 Grooves to front
R
E
QUIRE
Part No. 36008B

4 Bushings (Standard O.D.)
Note: 3 Grooves to front
Bushing Installation Tool

Part No. 36008C O
TO L
4 Oversized Bushings
R
E
Note: 3 Grooves to front, 1 to QUIRE
back late model design

SONNAX PART SUMMARY
Part No. 36008D
4 Bushings (Standard O.D.)
Note: 3 Grooves to front, 1 to
back late model design
T he OEM rear case bushings in the Ford C6/E4OD transmissions tend to
wear out prematurely or spin out causing damage to the case. After the
case is damaged, it is impractical to reinstall a standard bushing. Bushing spin
out may be due to lack of lubrication or too much load for a given bearing area.
Part No. T36008A
Sonnax has developed a Standard and Oversize One-Piece Bushing Installation
1 Bushing Installation Tool
system specifically designed for this application. This system includes a custom
Part No. T36605-03 designed 1-5/8" reamer, T36605-03; a reamer fixture, T36605-04; installation
1 Reamer tool, T36008A; and two bushing options: 36008A 3 groove early model and
36008C 4 groove late model. Our replacement bushings 36008B & 36008D
Part No. T36605-04
are improvements over the OEM, providing increased bearing surface area and
1 Reamer Fixture
lubrication flow on non-damaged cases.

E4OD 4R100 Part Nos. 36424-01K & 36424-03K
Complaint Poor line rise, soft shifts

Secondary Complaint: B O O S T VA LV E & S L E E V E K I T S
• Delayed reverse Pump Body
Cause
Severe wear of the boost
sleeve and loss of EPC &
reverse boost oil Boost Valve
Correction “Factory style”
Boost Sleeve
These replacement
assemblies eliminate these
O-Rings
problems with an anodized improve EPC circuit feed
and closely toleranced
pressure regulator boost
valve and "Factory style" or
o-ringed sleeve.
Part No. 36424-01K

1 Boost Valve SONNAX PART SUMMARY
1 Boost Sleeve
2 O-Rings V ehicles with an E4OD transmission frequently have problems with poor
line rise and/or soft shifts. These complaints are often caused by severe
wear of the pressure regulator sleeve, allowing EPC and reverse boost oil
leakage. The replacement assemblies 36424-01K and 36424-03K (“Factory
Part No. 36424-03K style”) eliminate these problems with a closely toleranced pressure regulator
1 Boost Valve
boost valve and sleeve. Our aluminum valve has
1 Boost Sleeve “Factory style”
been anodized to eliminate excessive wear. Wet
Air Test leakage discovered after correctly
installing the Sonnax boost valve may indi-
cate pump cross circuit leaks. In addition,
the Sonnax replacement assembly 36424-
01K comes with two o-rings to provide
additional protection against leakage at the
sleeve bore. A Wet Air Test must be per-
formed on re-machined pumps for verification
of flatness.
EPC Boost
Reverse Feed Hole Feed Hole

E4OD 4R100 Part Nos. 36948-09K & 36948-12
Complaint Loss of 2nd, 3rd or 4th gear

A C C U M U L AT O R C O N T R O L VA LV E K I T
• Soft shifts
• Premature
clutch failure
• OEM valve gets Spring
stuck closed Accumulator
Cause Valve Spring
Retaining Clip
Spring
Accumulator control
End Plug
valves stick or shut off
flow to clutches too
quickly and at too low
of a pressure
Clip
Correction Fits all 3 locations; 2nd, 3rd and 4th accumulator valve locations
SONNAX PART SUMMARY

Valve is now redesigned
to be a regulator which T he OEM E4OD & 4R100 accumulator control valves can stick, shutting
off flow to the clutches. This causes soft shifts and premature clutch fail-
ure. This sticking is caused by the valves wearing a step in the bore. The new
will not cut off oil flow
to the clutch. Improved Sonnax control valve has an increased length to prevent getting hung up. The
clip to prevent valve from Sonnax kit 36948-09K also has a stiffer retaining clip to keep the valve from
over-travel. over stroking. An annular groove keeps the valve centered within its bore and
reduces uneven bore wear. Spring shims supplied with each kit allows the
rebuilder to selectively increase the apply pressure and shift feel. The new valve
also has a reduction at the spool diameter, acting as an orifice to keep fluid
Part No. 36948-09K*
O
flow to the clutches at all times and eliminating premature clutch failure. The
1 Valve TO L
36948-12 bore sizing tool will repair worn bores, allowing smooth valve
1 Retaining Clip
R
E
QUIRE
travel, and is required to establish a clean bore.
4 Spring Shims
*The tool is not required unless the
bore is damaged.
Part No. 36948-12

1 Bore Sizing Tool

E4OD 4R100 Part Nos. 36948-03K, -05K & 96948-01K
Complaint Soft 1-2, 2-3 shifts, intermittent harsh shifts

Secondary Complaints: L I N E P R E S S U R E M O D U L AT O R VA LV E & S L E E V E
• Low EPC pressure Spring

Accumulator
• Poor line rise Valve Body
Cause Retaining clip
Spring &
Severe wear of line Spring Seat
pressure modulator sleeve

allowing EPC oil leakage
and /or plunger valve Line Pressure
Modulator Valve
hang up
O-Ring
Correction Line Pressure

Modulator Plunger Valve
annular grooves to prevent
side loading
There are three variations
of this line pressure
modulator sleeve and valve
kit. Each has o-ringed Sleeve
sleeves to prevent excessive
EPC oil loss and annular SONNAX PART SUMMARY
grooved valves to properly
center the valve in the sleeve
and eliminate side loading. S ome E4OD & 4R100 transmissions have soft 1-2 or 2-3 shifts, inter-
mittent harsh shifts or poor line rise complaints. This can be either
ECU (electronic control unit) related or accumulator pressure related.
These complaints are caused by severe wear of the line pressure modulator
Part No. 36948-03K sleeve allowing EPC (electronic pressure control) oil to leak past the valve,
(E4OD ‘94 and up - .331")
resulting in soft shifts. Severe wear will also make the valve intermittently
Part No. 36948-05K stick causing harsh shifts.
(E4OD ’89-’95 - .372")
Part No. 96948-01K Sonnax now offers 3 size variations of the line pressure modulator sleeve and
(Heavy Duty/High Performance - .427") valve kit: 36948-03K, 36948-05K, and 96948-01K that eliminate this oil
Each includes the following: loss problem with closely-held tolerances. The sleeves have an o-ring added,
similar to the AX4N style, to help prevent excessive EPC oil loss. The valves
1 Valve incorporate annular grooves to properly center the valve in the sleeve and
1 Sleeve eliminate side loading, which can lead to excessive wear.
1 O-Ring
For heavy duty street or high performance trucks, use the AX4N valve kit
96948-01K for quicker and firmer 1-2 and 2-3 shifts.

E4OD Part Nos. 36438A-01K & 36438AX-01K
Complaint Low line pressure, excessive pump noise

Secondary Complaints: PUMP GEARS
• Damaged pump gears

or torque converter
impeller hub
• Repeated converter
failure and code 62
caused by low
pump volume
Cause
Wear on the pump gears
and with the mating
impeller hub reduces
Inner Pump Gear
pump capacity and
increases pump noise
Correction Pump
Outer Pump Gear
These direct replacement SONNAX PART SUMMARY

and oversized gears are
specially designed to
improve the fit and
S onnax now offers high quality replacement gear sets for F5 and later
E4OD pumps. Two designs are offered: a direct replacement gear set
36438A-01K and an oversize gear set 36438AX-01K. Both Sonnax gear sets
durability of the pump to are designed to meet or exceed OEM pump gear performance. The Sonnax
torque converter interface. gears are specially designed to improve the fit and durability of the pump to
torque converter interface. The direct replacement gears are designed to fit
Part No. 36438A-01K existing F5 and later pump housings with no machining required. The over-
Direct Replacement size gears are designed for F5 and later pump housings with excessive wear.
Part No. 36438AX-01K The oversize gears allow worn pump housings to be refurbished by machining the
INI
CH
Oversized A
pump cavity.
N
M
G
R
E
QUIRE
Note: In 1995 the E4OD pump was redesigned to utilize pump gears with 10
Each includes the following: lobes on the outer gear. Prior to 1995 the outer pump gear had 11 lobes. The
pump casting was also revised. Prior to 1995 the pump casting was designated
as E9 or F1. Beginning in 1995 the casting designation was changed to F5 and
1 Inner Pump Gear
currently F8. The Sonnax pump gears will work with any F5 or later pumps.
1 Outer Pump Gear
The E9 and F1 E4OD pumps suffered from low pump output and should be
replaced with an F5 or later model pump.

Transmission Gerotor Pumps
BY BOB WARNKE
Figure 1: Variable Displacement, Rotary Vane Pump

uel economy, space limitations
F and production costs influ-

ence pump design.
Therefore, most gear pumps are
To verify pump condition:
• (In vehicle or on Dyno) Reverse 1200 RPM
• Extend TV or raise Boost to max.
• Good pressure rises to 230-270 and
designed with minimal require- does not drop off more than 20 psi.
ments for the clutch, accumu- • Worn pump pressure rises, then
shortly drops off by 50-75 psi.
lator, converter and cooler. • Pressure often surges.
As a pump’s components
wear, its output becomes less.
At the same time this is hap- and may be used for addi-
pening, bushings and seals wear, tional lube feed.
creating leaks, so a marginal
pump cannot supply enough volume Gear Pumps:
Slide in Low output
to keep the system pressure up. During The Gerotor pump (Figure 3,
position; equalized inlet
a rebuild, many of the leaks are fixed, so a and outlet chambers Gerotor) has slightly more
reduces output.
marginal pump “gets by” until oil loss returns. displacement per revolution
than a Crescent pump (Figure 4, Crescent) of the
Pump Basics: same size, but not by much. Each tip to tip contact
Gear pumps have a consistent output per revolution isolates a chamber, which increas-
(fixed displacement) which increases with higher es in area as it passes the inlet.
rotational speed. Because of hydraulic and frictional The expanding of this area
drag, gear pumps draw engine power in relation to results in low pressure, draw-
input speed. ing sump fluid into it by
By contrast, a rotary vane pump (variable displace- atmospheric pressure. Those
ment, as in Figure 1) repositions the slide under low chambers then decrease in
demand to reduce output and drag. area as they approach the
Dual stage scavenger pumps (Figure 2) allow a low outlet port. The pressure reg-
volume gear set to be used ulator valve in the outlet cir- Figure 3: Gerotor pump gears
during high rpm, low cuit varies the amount of
demand conditions. A fluid exhausted to the sump, converting output vol-
dual stage pump can also ume into pressure.
Scavenger
gear assist inlet prime
inlets;
Primary pump inlet: Suction from
Gerotor Design, Porting and
rotors
pull from upper sump filter. Inlet pressur- Cavitation:
bottom ized by regulator valve's exhaust.
Output charges line pressure In a Gerotor pump, the design elements
pan and
fill side include the number of lobes, thickness, and
pan sump
Secondary Pump inlet: Suction the shape and position of the inlet and out-
from upper sump filter. Output let ports (Figure 5, E4OD pumps). Note the
charges line pressure and boosts
primary inlet. size, sweep, inlet port and outlet slot varia-
tions. The size of the lobe and the speed of
Upper sump filter inlet each tip passing the inlet determines the flow. High
rotor tooth counts, with high rpm, limit the fill avail-
able to each inlet chamber and can contribute to cav-
itation. For example, cavitation of a boat motor leaves
a low-pressure area, on which the propeller blades
Figure 2: 4T80-E Pumps
cannot push. Similar to the propeller, high tip speed

will not allow atmos- another gear on the pump and measuring onto the
pheric pressure to fill face of the OE gear works well (Figure 6).
the inlet chambers. Plasti-Gauge™ used for for engine bearings also
The resulting cavi- works well to measure pocket depth. Insert the
tation produces Plasti-Gauge™ at the most critical wear point
gear rattle, which between the inlet and outlet ports. The gears must
can cause pump
damage. Tip Chamber
If cavitation Inlet/suction
Outlet/pressure
continues, air half side
bubbles become
trapped in the ATF and
affect the regulator valve
balance. A restrictive filter Note the rotor tip position and area of each cham-
Figure 4:
Crescent pump/41TE aggravates the problem because ber. Excessive tip to tip, face and outer diameter
clearance, reduce output.
the inlet will not fill properly.
Fluid becomes aerated from low oil level or suction Figure 5a:
leakage. Air will be pulled into the inlet easier than Left: 9 Lobe inner, 10 outer Gerotor
F-5 & later cover casting #
fluid, which reduces the charge. To minimize these Displacement of 1.7 cu.in. per revolution.
conditions, the filter must be clean and able to flow Right: 10 Lobe inner, 11 outer Gerotor
fluid at sufficient volume, the fluid level must be cor- E-9 to F-2 cover casting #
Displacement of 1.5 cu.in. per revolution
rect, and the ATF should contain anti-foaming addi-
tives. Excessive tolerance reduces output.
Gerotor standards below:
1) Converter hub to inner gear max. radial .004"
Clearance: 2) Face to pocket; min. .001" max. .002"
Pump output is least at low rpm during hot idle. 3) Tip to tip; .0025" per side, total radial .005"
Internal clearance, together with thermal expansion, 4) Outer Gerotor to pocket: total radial. 004"
further reduces output. This explains why a worn 5) Pump housing flatness: .001".
pump contributes to delayed engagement, low pres-
sure and TCC engine stall. Slot depth and Higher capacity pump;
The centerline of the inner rotor is controlled by length is critical. note the reinforced
Must be matched outlet pressure port.
hub-to-gear and hub-to-pump bushing clearance. to gear design and
When the inner gear is allowed to move off center, replaced.
each chamber’s seal and efficiency is reduced.
Pressure build up at the outlet forces the rotors
apart, which loads the outer rotor into the wall/bear-
ing surface, reducing the oil film. As wear increases,
pump output further decreases, and the pocket or
gear becomes scored.
Gear face to pump clearance (gear vs. pocket
depth) is critical in controlling output and drain-
back. Remanufactured clearances cannot be held
overly tight or the oil film on the surfaces will be
wiped off resulting in scoring.
Measurement and Leakage:

The Gerotor figure references indicate specific meas-
urements. There are a few “tricks” that will improve
Gerotor inspection. Some pumps have curved sur-
faces, which make it difficult to use a straight edge
Figure 5b: E4OD pump variations
when measuring face to pocket clearance. Setting

Fill to flush,
drain-down
timed to
recess.
then be assem-
bled and reset
by pressing a
plate over the Figure 6: Measuring gear pocket.
pump to duplicate The inner Gerotor should be held
firmly as illustrated. Pocket depth can
assembly . then be measured with feeler gauge
Timing the leak- or Plastigauge.
This is an alternative to using depth
down of the outlet micrometer. Most critical wear point
chambers can be is separation between inlet and out-
let. Clearance not to exceed .002" Figure 7: E4OD leakdown test
used as a quick Go-
No-Go test (Figure
7). The output of the pump is directly related to the 47RE turbine shaft seal. When this seal leaks (Figure
internal tolerances. Knowing this, a Go-No-Go leak- 9, 47RE pump), oil pressure builds at converter
down test can be used with an assembled pump. In release, causing slip and overheating of the lining.
this test, the converter or a hub must be installed to When stator tubes are replaced, the press proce-
position the gears. dure often moves material, allowing oil loss at the
Place the filter port at 12:00. Fill the pump inlet feed ports. Before pressing another tube in place, de-
circuit with solvent (mineral spirits) until level with burr the radius of the holes and apply Loctite™ to the
the outer casting as shown in Figure 7. A good pump surfaces.
will not drain below the recess for over forty-five sec-
onds. Air Tests for Warpage and Cross Leaks:
Pumps that cause the condition of engine stall, low Air testing an assembled pump should be a rebuild
cooler flow or various TCC related concerns, drain procedure on 41TE/ 42LE, 42/47 RE, E4OD, 4L80-
down rapidly. Experiment with this on the next new E, 4L60/-E, CD4E, G/F4EAT units. Any pump that
pump that is purchased. The nice part of this test is has been overheated or resurfaced should be checked
that it provides insight before dis-assembly. for warpage, poor machining, or worn boost valves.
Finding these problems before installing the
Stator Support: pump can eliminate high pressure in
On some pump stators, a bushing iso- reverse, engine stall and clutch bind up
lates the oil circuit (see 4L80-E bush- from cross leaks. Refer to E4OD boost
ing 34016-W). On the E4OD, release valve 36424-01K WAT test on page
oil must flow though the six slots 56.
around the front stator bushing
(Figure 8, E4OD stator). Confirm this Inspection and Rework:
by using a paper clip (of .036” wire) Experience is success, and this saying
to see if the wire will pass through relates to a pump as well. An
each slot. Restricted ports can cause “untouched,” mated and experienced
engine stall, poor converter fill and a Fig.8 pump, is often the best replacement. Using
glazed TCC lining. E4OD stator mixed halves, resurfacing or sometimes just taking
ports
Turbine shaft sealing rings require If ports are a pump apart seems to create problems. The slightest
stability and 100% surface contact. restricted,
remove bushing repositioning of the halves relocates high-low spots
An example of a problem area is the and enlarge. and increases cross leaks (Note: Importance of align-

Converter apply Release psi.
/charge oil
bench, but verifying the pump on a Dyno or the vehi-
Forward clutch oil cle is most beneficial. The pump has one job, and that
is to produce enough volume to maintain regulated
pressure in all circuits. A weak pump at low RPM
will not maintain line pressure, unless the RPM is
raised to increase output. The Sonnaflow™ indicates
a weak pump; as the regulator strives to maintain
line pressure, the cooler feed is reduced. Some
Inspect stator support closely for pumps become so bad that even higher RPM will not
scoring at this ring area.
produce enough volume. In this condition both a
Scoring is caused from turbine shaft
runout at converter cover bushing pressure gauge and the Sonnaflow™ will dip dramat-
or pilot. Dowel pins, flex plate and ically during a shift and engagements. The CD4E,
crankshaft affect this also.
Cross leaks during lockup, will
G4A-EL, and 41TE pumps can be diagnosed easily
overun the ability to exhaust. This with this method.
creates a build up of release pres-
sure causing TCC piston slip, heat Another pump test procedure is to tax the pump at
and failure. mid-range RPM and call for the highest pressure
with full EPC or throttle boost. A weak pump will
often struggle to get to specifications for maximum or
peak and then taper off.
Aeration and low fluid level can be found as errat-
ic line pressure readings, or by using the Sonnaflow™
tied into a digital graphing meter, which would indi-
cate erratic frequency readings.
Filter restriction can also be found using the
Figure 9: 47RE turbine shaft Sonnaflow™, indicated as lower than normal cooler
flow and a large dip in flow seen during shifts. If a fil-
ment pins on CD4E and the E4OD, Figure 10). ter is suspected, pressurize the fill tube and watch
Look for surface patterns near the bolt holes and flow and line pressure for significant increase.
passages, which indicate cross leaks and warpage. Pressurizing the case forces the fluid through the fil-
Designs using gaskets or plates should have well ter and raises the pump inlet pressure. A case vent
defined witness Figure 10: E4OD pump that is plugged will not allow
marks or gasket 2-727 rear band anchor pins
work well for alignment. This
alignment and atmospheric pressure to
WAT test.
crush patterns. method aligns the O.D. and force fluid into the pump
Use care during the hole index, without using
a band. inlet, which results in no
handling to pre- flow or pressure.
vent surface If you have any pump
dents, which raise material rebuild concerns or tips,
and cause cross leaks. please contact us via the
Before assembly, use a sur- Sonnax website.
face block or very fine pol- Wet Air Test each of
ishing stone to re-work these ports.
irregular surfaces. Flush There should not be
threads should be counter- cross leakage between
them or from the
sunk slightly to avoid pull- orange painted areas.
up on retorque. If leaks occur, clamp
outer edge and install
o-ringed boost valve.
Gauge and SonnaflowTM
Diagnostic Procedures Continued leakage
requires resurfacing or
(refer to pages 78 &79): replacement.
The inspection and rebuild proce-
dures mentioned above apply to the

E4OD Part No. 36402-Z
Complaint Rear component drive line wear

Cause Excessive total unit endplay
• Driveline clunk
This shim allows for proper setting of unit endplay. The shim fits
• Reduced seal ring life Correction between the OEM washer and planet.
U N I T E N D P L AY S H I M
Part No. 36402-Z
10 Shims (4 slots - .010" thick)
Ring
Reverse Gear
Planetary
Input Shell with

Sun Gear
Assembly
Thrust Washer,
4 Tanged
Thrust Washer,
4 Tanged
Shim, 4 slots
E4OD Part No. 36743G
Complaint Forward clutch failure and poor lube flow

Cause Leakage between the center support and hub
Part No. 36743G
5 Gaskets
This center support gasket eliminates leakage between the center
Correction
support and the hub.
CENTER SUPPORT GASKET
Center Support Hub
Also Available:
Part No. 36743H
1 Center Support Hub-Bearing type
Part No. R16 Center Support

INI
CH
1 Bearing for 36743H A
N
M
Note: Center support shaft

R
must be machined to
E
QUIRE Silicone Printed Gasket
accomodate bearing.
Note: Sonnax Part No. 36743G is U.S. Patent pending.
Patent infringement will not be tolerated.

A4LD C3, 4R44E & 5R55E Part No. 56532-01K
Complaint ??Forward clutch and reverse band failure

Secondary Complaint: R E V E R S E S E R?V?O S L E E V E K I T
• Case needing
replacement
Cause
Sleeve
Heavy scoring at the inner

piston bore causes drive oil
loss; when severe enough,
this oil loss can reduce
forward clutch or reverse
band life
Correction Servo
This reverse servo sleeve

kit restores the function
of the reverse piston and Back-up Ring
O-ring
salvages the case.
SONNAX PART SUMMARY

Part No. 56532-01K
1 Servo Sleeve A
CH
INI
T he reverse servo bore on the A4LD case can become scored. Scoring is
N
caused by repeated oscillation of the reverse servo piston within the bore
M
1 Back-up Ring during normal operation. Once this bore is damaged the case must be scrapped.
R
E
QUIRE
1 O-ring Install the Sonnax A4LD Reverse Servo Sleeve Kit 56532-01K. This kit
Note: Machining of original servo
is required. contains a steel sleeve, an o-ring and a back-up ring.
Note: The kit also contains instructions to save the servo piston assembly by simply turning
the piston O.D. 1/16" smaller. No machining of the transmission case is required.

A4LD Part Nos. 56947-02K & -04K, 56947-03K & -05K
Complaint Delayed reverse and soft upshifts

Secondary Complaints: H I G H & L O W R AT I O B O O S T VA LV E K I T S
• Poor modulator Valve Body

control
• Low line in forward
or reverse
Cause
Boost Sleeve
“Factory style”
A worn boost sleeve, which
allows reverse and/or TV
pressure to cross leak or Boost Valve
exhaust
Correction Diameter I.D. Spring Seat
These replacement boost

valve kits are consistent
O-Rings
with the OEM sizes, have a
sleeve made from aircraft Boost Sleeve
quality aluminum and a O-ring style
hard anodized valve to
resist wear; they are held to
SONNAX PART SUMMARY
tight tolerances to restore
Part No. 56947-02K
S ome typical complaints of vehicles with an A4LD transmission are low line
pressure in forward or reverse, soft upshifts, delayed reverse, and poor
modulator control. These complaints can often be caused by a worn boost
(High-ratio with O-rings)
sleeve, which allows reverse and/or TV pressure to cross leak or exhaust.
Part No. 56947-04K
(Low-ratio with O-rings) Sonnax now has replacement boost valve kits consistent with the two OEM
Each contains the following: sizes. These kits are available with o-rings 56947-02K & -04K and also
1 Sleeve “Factory style” 56947-03K & -05K. The sleeve has been manufactured
1 Valve from aircraft quality aluminum designed to resist wear. The aluminum valve
2 O-Rings has been hard anodized to also prevent excessive wear. These parts are held
to very tight tolerances to restore the hydraulic integrity of the assembly.
Part No. 56947-03K High ratio - .388" diameter I.D. 2.3L

(High-ratio “Factory style”)
Low ratio - .323" diameter I.D. 2.8, 2.9, 3.0, and 4.0L
Note: The High-ratio valve offers higher line rise than the Low-ratio valve.
Part No. 56947-05K
(Low-ratio “Factory style”)
Each contains the following:
1 Sleeve
1 Valve

A4LD Part No. 56947-06K
Complaint Soft shifts, low line pressure

Secondary Complaint: P R EPSR SE SUSRUER ER REEGGUU LL A
ATTOORRV A
VLAVLE VKEI T K I T
• Converter fill
problems Valve Body
Cause Pressure Regulator Valve
Spring Seat
A worn valve body bore

allowing line to leak
Spring
to exhaust OEM Washer
Spring Seat
Correction O-rings Boost Sleeve
Spring
This oversized valve and
reamer kit re-sizes the
valve bore and restores Boost Valve
the hydraulic integrity
of the circuit.
SONNAX PART SUMMARY
Part No. 56947-06K

O
S ome typical complaints of vehicles with an A4LD transmission are soft
shifts, low line pressure, and/or converter apply problems. A worn valve
body bore at the pressure regulator valve can often cause these complaints. Line
1 Pressure Regulator Valve TO L
2 Springs pressure is allowed to leak to exhaust, preventing the valve from stroking prop-
R
E
QUIRE
1 Boost Valve & Sleeve Assembly erly and feeding the converter apply circuit
2 O-rings Sonnax now has a replacement pressure regulator valve kit 56947-06K. The
oversized pressure regulator valve restores the hydraulic integrity of the
Part No. 56947-TL circuits. Sonnax reamer kit 56947-TL must be used to re-size the valve body
1 Reamer bore to accept this valve. The reamer kit works for both the early and late
1 Drill Jig A4LD valve bodies. The replacement valve has been anodized to prevent
excessive wear. The converter apply spool land has been lengthened to increase
spring force against the oversized valves. Two stiffer springs have been
included in the kit, to be used only for the late valve bodies (2nd and 3rd
designs). A high ratio boost valve kit is included to counteract the increased
balance diameter on the pressure regulator valve.
Note: See the instruction sheet for complete WAT instructions.

A4LD 4R55E & 5R55E Part No. 56001X
Complaint Repeated front seal leakage

Secondary Complaints: Excessive hub to bushing clearance and soft babbitt
Cause bushing material
• Worn converter hub
This finish-in-place bushing replicates the OEM bell housing
• Worn pump bushing Correction bushing assembly and has a steel backed bronze lining.
FINISH-IN-PLACE BELL HOUSING BUSHING

Part No. 56001X
5 Bushings A
CH
INI
N
M
Note: Finish-in-place style

R
E
QUIRE
bushing requires advanced
machining skills to insure proper
I.D. & location after installation.
Bushing
steel backed bronze lining
Bell Housing
A4LD Part No. 56521-K
Complaint 1-2 bind up, costly replacement of cases

Cause A dragging band due to a deformed bore and loosened pin
Part No. 56521-K
10 Oversized Pins
This rear band anchor pin kit insures correct pin depth set-up and
1 Reamer Correction salvages A4LD cases with early uncapped rear band anchors.
REAR BAND ANCHOR PIN KIT
Reamer
use to ream out
existing hole
Case
Anchor Pin

A4LD Part Nos. 56600B-01K, 56600B, 56250-01K, 56600 & 56600-DJ
Complaint Sticking governor, bronze in the pan

Secondary Complaint: L A TLEA TM
E O
MDOE
DLE L LLOOW
W SSPPRRAA
G GU PUDPAD
T EA T E
• Sprag thrust Thrust Washer

washer failure Hardened Steel
End Cap Reverse Drum
Cause
The steel wave thrust
washer and bronze “scoop” Rear Sprag
washers flex and contami- Inner Race
Thru-hardened
nate unit
Correction
Drill Jig
This kit salvages cases, (suggested)
allows for 2.8, 2.9, & 3.0
cases to be converted to a Part No. Application Race Dia.
4.0 case, prevents metal 56600B 4.0 Liter Engine 2.70” End Cap
56600 2.8, 2.9 & 3.0 Liter Engines 2.50”
contamination of worn
washers, has an upgraded
inner race, and the compo- SONNAX PART SUMMARY
nents are available separate-
ly as well. A sticking governor after rear sprag service or sprag thrust washer failure is
a common complaint in late model A4LD 4.0 units. This is caused by the
steel wave thrust washer (located behind the rear sprag inner race) and the
Part No. 56600B-01K bronze “scoop” washers flexing and contaminating the unit with metal. During
2 End Caps O
TO L
fabrication of the bronze washer, small cracks are formed between the bronze
1 Rear Sprag Inner Race and steel layer of the washer. Once in service, these cracks allow bronze parti-
R
E
QUIRE
1 Thrust Washer cles to flake off from the washer, and the problem is compounded by the flim-
sy steel thrust washer that it is running against.
Part No. 56600B
1 Rear Sprag Inner Race O
TO L
Sonnax now offers an A4LD Late Model Low Sprag Update Kit 56600B-01K.
(see chart for applications) This allows A4LD 4.0 cases with worn or loose sprag races to be salvaged. The
R
E
QUIRE
kit contains a new inner race which is thru-hardened AISI 52100 steel with
Part No. 56250-01K longer, deeper cutting serrations (to insure a tight fit after reinstallation), a
2 End Caps sturdy hardened steel thrust washer and two high quality solid bearing bronze
1 Thrust Washer end caps. Sonnax kit 56600B-01K also allows 2.8, 2.9 & 3.0 cases to be con-
verted to 4.0 liter cases.
Part No. 56600 The steel thrust washer and two solid bearing bronze end caps 56250-01K are
O
1 Rear Roller Clutch TO L
also sold separately for use with 4.0 cases. Also available is Sonnax 56600
Inner Race
which is a replacement race for the 2.8, 2.9 and 3.0 roller clutch units. This race
R
E
QUIRE
(see chart for applications)
is also thru-hardened AISI 52100 steel with longer, deeper cutting serrations.
The Sonnax drill jig 56600-DJ allows for easy removal and installation of the
Part No. 56600-DJ
inner race and eliminates the risk of damaging the case.
1 Drill Jig
1 Dowel Pin

A4LD Part No. 56947-01
Complaint Burned forward clutches

Cause Manual valve indexed out of position
• Binding condition
in park This index will overcome loose linkage tolerance and prevent the
Correction manual valve from opening up the forward clutch circuit in park.
• Valve related
delayed reverse M A N U A L VA LV E I N D E X
Valve Body
Part No. 56947-01

1 Manual Valve Index
Manual Valve
Manual Valve Index
A4LD Part No. 56995A
Complaint Early lock-up

Cause A weak converter clutch shift valve spring
• Engine chuggle when
coasting to a stop This spring is stronger than the OEM version and offers lock-up apply
Correction (and release) at a higher vehicle speed.
Part No. 56995A ANTI-SHUDDER SPRING

2 Springs
Note: This is a shudder related to TCC Pressure Modulator Valve
the converter clutch shift valve,
not the shuttle valve.
Valve Body
Converter Clutch
Shift Valve
TCC Solenoid and

Shuttle Valve Bore
Anti-Shudder Spring

4R44E 4R55E Part No. 37947-01K
Complaint Soft shifts, delayed reverse

BO
BO OOSSTT V
VAA LLVVEE K K
I TI T
•Low line pressure
•Poor modulator
control
Valve Body
Cause
Worn boost sleeve and
boost oil loss
Correction
Boost Valve
OEM ratio
Restore hydraulic integrity
with a hard anodized,
aircraft-quality aluminum,
replacement boost valve kit. Boost Sleeve
Part No. 37947-01K

1 Boost Valve SONNAX PART SUMMARY
1 Boost Sleeve
S ome typical complaints of vehicles with an 4R44E & 4R55E transmission
are soft shifts, delayed reverse, poor modulator control, and/or low line
pressure in forward and reverse. A worn boost sleeve contributes to these com-
plaints. Reverse and/or TV pressure will be allowed to cross leak or exhaust.
Sonnax now has a replacement boost valve kit 37947-01K for these transmis-
sions. The sleeve has been manufactured from aircraft quality aluminum, and is
designed to resist wear. The aluminum valve has been hard anodized to also
prevent excessive wear. These parts are held to very tight tolerances to restore
the hydraulic integrity of the assembly. This kit will improve engagement
related to loss of boost oil and increase line rise in forward and reverse.

AOD Part Nos. 76989K & 76989K-03K
Complaint Insufficient line rise

Secondary Complaints: T H R O T T L E VA LV E P L U G & S L E E V E K I T S
• Uncontrollable
shift timing
• Imbalance of
TV pressure
No leakage Valve Body
• Clutch or band failure from casting
(bottom) side of
the valve body.
Cause Spring
Throttle Valve Plug

Throttle Valve Sleeve
The throttle valve plug
wears the sleeve, allowing
throttle valve feed oil to
leak past the plug and
exhaust
Correction Retaining Clip
The replacement kit Throttle Valve Sleeve

includes a tightly “Factory style”
O-Rings
toleranced sleeve that has
been manufactured from
Deltalloy® 4032 SONNAX PART SUMMARY
to resist excessive wear.
Part No. 76989K

U ncontrollable throttle pressure due to oil loss is a common complaint in
vehicles with an AOD transmission. This results in low line pressure
and poor throttle and shift timing adjustments. The hardened steel throttle
1 Throttle Valve Plug valve plug continuously reciprocates within the aluminum throttle valve
1 Throttle Valve Sleeve sleeve, thus wearing the inside diameter of the sleeve. This wear allows throttle
2 O-Rings valve feed oil to leak past the plug and exhaust, resulting in poor line rise.
This excessive leakage can be eliminated by installing Sonnax throttle valve

Part No. 76989-03K plug and sleeve kits 76989K or 76989-03K. The replacement throttle valve
1 Throttle Valve Plug sleeve has been manufactured out of a special aluminum designed to prevent
wear. The sleeve is available without or with o-rings added to the sleeve to
1 “Factory style” Throttle
prevent feed oil from escaping past the valve body bore. The steel plug has
Valve Sleeve
been tightly toleranced to allow minimum clearance with the inside diameter
of the sleeve, thus restoring the hydraulic integrity of the assembly.

AOD Part Nos. 76990K & 76990-03K
Complaint Direct clutch failure

Secondary Complaints: B O O S T VA LV E & S L E E V E K I T S
• Insufficient
line rise
• Soft slide shifts,
Valve Body
delayed reverse
Cause
Leaks at the boost valve Boost Sleeve
prevent proper line rise made from ALCOA
Deltalloy® 4032 aluminum
to prevent wear
Correction Boost Valve
Replace the boost valve O-Rings

added for additional
and sleeve to restore leakage protection “Factory style”
from boost oil loss
Part No. 76990K

1 Boost Valve
1 Boost Sleeve
3 O-Rings
SONNAX PART SUMMARY

Part No. 76990-03K
1 Boost Valve
1 “Factory style”Boost Sleeve
V ehicles with an AOD transmission frequently have problems with poor line
rise which results in direct clutch failures and soft shift slides. These com-
plaints are often caused by severe wear of the pressure regulator boost sleeve,
allowing oil leakage. The hardened steel boost valve continuously reciprocates
within the aluminum boost sleeve, and wears the inside diameter of the sleeve.
This excessive leakage can be eliminated by installing the Sonnax pressure

regulator boost valve and sleeve kits 76990K and 76990-03K. The replace-
ment boost sleeves have been manufactured out of a special aluminum
designed to prevent wear and are available with or without o-rings. The o-
rings are added to the outside diameter of the 76990K sleeve to prevent feed
oil from escaping past the valve body bore. The steel valves has been tightly
toleranced to allow minimum clearance with the inside diameter of the
sleeves, thus restoring the hydraulic integrity of the assembly.
Note: The WAT procedure is clearly shown in the instructions included with the parts.

AOD Part Nos. 76999-04K, -05K, -SML, -MED & -LRG
Complaint Erratic shift timing

O - R I N G E D VA LV E E N D P L U G K I T S
Cause
Small (SML) Medium (MED) Large (LRG)
Leaking valve end plugs
1-2 Capacity
Correction Modulator (SML)
1-2 Accumulator (LRG)

These plugs have been
2-3 Shift (MED)
manufactured of high 3-4 Shuttle (SML)
quality aluminum to resist 1-2 Shift (MED)
wear. The o-ring on the
outside diameter prevents 3-4 Shift Valve
(Late: Post Mid-’83)
leakage between the plug
and the valve body. The
medium 3-4 plug is 3-4 Shift (MED)
replaced by the 3-4 shift
valve assembly after mid-’83.
Note: All plugs have been End Plug (MED)
redesigned with a single (Early: Pre Mid-’83)
o-ring and tapped holes
to ease the installation Orifice Control (SML)
Part No. 76999-04K & removal of the plugs
(Early: Pre Mid-’83) 2-3 Back-out (SML)
3 Medium Plugs
1 Small Plug SONNAX PART SUMMARY
8 Small O-rings
Part No. 76999-05K

V ehicles with an AOD transmission often have shift timing complaints due
to governor or accumulator oil circuit leakage caused by leaking valve
end plugs in the valve body. Most AOD valve assemblies are designed with
(Late: Post Mid-’83)
an end plug to help retain the line-up and seal the circuitry. As these end
1 Small Plug
plugs wear, circuit oil is lost and affects shift timing. Installing Sonnax
8 Small O-rings
o-ringed valve end plugs can eliminate this excessive leakage. These include
2 Medium Plugs
replacement plugs for the following valve applications: 1-2 accumulator, 1-2
1 3-4 Shift Valve Sleeve Assembly
shift, 2-3 shift, 1-2 capacity modulator, orifice control, O.D. servo regulator,
3-4 shift (plug or sleeve), and either the 3-4 shuttle or 2-3 backout. These
Part No. 76999-SML plugs have been manufactured out of high quality aluminum designed to
3 Small Plugs resist wear. The o-ring on the outside diameter prevents leakage between the
Part No. 76999-MED plug and the valve body. The plugs have a standard 8-32 UNC threaded hole
3 Medium Plugs for assistance in installation and removal. These o-ringed plugs are more
durable than knurling the O.D. of the original plug and will not leak after
Part No. 76999-LRG time. For your convenience, bags of 3 of each of the small, medium and large
3 Large Plugs plugs are also available separately.

AOD Part Nos. 76970 & -RM
Complaint Poor line rise, sticking TV plunger

Secondary Complaint: O V E R S I Z E D T H R O T T L E V?A?L V E P L U N G E R & R E A M E R
• Uncontrollable
throttle pressure
Cause
Valve Body
Valve body wear allows Oversized Throttle

Valve Plunger
throttle valve feed oil to annular grooves to
prevent side loading
leak past the plunger and
exhaust, resulting in poor
line rise
Reamer
Correction
Valve Body with
The reamer resizes the Separator Plate
valve body bore to accept
the oversized TV plunger
and restore hydraulic
integrity.
No Excessive
Leakage
Note: The leakage you're checking for during

the WAT is from under the valve body.
Plunger Here
TV Plug & Sleeve Here
Part No. 76970

O
1 TV Plunger TO L
SONNAX PART SUMMARY
P oor line rise, uncontrollable throttle pressure, and sticking plungers due to
R
E
QUIRE
worn bores are common complaints in vehicles with an AOD transmission.

The hardened steel throttle valve plunger continuously reciprocates within the
Part No. 76970-RM
aluminum valve body, wearing the valve body bore. This wear allows throttle
1 Bore Reamer Tool
valve feed oil to leak past the plunger and exhaust, resulting in poor line rise.
This excessive leakage can be eliminated by installing an oversized throttle valve

plunger 76970 which has a slightly oversized diameter. The replacement valve
is made with annular grooves to center the valve and prevent wear due to side
loading. By utilizing Sonnax reamer tool 76970-RM material can be removed
from the valve body bore in order to accept this oversized TV plunger and
restore the hydraulic integrity of the circuit. In addition, to insure full circuit
integrity, use Sonnax 76989K TV plug and o-ringed sleeve kit (see page 72).

AOD Part Nos. 76991-01K & -TL
Complaint Slide shift into 2nd gear

Secondary Complaint: A worn 1-2 capacity modulator bore causes second clutch oil leaks
Cause and insufficient clutch pressure
• Intermediate
clutch failure Correction
This oversized modulator valve is made of anodized aluminum to
prevent wear, restoring the hydraulic integrity of the circuit.
O V E R S I Z E D 1 - 2 C A PA C I T Y M O D U L AT O R V A LV E K I T
Part No. 76991-01K
O
TO L
1 Valve
3 Springs
R
E
QUIRE
2 O-Rings
Springs
1 End Plug
Valve
Valve Body
End Plug
Part No. 76991-TL Reamer
O-Rings
1 Reamer & Drill Jig Tool
Reamer Guide
Springs allow adjustment

of 1-2 shift.
AOD Part No. 76833
Complaint Overdrive band failure

Secondary Complaints: Excessive clearance of servo-pin to case-bore and leakage of
Cause release oil
• 3-4, 4-3 shift
concerns Correction
This overdrive servo pin has an o-ring to positively seal against
the case bore.
• Forward clutch
failure OVERDRIVE SERVO PIN
Part No. 76833 Servo Piston
1 Servo Pin Spring

1 O-Ring
1 Retaining Ring
Overdrive
Servo Pin
Retaining
Ring O-Ring

AOD-E 4R70W Part No. 76948-06
Complaint Forward clutch failure

Cause Low line pressure
Part No. 76948-06 Correction Replace the spring with this stronger PR spring.
5 Springs E L E VAT E D P R E S S U R E R E G U L AT O R S P R I N G
Pressure Regulator
Spring
SONNAX PART SUMMARY
L ow line pressure on heavy-duty applications of Ford AOD-E and 4R70W

transmissions results in forward clutch failure due to slippage. A stronger
regulator spring is required to bring base idle line pressure up to 68 psi. The
Sonnax regulator spring 76948-06 will insure the proper clutch engagement.
Typical applications for this PR spring are squad cars and vehicles requiring
frequent and hard acceleration.
AOD & E Part No. 76811-01K
Complaint Restricted lube flow

Spline wear causes the direct drum shaft to contact the output
Cause shaft and shut off lube flow
This retaining ring fit prevents the direct drum shaft from
Part No. 76811-01K Correction contacting the output shaft and shutting off lube flow.
INI
5 Retaining Rings A
CH
N
M
Late model shafts require no

D I R E C T D R U M S H A F T R E TA I N I N G R I N G
R
E
QUIRE
modifications, early style shafts
will require machining a ring
groove.
Retaining Ring
Direct Drum
Direct Drum Shaft

Sonnaflow™: Cooler Flow Sensor
BOB WARNKE AND DENNIS MADDEN
Using the tool to prevent repeat planet failure

. . . an Insurance Policy!
Why can’t I rely on a bucket and the typical
Q 1 qt. in 20 second shop test to verify if my

radiator is plugged?
Using a bucket and testing the flow on the lift
A
Part No.: FM-01K Sonnaflow™
does not duplicate the driving con- Part No.: FM-03K Diagnostic lead
ditions of TCC apply, aerated
fluid, failsafe or radiators that plug
as their heat increases (The
Chrysler units 41TE, 46RH are a
good example). When restricted,
they often flow less with higher
operating temperature. Besides the
greater accuracy of a road test, there
is less mess. A pressure gauge by
itself cannot measure flow. Using two
gauges and measuring the difference or the pressure The Sonnaflow installs easily in the return cooler line. You can
drop across cooler circuit can be used to calculate the then monitor cooler return (lube) oil during any driving condi-
tion. For an even more accurate test you can monitor the
flow rate. This procedure is be very time consuming Sonnaflow system with an oscilloscope or Graphing DMM,
and not as accurate in regards to viscosity changes. like Snap-On's Vantage.
GPM/Hz GPM/Hz
2.6/361
42-47RE 2.6/361
41TE/42LE
2.5/333 Condition: Repeated planetary failure, TCC lining failure 2.5/333 Condition: Good vs. bad flow
2.2/305 Correction: Replace cooler lines and/or radiator. 2.2/305 Correction: Repair cooler flow, replace bypass valve, replace pump.
Converter failure plugs lines and 2.0/278
2.0/278 then overheats planets.
1.8/250 Good Flow 1.8/250
1.6/222 1.6/222
1.4/194 1.4/194
Pressure
1.2/167 Regulator 1.2/167 Good
Buzz Idle
1.0/139 1.0/139
0.8/111 Restricted 0.8/111
Cooler
0.6/83 0.6/83
0.4/56 0.4/56
Bad
0.0/0 0.0/0
PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL HOT IDLE DRIVE
Notes: Flow is less due to 5/16" vs. 3/8" cooler line on 42RE & 47RE units. Good cooler flow Notes: #46 and later plate # increase cooler flow. #33 plates decrease flow in TCC. Pump output
circuits have sharp increase/decrease of lock-up control. Updated valves allow fluid in park to very crucial, flow drops hot, during shifts and return to idle.
charge converter.
GPM/Hz GPM/Hz
2.6/361
E4OD 2.6/361
RE4RO1A
2.5/333 Condition: Repeat code 62, TCC failure leading to lube failure 2.5/333
2.2/305 Correction: Replace radiator to increase cooler flow. 2.2/305
Install high volume pump.
2.0/278 2.0/278
1.8/250 1.8/250
Good
1.6/222 1.6/222
1.4/194 1.4/194
1.2/167 Good 1.2/167
1.0/139 1.0/139 Bad
0.8/111 0.8/111
0.6/83 0.6/83
0.4/56 0.4/56
Bad
0.0/0 0.0/0
PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL REVS ENGAGEMENT PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL
Notes: RE4RO1A critical to flow coolant to prevent lube failure. All restricted radiators
affect/reduce TCC apply spike.

Sonnaflow™ as a diagnostic tool.
I have seen in the advertising that the Sonnaflow™ has
Q a diagnostic lead (FM-03K). What advantage is it for

me to purchase this lead? What can it tell me, to justify
its purchase?
The optional diagnostic lead has Banana Jacks that attach
A to most DVOM or graphing multimeter, such as the Snap-

On Vantage. These leads transfer a Hz (cycles per second)
output, which is read on the scope as a frequency. In short, more
flow generates more cycles per second and a constant flow out-
puts a steady frequency. The slightest decrease or erratic increase
in cooler flow is observed on the scope when set on the correct
frequency scale. By monitoring this signal you can:
• Identify a low oil level or filter sucking air
• Identify poor pump capacity or low output
A restricted cooler is a sure way to wipe out
the geartrain. The Sonnaflow will quickly alert • Identify valve action
you to a restricted cooler. • Isolate hydraulic versus electronic complaint
Effects of cooler restriction on TCC; Snap-On Vantage; stored screen memory of E4OD
GOOD: E4OD BAD: E4OD Cooler
BAD: E4OD
200 Cooler flow with OE 200 Cooler flow, with 200 flow, with maximum
restriction. Shows flow restricted to .5
applied, release and flow restricted to
GPM. Shows applied
re-apply flow .9 GPM
TCC, release and
re-apply.
100 100 100
GOOD
0 0 0
GPM/Hz GPM/Hz
2.6/361
AX4S 2.6/361
4L80-E
2.5/333 2.5/333 Condition: Purple Line: Normal Green Line: Poor - TCC valves not
completely stroking Red Line:
2.2/305 2.2/305 Poor - Idle engaged engine surge
2.0/278 2.0/278 Correction: To eliminate TCC
1.8/250
Drop out 3rd 1.8/250 apply valve cycle-seal Normal
off TCC regulator and
1.6/222 1.6/222 TCC shift valves. Idle
Poor TCC
1.4/194 1.4/194 engine surge requires Valve Control
higher pump output
1.2/167 1.2/167 and more release oil
1.0/139 Mis-wired 1.0/139 pressure: VCM Restricted
EPC to shift recalibrate. Radiator
0.8/111 Bad Bypass 0.8/111
0.6/83 Sleeve 0.6/83
0.4/56 0.4/56 D-R Low
Failsafe Idle Surge
0.0/0 0.0/0
PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL
GPM/Hz GPM/Hz
2.6/361
General Diagnostics 2.6/361
General Diagnostics
2.5/333 Drain-Back = No flow on initial start (above 50ºF) 2.5/333
Restricted Filter = Low flow, large dips in flow, sluggish
2.2/305 shift reaction and increase. 2.2/305
Aerated Fluid = Low oil level,
2.0/278 filter inlet leak, 2.0/278
1.8/250 mis-matched pump 1.8/250
halves No Control
1.6/222 1.6/222
Over TCC
1.4/194 1.4/194 Valve
1.2/167 Aerated Fluid 1.2/167
2-3
1-2 Weak
1.0/139 Shift
Pump 1.0/139
Shift Drain-back
0.8/111 0.8/111 Delayed
Engagements Engage
0.6/83 0.6/83
Bad Filter, Stuck
0.4/56 Pump, 0.4/56 Lock-up
0.0/0 Cooler 0.0/0 Valve
PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL PARK DRIVE IDLE O.D. TCC OFF TCC APPLIED TCC CANCEL

AOD-E 4R70W Part No. 76948-04K
Complaint Code 628, shudder condition

Secondary Complaints: B Y PA S S C L U T C H C O N T R O L S L E E V E & P L U N G E R VA LV E
• Delayed or no lock-up
• Uncontrollable TCC
Cause
The complaints are
symptoms of too much oil
to the bypass control valve Look for leakage
plunger, or wear at the from exhaust
port on casting
control sleeve (bottom) side of
valve body.
Correction Valve Body
Plunger Valve
Restore the hydraulic

integrity at the bypass
control sleeve, and
regulate converter charge
oil flow to the plunger.
Bypass Sleeve
with control orifice
Part No. 76948-04K

1 Bypass Sleeve
1 Plunger Valve
SONNAX PART SUMMARY
S ome common complaints with AOD-E & 4R70W transmissions include

delayed lock-up, shudder, no lock-up, or converter codes. When too
much oil is routed to this plunger valve, the bypass valve has slow reaction
from MCC/TCC solenoid oil. If there is excessive wear at the plunger valve,
regulated converter charge oil can leak to exhaust. Because this regulated
converter charge oil is always present, either as release or apply pressure,
severe leakage at the sleeve can result in a no TCC apply situation.
Sonnax now offers a replacement bypass clutch control sleeve and plunger
valve 76948-04K with a restricted oil flow orifice. The single .030" orifice,
much smaller than the OEM size, allows the bypass clutch control valve to
properly stroke to the TCC apply position. This eliminates the need for
modifying the plunger feed hole in the separator plate, which is a common
industry adjustment.

AOD-E 4R70W Part Nos. 76948-01, -02K & -09
Complaint Premature clutch/band failure, poor reverse boost

Secondary Complaints: P R E S S U R E R E G U L A T O R V ?A?LV E & B O O S T S L E E V E K I T
Retaining Clip
• Poor soft shift quality
Identification recess here
• Insufficient line rise on '96 and later valve
• Erratic, buzz, or
Spring
uncontrollable
pressure in reverse Valve Body
Pressure Regulator
• Broken cases Main Pressure Boost Sleeve
Regulator Valve
annular grooves to
prevent valve side loading
Cause Pressure Regulator Boost Valve

(correct assembly shown, may not
have a spring over boost valve stem)
Worn main regulator valve
and worn reverse boost Exhaust to
Pump Suction
Line, EPC Reverse
from Boost Boost
sleeve Line Converter Pump Oil Oil
Balance Oil Charge
Correction
These direct replacement
main regulator valves are
closely toleranced, made
from high quality aluminum, Valve wear at this point will allow If wear and cross leaks are severe enough, reverse oil will
specially coated to resist wear, EPC boost oil to leak off into react on the full diameter of the regulator valve and create
exhaust. This lowers line rise ability. Exhaust to extremely high pressure in reverse (i.e. case & parts
and have annular grooves to Pump Suction breakage). Minimal wear causes poor reverse line rise.
center them in the bore and
prevent premature wear. SONNAX PART SUMMARY
Part No. 76948-01 A common complaint in vehicles with an AOD-E/4R70W transmissions is

low line pressure or throttle sensitive buzz, especially when hot. This is
often caused by a worn main regulator valve. This wear allows EPC (electronic
1 Main PR Valve
'91-’95 version pressure control) oil to leak to exhaust, resulting in poor line rise. When the oil
temperature increases, the oil becomes less viscous and more leakage occurs.
The Sonnax replacement valves 76948-01 & 76948-09 eliminate the above
Part No. 76948-09 problems with close tolerances and they are made from high quality hard coated
1 Main PR Valve aluminum to eliminate excessive wear. Annular grooves have also been added to
'96 and up version the pressure regulator valve. These grooves allow oil to surround the valve, thus
centering it in the bore to prevent side loading which causes premature wear.
Part No. 76948-02K Another common complaint with these transmissions is poor reverse boost,
1 PR Boost Valve often the result of a worn pressure regulator boost sleeve. The sleeve should be
1 PR Boost Sleeve checked while replacing the main pressure regulator valve. Sonnax offers a
Note: 76948-01 is for valve bodies replacement pressure regulator boost valve and sleeve kit 76948-02K.
identified by having 13mm socket
heads on the alignment bolts.
76948-09 applies to valve bodies
having .173" alignment pins with
10mm heads.

AOD-E 4R70W Part No. 76833E
Complaint Overdrive band or forward clutch failure

The O.D. servo pin wears the case bore, causing forward clutch
Cause
Part No. 76833E circuit leaks
1 Servo Pin
This Overdrive servo pin has two o-rings to positively seal against
2 O-Rings Correction the piston I.D. and the case bore.
1 Washer
Note: Comes with an optional OVERDRIVE SERVO PIN
washer to pre-load the spring for
a firmer 3-4 shift.
Spring Retainer
Washer
Servo Piston O-Rings

Piston Sleeve
Overdrive Servo Pin
AOD-E 4R70W Part No. 76204-01
Complaint TCC apply & release problems

Secondary Complaints: A worn stator support I.D. at the input shaft Teflon® ring area
Cause allows oil leakage
• Cross leakage of
forward clutch Correction
This hardened steel sleeve is pressed into a machined stator support
and converter to provide a new seal surface and restore oil circuit integrity.
release pressure S TAT O R S U P P O R T S L E E V E
• Lube and converter
release oil Inspect here for wear
Stator Support Sleeve

Part No. 76204-01
1 Sleeve A
CH
INI
N
M
G
R
E
QUIRE
Stator Support
Converter Release Orifice

ATX Part Nos. 86940-01 & -03
Complaint ??Very late or no upshift

T H R O T T L E C O N T R O L V A LV E & T H R O T T L E P L U N G E R S L E E V E S
• Hydraulic bind on
Valve Body
accelerator linkage
• Poor throttle
pressure control
Cause Throttle
Control Valve
Throttle Control Throttle

Wear on the throttle control Valve Sleeve Plunger Sleeve
valve sleeve and/or throttle
plunger sleeves from the steel
valves can allow TV oil to
exhaust
Washer
Correction
The replacement throttle
control valve sleeve is Throttle Plunger
made from high quality
aluminum to eliminate
excessive wear. The throttle SONNAX PART SUMMARY
plunger sleeve of anodized
aluminum resists wear
from the throttle plunger.
V ehicles with an ATX transmission frequently experience poor throttle
pressure control, very late or no upshift and a hydraulic bind on acceler-
ator linkage. These complaints can be the result of a worn throttle control valve
sleeve. The hardened steel throttle control valve continuously strokes in the alu-
Part No. 86940-01 minum sleeve. This wears the inside diameter of the sleeve and allows oil cross
1 Throttle Plunger Sleeve leakage. Regulated TV oil can become open to exhaust, resulting in throttle
pressure and shift problems. If TV balance oil leaks, the result can be very late
Part No. 86940-03 or no upshift. The replacement throttle control valve sleeve 86940-03 elimi-
1 Throttle Control Valve Sleeve nates these problems. The direct replacement sleeve is manufactured from high
quality aluminum to eliminate excessive wear from occurring on the inside
diameter of the spool.
Vehicles with ATX’s also experience problems with sensitive shift timing, unad-
justable TV response, low line pressure and/or no kickdown. These complaints
are often caused by wear in the throttle plunger sleeve caused by the throttle
plunger. Sonnax offers a replacement throttle plunger sleeve 86940-01. This
sleeve is made from anodized aluminum to resist wear.

ATX Part Nos. 86412-01 & -T
Complaint Erratic or no 1-2 & 2-3 shift

Cause Wear of the governor body and pins
• Pin and weight
hang-up This oversized governor pin allows weights to move freely after pin
Correction holes are drilled to accept the oversized pins.
Part No. 86412-01
OVERSIZED GOVERNOR PIN & TEST TOOL
4 Governor Pins
Part No. 86412-T

1 Test Tool
Governor
Test Tool Features:
• Allows easy testing of ATX
governor oil circuit
• Tests for these conditions:
-Worn transmission governor bore Governor Circuit Test Tool
-Obstructions in the governor circuit
-Incorrect shift points Governor Pin
ATX Part No. 86539-Z5
Complaint Difficulty obtaining correct preload of idler gear

Cause Normal wear
Part No. 86539-Z5
10 Shims (.005" thick)
These shims, used in conjunction with the selective spacer, allow
Correction the proper preload of .001"-.003" to be acquired.
SELECTIVE IDLER GEAR SHIM

Idler Shaft Tapered Bearing Cone Idler Gear
Selective Cone
Spacer
Tapered
Bearing
Cone
Shim
used between the bearing cone and
selective cone spacer

AXOD-E Part Nos. 96201-16K & 96201-BST
Complaint No forward or reverse, slips forward and reverse

F O R W A R D C O N T R O L VA LV E & B O R E S I Z I N G T O O L
• Shifts 1-2-3-2
• Burnt
forward clutch
Forward Clutch
Control Valve
Cause
Spring
The forward clutch Retainer

control valve is stuck 96201-09
Correction Bore Sizing

Tool
Resize the bore with this

sizing tool and replace the
forward clutch control SONNAX PART SUMMARY
valve.
T he forward clutch control valve strokes to turn the forward clutch on and
off. Each time it strokes to the on position it bangs against the steel
retainer. This constant banging can eventually break the retainer. The broken
retainer forces the valve off center, often bends the valve, or the valve pushes
Part No. 96201-16K right through the retainer. The complaint depends on where the valve sticks,
O
TO L
1 Forward Control Valve and whether the valve has broken through the plate. Sonnax has developed a
1 Replacement Spring replacement valve 96201-16K with a longer and sturdier spool, eliminating
R
E
QUIRE
Note: This valve does not the OEM stem. This allows a larger contact area with the retainer, preventing
require a reamer. The bore
sizing tool restores the the valve from bending or breaking the retainer. This design is sturdier than
original bore. the original valve and will not break through the plate. This valve kit also
includes a replacement spring. If the original valve is bent, repair the bore with
the Sonnax resizing tool 96201-BST.
Part No. 96201-BST

1 Bore Sizing Tool

AXOD Part No. 96201-06K
Complaint TCC apply and release problems, code 628

Cause Severe wear of the bypass clutch control plunger valve sleeve
• Reduced cooler and
lube pressure These tightly toleranced items restore hydraulic integrity and are
Correction designed to prevent wear.
B Y PA S S C L U T C H C O N T R O L S L E E V E & P L U N G E R VA LV E
Part No. 96201-06K
1 Bypass Sleeve
1 Bypass Plunger Valve
Bypass Plunger Valve
Bypass Sleeve
Valve Body
Clip
Place ATF into the retaining clip passage
with sleeve installed in valve body.
Pressurize this cavity. Leakage at plunger
end of sleeve is line pressure.
AXOD & E Part Nos. 96945S, 96728, 96995A & 96945R
Complaint Delayed forward engagement

Cause Servo pin-bore leakage, incorrect spring calibration & retainer breakage
• Downshift clunk
The upgraded servo piston and spring correct delayed engagements.
• 2-3 shift flare Correction The servo rod is longer & the retainer is upgraded & resists breaking.
UPGRADED LOW/INTERMEDIATE SERVO, SPRING, ROD & R E TA I N E R C L I P
Part No. 96728
1 Servo Piston Servo Piston
Servo travel is just as important
as oil integrity. Set up servo
Part No. 96995A travel to a maximum of .120".
1 Servo Spring Servo Piston Cover
Servo Spring
Part No. 96945R Spring Retainer Clip
5 Spring Retainer Clips
Servo Pin
Part No. 96945S
1 Servo Pin

AXOD & E AX4N & AX4S Part Nos. 96201-01K,
-08K, -12K & -13K

Secondary Complaints: R E V E R S E B O O S T VA LV E & S L E E V E K I T S
• 2-1 downshift clunk

• Non-adjustable Valve Body
throttle pressure,
high pressure
• Harsh reverse, &
clutch or band failure
O-Rings
Cause insures boost oil
Boost Valve
The boost valve wears the
inside diameter of the
Boost Sleeve
boost sleeve and causes oil highest quality
to leak & exhaust through aluminum
the reverse orifice, result- “Factory style”
ing in poor line rise
Correction
This replacement assembly
eliminates these problems SONNAX PART SUMMARY
with a closely toleranced
boost valve & sleeve, and
the hard aluminum valve
eliminates excessive wear.
V ehicles with an AXOD, AXOD-E, AX4N, or AX4S transmission frequently
have the following problems: flare 1-2 or 2-3 upshifts, 2-1 downshift clunk,
non-adjustable throttle pressure, High pressure, harsh reverse (300 PSI) and
clutch or band failure from poor line rise. This can be caused by the reciprocating
Part No. 96201-01K
boost valve wearing the inside diameter of the boost sleeve. When this occurs oil
(3.8 Liter)
that enters the TV orifice leaks past the boost valve and exhausts through the
reverse orifice, resulting in poor line rise. The outside diameter of the boost sleeve
Part No. 96201-12K also allows some leakage through the valve body, which can result in poor reverse
(3.0 Liter) boost.
1 O-ring Boost Sleeve
1 Boost Valve The Sonnax replacement assemblies 96201-01K, 96201-08K, 96201-12K, &
2 O-Rings 96201-13K eliminate the above problems with a closely toleranced boost valve
and sleeve. The boost sleeve is manufactured from Alcoa Deltalloy® 4032. This
high quality aluminum has a special composition that eliminates the need for hard
anodization, while remaining equally wear resistant. The boost valve is made from
Part No. 96201-08K aircraft quality aluminum with a special hard coat. This will eliminate excessive
wear from occurring on the inside diameter of the sleeve. Two o-rings on the
(3.8 Liter)
96201-01K & 96201-12K provide additional protection against leakage through
Part No. 96201-13K the valve body and assist in retaining pressure in the areas that supply the boost
(3.0 Liter) valve. Hydraulic tests conducted on these replacement parts, simulating actual
application usage, show zero to minimal leakage. Each of these Sonnax kits are leak
1 “Factory style” Boost Sleeve
tested before leaving the factory.
1 Boost Valve

AXOD & E AX4S Part No. 96730-RR
Complaint No movement
Cause OEM retaining ring does not fill groove
• Retaining ring
becomes loose and This retaining ring is thicker and fits more securely in the groove,
Correction eliminating excess clearance that leads to the ring popping out.
pops out
R I N G G E A R R E TA I N I N G R I N G
Part No. 96730-RR
1 Retaining Ring Retaining Ring
is thicker than OEM and
fills entire ring gear groove
Ring Gear
Drum
AXOD & E Part No. 96806
Complaint No forward or no 3rd gear

Insufficient factory press fit between the tubes and case, resulting
Cause
Part No. 96806 in tube blow-off
1 Servo Tube Bracket
This bolt-on bracket positively retains the servo tubes, eliminating
Correction the chance of blow-off.
SERVO TUBE BRACKET
Servo Tube Bracket

Servo Apply Tubes

AXOD-E AX4S Part No. 96206-01K
Complaint ??No TCC apply or code 628

Secondary Complaints: B Y PA S S C L U T C H C O N T R O L S L E E V E & P L U N G E R V A LV E
• TCC apply unnotice-

able, slippage occurs
or TCC stays applied Valve Body
during coast
• Lube system failure
Spring
Cause
Lube/Coverter
oil located between the
valve and sleeve
Excess wear allows

regulated converter charge
and cooler oil leakage Retaining Clip
Bypass Plunger Valve
Correction Smaller feed ports result in

responsive TCC control.
Restore hydraulic control

and prevent cooler/lube oil Bypass Clutch
Control Sleeve
loss by replacing the valve
and sleeve. SONNAX PART SUMMARY
Part No. 96206-01K

1 Bypass Plunger Valve
V ehicles with an AXOD-E or AX4S transmission frequently have lube
system failures, TCC apply and release problems and code 628. These
complaints can be aggravated by severe wear of the bypass clutch control
1 Bypass Clutch Control Sleeve plunger sleeve. Excess wear allows regulated converter charge and cooler oil
leakage. This oil is fed to the lube circuits, cooler, TCC and into the sleeve to
help maintain the TCC in the release position. If the sleeve is worn, oil will
exhaust past the plunger sleeve through the manual valve. Because this regu-
lated converter charge oil is always present, either as release or apply pressure,
severe leakage at the sleeve can result in a no TCC apply situation.
Sonnax has a tightly toleranced bypass clutch control sleeve and plunger
valve 96206-01K which restores hydraulic integrity and eliminates the above
problems. To minimize wear of the precision sleeve, it is manufactured from
4032 Deltalloy® aluminum and the aluminum plunger valve has been
anodized. The sleeve has also been lengthened to prevent oil loss at the valve.
The regulated converter feed holes in the sleeve have been made smaller than the OEM
size to restrict flow and allow for a quicker stroke/apply of the TCC bypass valve.
Note: The orifice size in the sleeve has been reduced which increases TCC control. The orifice
may be opened to restore OEM size and control.

AXOD & E AX4N/AX4S Part No. 96201-05
Complaint Delayed forward engagement

Cause Worn valve body and oil loss at the valve bore
• Burned forward
clutch This manual valve restores the intended fit with the bore. Its special
Correction hard coat finish prevents wear.
• Low converter
charge M A N U A L VA LV E
Part No. 96201-05

1 Manual Valve
Valve Body
Manual Valve
wide spools supported by unworn
valve body to seal circuits
AXOD & E AX4N/AX4S Part No. 96803
Complaint Low cooler flow, slips in all ranges

Cause Turbine seal ring wear on the soft aluminum channel casting surface
• Excessive converter
clutch slip This hardened and ground steel sleeve salvages worn channel plates
Correction and retains original OEM alignment.
Part No. 96803 C H A N N E L P L AT E R E PA I R S L E E V E

5 Repair Sleeves A
CH
INI
N
Channel Plate Repair Sleeve

M
Note: This repair sleeve hardened & ground - restores to

R
E
requires machining. QUIRE
“better than new” condition
Channel Plate

AXOD & E AX4S Part Nos. 96511K, -12K, -13K & -123K
Complaint ??Delayed engagement, flare shifts

Secondary Complaint: A C C U M U L AT O R B O R E S L E E V E K I T S
• Harsh shifts
Cause
Scored accumulator bores Sleeve
create loss of clutch pressure Piston
No machining
required
or cross leaks
Viton® O-Ring
Correction
This drop-in accumulator
kit has an aluminum sleeve
and new steel piston with a
Viton® o-ring. The length
of the piston-to-pin contact
area has been increased to
reduce piston cocking and
increase sealing surface area.
SONNAX PART SUMMARY

Part No. 96511K (N-D)
Part No. 96512K (3-4)
Part No. 96513K (1-2)
T he accumulator bores on AXOD & E/AX4S channel castings can become
scored, which creates loss of clutch pressure or cross leaks. The continu-
ous oscillation of the piston within the bore causes excessive wear. Also a bro-
Each includes the following: ken accumulator spring can get caught between the piston and the bore caus-
ing a deep groove.
1 Sleeve
1 Piston Sonnax now offers accumulator bore sleeve kits. These drop-in kits contain an
aluminum sleeve and a new steel accumulator piston with a Viton® o-ring. The
1 Viton® O-Ring
piston is compatible with all OEM springs as well as the OEM piston pins. The
length of the piston-to-pin contact area has been increased to reduce piston
Part No. 965123K cocking and increase sealing surface area. Sonnax offers 3 different kits: the N-
1 Each of the kits above D accumulator kit 96511K, the 3-4 accumulator kit 96512K and the 1-2 accu-
mulator kit 96513K. Sonnax also offers a master kit 965123K, consisting of
all three items. These kits require no machining and easily press into the bore.

AX4N Part No. 96206-03K
Complaint No TCC apply & code 628

Secondary Complaints: A worn bypass clutch control sleeve allowing regulated converter
Cause charge and cooler oil leakage
• Poor TCC apply
and release Restore the hydraulic integrity and prevent cooler oil leakage at the
Correction bypass clutch control sleeve.
• Lube system failure
B Y PA S S C L U T C H C O N T R O L S L E E V E & P L U N G E R K I T
• Excessive cooler
circuit oil loss
Plunger Valve
Part No. 96206-03K
Bypass Clutch
1 Plunger Valve Control Sleeve
1 Bypass Clutch Control Sleeve
Note: Inspect for worn bore.
Retaining Clip
Spring
Valve Body
located between
valve and sleeve
AX4N Part No. 96948-01K
Complaint Soft 1-2 or 2-3 shifts

Cause Severe wear of the line pressure modulator sleeve
• Intermittent harsh
shifts
Correction Restore EPC circuit integrity by replacing the sleeve and valve.
• Poor line rise
L I N E P R E S S U R E M O D U L A T O R P L U N G E R V A LV E & S L E E V E
Spring
Part No. 96948-01K
1 Valve
1 Sleeve
1 O-Ring Spring &
Accumulator Spring Seat
Valve Body
O-Ring
Line Pressure
Modulator Valve
Line Pressure
Modulator Plunger Valve
annular grooves to prevent
side loading Sleeve Retaining clip

AXOD-E AX4S Part No. 96201-15K
Complaint ???
Neutrals on the 3-2 downshift, harsh 3-2 kickdown
The valve constantly bangs the retainer, resulting in broken retainers
Cause that get lodged and sometimes damage the end of the valve
Part No. 96201-15K
5 Valve Saver Caps This valve saver cap and retainer allow re-use of the
5 Retainer Clips Correction 3-2 shift timing valve.
VA LV E S A V E R C A P
Also Available
3-2 Shift Timing Valve
Part No. 96201-09
1 Retainer Spring
Spring
Part No. 96201-10
1 Retainer
Note: These retainers are Valve Saver Cap
Pull-in Valve
used in numerous Ford valve 96201-15K
body locations.
Plug
Retainer
96201-09
Retainer
Mangled valve Broken retainer 96201-10
CD4E Part No. 73251-01K
Complaint Excessive endplay

Cause OEM shims have too great a difference between shim selections
Part No. 73251-01K This shim kit adjusts the planet, drum, and differential endplays
2 Shims ea. (.008" & .015" thick) Correction and offer a more precise adjustment.
for #9 Bearing
2 Shims ea. (.005" & .010" thick) S H I M K I T F O R S E T T I N G E N D P L AY
for #13 Bearing Driven
Sprocket Shim Shim
#9 Bearing Drive Sprocket to #13 Bearing Differential

Overdrive/Reverse Carrier to Driven Sprocket Differential

CD4E
Complaint ??Codes 628 / 1744 / 1740, high line pressure
P R E S S U R E R E G U L AT O R & B Y PA S S C L U T C H C O N T R O L K I T S
• Lube oil loss Bypass
Clutch Valve
• Reduced converter Land for
clutch life sag test Plunger
Valve
Bypass Clutch
• Bushing or planet Control Sleeve
failure
End plug
Converter
Regulator Valve
Cause
Valve Body
Spring
OS Pressure
Regulator Valve Spring
includes built-in
Worn bores in the converter pressure relief Spring
Retainer Clip
bypass and pressure regulator

line-up End Plug
This pressure regulator V ehicles with CD4E transmissions often have complaints of runaway
high line, broken hard parts and Code 628/1744/1740. High pres-
sure concerns are caused by wear in the pressure regulator valve bore and con-
and bypass clutch
verter concerns are caused by wear at the bypass clutch control valve bore.
control kit restores
Sonnax now offer the 73840-RK for pressure regulation concerns and
hydraulic integrity of
73840-BK for converter concerns. These two kits are also available together
the valve circuits.
in a master kit 73840-MK. All valve kits require the associated reamer tool
listed on this page.
Part No. 73840-BK
O
TO L
1 OS Bypass Clutch Valve SAG TEST
1 Plunger Valve
R
E
QUIRE To test for a worn bypass clutch
1 Bypass Clutch Control Sleeve control valve bore, install OEM
4 Lubrication Plugs (1 extra) valve backwards, with large spool
in position. With .070" or less
clearance between bottom of the
Part No. 73840-RK valve and the bore means the
O
TO L
1 Converter Regulator Valve bore is worn out. A good tool to
1 OS Pressure Regulator use for a gauge is a .070" drill bit.
R
E
QUIRE
Valve
1 End Plug
4 Lubrication Plugs (1 extra)
1 O-Ring
Part No. 73840-BTL Part No. 73840-MTL
Services the 73840-BK only Master Tool Kit
1 Spring
Services the 73840-MK, -BK or
Part No. 73840-MK Part No. 73840-RTL -RK
Master Kit: Includes Converter
O
TO L
Services the 73840-RK only
Bypass & Pressure Regulator
R
E
QUIRE
Kits above

Part Nos. 73840-BK, -RK, -MK, -BTL, -RTL & -MTL
BYPASS CLUTCH CONTROL & LUBE IMPROVEMENTS FIG. 1
OEM VALVES SONNAX IMPROVED VALVES
SONNAX PLUG KIT

The OEM control sleeve & bypass bore wear, causing: Increases Converter & Rear Lube PSI Front Lube
Feed to Lube is Now from Line PSI
Differential Lube
• Low converter pressure
Sonnax Plug
• Converter slip codes 628/1744/1740
• Low lube pressure (front lube) OEM Converter PSI Feed
• Bushing and planetary failure
• Converter crowding, engine stall in D-R Lengthened Spool Lengthened Spool with
Provides Better Support Exhaust Slots Provides
& Prevents Leakage Continuous Bore Support
• No TCC apply when hot

• Slip converter codes
628/1744/1740
Annular Grooves Oversized Valve Annular Grooves

Prevent Side Loading Re-Establishes Valve/Bore Fit Prevent Side Loading
NOTE: Reparing this sleeve or bore alone won’t address:

• High Line pressure run-away • Harsh engagements
• Failsafe lube shutdown • All lube concerns
Complete fix includes pressure regulators in Fig. 3.
Both valve assemblies in kit 73840-MK.
OEM PRESSURE REGULATOR CONCERNS FIG. 2
FAILSAFE POSITION OF OEM LINE PRESSURE

REGULATOR VALVE, NO FLOW TO COOLER OEM HIGH LINE PRESSURE POSITION
No Converter Sump Balance Circuits Worn OEM Spring Regulates at Approx. 100PSI, Which
Exhaust Bore Here Causes means Any Converter Feed Over 100PSI Shuts OEM Bore Wears
or Lube Feed Here, Lowers
Valve to Stay in High Valve Down To No Flow. The Valve Is Not an
Line/No Exhaust Exhaust Control Design, But Flow Control. Converter Pressure
High Pressure
EPC/TV Pump
Line In
Ø.060˚ OEM
Converter
Feed
Bypass. If
Opened
Further
High Line
Feeds to
TCC/Lube
OEM Very Low Flow
or No flow
High PSI
High PSI Out Line Pump
In

Part Nos. 73840-BK, -RK, -MK, -BTL, -RTL & -MTL
IMPROVED SONNAX LINE PRESSURE & CONVERTER REGULATOR VALVES FIG. 3
SONNAX VALVE IN START UP POSITION, SONNAX VALVE IN HIGH PRESSURE POSITION

OR FAILSAFE, ALLOWS FLOW TO COOLER REGULATING MAXIMUM CONVERTER PRESSURE
BENEFITS:
1 4
LOCATION 1: No oil loss at worn bore, stabilized OD
LOCATION 2: High flow cooler/converter circuit
LOCATION 3: Valves will not shut off flow, but regulate
at full line pressure
1 2 3
2 3 5
Cooler/Lube Balance
OEM Ø.060˚
Lube Feed To Lube
BENEFITS: Converter
LOCATION 1: Full time converter/cooler feed at

start and low pump output
LOCATION 2: Controls line and cooler in advent

of EPC/TV failsafe
LOCATION 3: Regulates flow to converter regula-

tor through high or low line pres-
sure
NOTE: Installing these two valves will improve the source of
LOCATION 4: Converter feed-to-line timed with lube/converter feed, but will not overcome a worn
line-to-exhaust bypass sleeve and bypass valve.
LOCATION 5: Oversized valve/reamed bore Complete fix includes bypass valves in Fig. 1.
restores balance circuits Both valve assemblies in kit 73840-MK.
CD4E PRESSURE TESTING FIG. 4
Poor Pressures: Listed below, result from

worn valve bodies and loose bushings.
• Less than 2 psi when Hot Front Lube

• Less than 10 psi when Cold
Less than 20 psi at an idle, while hot,

- CT -
and a pressure spike above 110 psi Converter Turbine psi
during TCC engagement.
All pressure tests are taken in drive range.

CD4E Part Nos. 73840-24, -LR & -FWD
Complaint ??Soft 1-2, flare 2-3

Secondary Complaints: O - R I N G E D A C C U M U L AT O R P I S T O N & S P R I N G K I T S
• Burned band
• Drum overheat
Accumulator Piston
Cause Viton® o-rings installed
Accumulator bore wear

and/or piston sticking Springs
Valve Body
Correction
Prevent leakage of worn
valve body castings with
this o-ringed accumulator
piston and spring kit.
Retaining Clip
Part No. 73840-24

(2-4 Clutch), 1 Spring
Part No. 73840-LR
(Low/Reverse Piston), 3 Springs
Part No. 73840-FWD
(Forward Piston), 2 Springs SONNAX PART SUMMARY
1 Accumulator Piston
V ehicles with a CD4E transmission may have complaints of harsh engage-
ment, soft or harsh shifting particularly from 1st to 2nd gear. These com-
plaints can be due to worn or out-of-round accumulator bores and/or pistons
2 Viton® O-Rings sticking in the bore.
Modified Springs (see above)
Sonnax now offers an accumulator piston kit 73840-24 for the 2-4 piston,
1 Rivet (used in installation) 73840-LR for low/reverse, and 73840-FWD for forward. This anodized alu-
minum replacement piston has two o-rings that will prevent blow-by leakage.
The piston has been dimensionally modified to stop in different axial locations
than OEM to prevent it from hanging-up or sticking on the previously worn
bore ridges. Modified replacement springs are included for each application to
fit in the smaller piston pocket.

Bushings Take a Beating
By MAURA STAFFORD of Sonnax and MIKE STEEN of Certified Transmissions
B
ushings are designed to be wear items, and ing why the bushing failed. Dirt
often reach the full extent of their expected embedment (Figure 2) is one of
lives. But during a rebuild, we often see signs the most common causes of bush-
of premature wear or failure. While at first glance ing failure. While a bushing is
Figure 1:
bushings seem like insignificant low-tech items, fail- designed to accommodate some NEW BUSHING
No sign of wear.
ing to pay close attention to them can cause some dirt, embedded dirt, abrasives, or
high-tech problems. For example, converter hub metal fragments will lodge and displace the surround-
bushings are subject to high loads due to hydraulic ing bushing material. This creates high spots that con-
unbalance, flex of the converter mounting plate and tact the journal and create a halo around the debris.
slight misalignments that might exist. If the bushing I.D. (inside diameter) has
Too much clearance in this area can a polished or finely scratched appearance,
cause front seal blow out, converter this is a sign of abrasive wear (Figure 3).
drainback, poor converter charge, and This is commonly caused by particulate
cooler pressure and flow problems. Figure 2: in the oil, direct contact with the journal,
EMBEDMENT
These can lead into potential geartrain Debris embedded in bush- or a rough journal finish. Scoring is more
failure due to poor lubrication, converter ingcausing
displacing material and
wear “halos” extreme than abrasive wear, and is typical-
shudder and converter slip. This article ly caused by severe contamination.
is intended to provide a basic understanding of bush- A bushing that has a smeared or wiped surface most
ings, causes of distress, design considerations, and likely has suffered from oil starvation (Figure 4). This
which rebuild procedures prevent bushing failure allows the journal to contact the bushing and smear
and improve transmission performance. material. This can be caused by blocked lube holes,
The basic function of an automatic transmission pump volume or pressure
bushing is to align and provide load support for shafts, problems, cold weather
gears and clutch drums. During normal operation and starts, too tight clearances,
when properly aligned, the clearance between a bush- or overheated and diluted
ing and journal diameter fills with oil, allowing the oil. A “hot short” condition Figure 3:
RADIAL ABRASION
shaft to float on the oil film. The housing into which looks severely wiped, black AND AXIAL SCORING
Debris caused slight radial
a bushing is pressed often functions as a heat sink, from heat, and actually has scratches. Debris and axial part
drawing heat away from the bushing and journal. patches of alloy torn away movement created severe scoring.
This reduction of friction and heat increases the over- from the steel backing. This can be caused by pro-
all efficiency of a transmission. longed wiping, overloading, bushing overheat, or oil
Bushings also act as restrictors to prevent oil flow starvation.
between components. The front stator support bush- Localized spots of wear on the bushing I.D. may be
ing in many units prevents release oil from blowing caused by debris trapped between the housing bore
past the turbine shaft to the apply side of the con- and bushing O.D. (outside diameter). This debris
verter. In other instances, bushings are used to inten- will cause the bushing I.D. to have high spots that
tionally direct oil flow to components. Virtually all contact the journal. Axial or radial grooves and
rear extension housing bushings have oil grooves to scratches on the O.D. can indicate a bushing that is
provide a pumping action that sends lubrication to spinning or walking out of the bore (Figure 5). This
the rear seal of the transmission. is usually due to an undersized bushing or a housing
Generally, during a rebuild, bushing wear or failure that has lost its size and shape from repeated service
is obvious. Much can be learned about the overall or extreme pounding.
health and function of the transmission by determin- Wear patterns can indicate if the journal or housing

is non-cylindrical or ings works well. Clearances should be checked with
misaligned. Wear at feeler gauges. If not available, a standard sheet of
the edges of a bushing paper is . 002” thick and is an excellent gauge.
Figure 4: indicates a barrel When replacing bushings, the real challenge might
WIPING AND OVERHEATING
Oil Starvation caused bushing to shaped bore or hour- be maintaining these proper clearances. There are
overheat and wiping to occur. glassed shaped jour- generally two types of replacement bushings avail-
nal. The reverse is true for wear at the middle of a able: finish-in-place or precision manufactured.
bushing. Wear towards only one edge of the bushing Most original equipment bushings have been fin-
indicates a tapered journal or housing. A skewed or ished in place, which provides closer control of align-
angled wear pattern typically represents parts out of ment and running clearances. Precision bushings are
alignment. carefully sized to have a specific press-fit into the
There are some design and Figure 5: SPIN OUT housing bore, which then “crushes”
Radial scoring on bushing O.D. indicates
assembly specifications that should bushing spun out of the the bushing inside diameter to a pre-
be considered during a rebuild that housing bore. determined size and clearance with
concerns bushings. The surface fin- the journal. Due to housing bore tol-
ish on bushings, housings, and jour- erances, loss of bore size and shape
nals greatly affect performance and from multiple bushing replacements,
longevity. A surface that is too rough will supply journal wear, and bushing manufacturing meth-
the contamination to hang valves, plug solenoids and ods, precision bushing to journal clearances will usu-
wipe a bushing out in no time. To aid in retention, ally be greater than that of finish-in-place bushings.
the housing bore for a steel-backed bushing should be If the original bushing is worn and must be replaced,
60-125rms and between 40 to 70rms for solid bronze an oversized bushing that may be finished in place is
bushings. A bushing I.D. should be a 30rms finish or recommended. If they are not available or impracti-
better. Journals should have a finish between 8 to cal, a precision type aftermarket bushing should be
12rms, although up to 20rms is acceptable. The jour- used, and a close check for excessive clearance would
nal should be polished while rotating against the pol- be advised.
ishing paper in the same direction it will rotate in Bushings should be removed and installed with the
assembly. This prevents the microscopic journal correct tools to prevent housing, journal, and/or
scales from kicking up during actual rotation and bushing damage. There are generic sets of bushing
prematurely wearing the bushing or journal. For chisels designed to cut a bushing out of a bore. For
journal touch-ups, a 280 to 320 grit paper may be extra small bushings, thread taps can be used suc-
used. cessfully. The best way to install a bushing is with an
There are many factors that influence the appro- arbor press and an adapter specific to the bushing.
priate bushing clearance, such as bushing and hous- The adapter should press flatly and firmly on the
ing materials, type of journal material and hardness, bushing edge and have a mechanical stop for proper
operating temperatures, quality of machining, and axial location. Avoid manual pounding of a bushing
lubrication methods. Bushing manufacturer’s recom- into place. The bore should be free from debris.
mend a clearance of 0.0005 in./in. of shaft diameter, Pressing in new bushings shaves small pieces of
with a 0.0005 inch minimum for babbits, and material off the O.D. or housing bore, and can be a
0.00075 in./in. of shaft diameter, with a 0.0005 inch source of unwanted contamination. Lubricant on the
minimum for copper-lead and bronze bushings. It is bore or bushing O.D. can be used to prevent galling
usually necessary to increase these amounts in appli- and ease assembly. Proper unit endplay specifica-
cations with heavy loads, or high speeds or tempera- tions should be maintained to prevent shafts ending
tures. From experience we’ve found that .001” of within bushings and oil holes being misaligned.
clearance for every inch of journal diameter is rec- Hopefully this will provide some food for thought
ommended for most transmission applications, and during rebuilds.
.003” to .004” total clearance for converter hub bush-

A404 A413, A470 & A670 Part No. 32710-01
Complaint No reverse, rear band strut breakage

Thin struts cannot withstand the force of servo piston lever as it
Cause applies the reverse band
Part No. 32710-01
1 Reverse Band Strut This reverse band strut has a thicker cross section and is made of
Correction higher yield strength alloy steel.
REVERSE BAND STRUT
Lever Reverse Band Strut

Adjusting Screw
Reverse Band
A404 A413, A470, A670 Part Nos. 32539-Z5, 35539-Z5, 39539-Z5
Complaint Excessive endplay, left-over unpopular spacers

Some spacers provided in spacer kits are commonly unused because
Cause of the unpopular size
Part No. 32539-Z5
These shims allow for accurate setting of endplay & preload and the
Transfer Shaft Shim Correction use of leftover, unpopular washers.
Part No. 35539-Z5 P R E L O A D & E N D P L AY S H I M S
Output Shaft Shim
Part No. 39539-Z5

Transfer
Differential Preload Shim Output Shaft Gear
Shaft Gear
Also fits 41TE & 42LE
Shim Shim Shim

32539-Z5 35539-Z5 39539-Z5
Transfer Shaft Output Shaft Differential
100 sonnax 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www. sonnax. com • info@sonnax. com
41TE 42LE Part No. 92835-03K
Complaint Repeat planetary meltdown, no cooler flow

Secondary Complaints: C O N V E R T E R R E G U L AT O R VA LV E K I T
• Converter shudder Valve Body
• Clogged filter or
radiator
• TCC lining failure
Bias Valve
with internal apply
pressure control
Cause Bias Valve Sleeve
High converter apply

pressure and insufficient
Switch Valve
control of apply and
release oil circuits Bias Valve Spring
SONNAX PART SUMMARY

Correction
H igh converter apply pressures in the 41TE & 42LE transmissions cause
deflection of the TCC. This in turn causes a chain reaction of
failures. The TCC "balloons", the lining disintegrates, clogs the filter and
This converter apply pres-
radiator cutting off lube and the planets or the unit itself burns up. This high
sure regulator valve kit
apply pressure occurs because of insufficient control of the apply and release
will reduce comebacks,
oil circuits. Sonnax now offers a redesigned converter regulator valve kit, that
planet failures, and con- is compatible with all controllers and will regulate TCC apply and release oil
verter claims. (see chart below). This improved design includes a new switch valve to control
the flow entering the converter, a regulator bias valve to prevent the apply
pressure spike and as cost savings re-uses the OEM bias spring and sleeve.
Part No. 92835-03K
1 Switch Valve Converter Apply Pressure Comparison
1 Regulating Bias Valve Increasing
Apply Pressure
OD, Idle Increase Pump TCC Application TCC Off/

RPM/TCC Off Canceled
Stages of Converter Application with EMCC Body
OEM
with the Sonnax valve

41TE 42LE, A670 & A904 Part No. 12502-01
Complaint Pump seal leakage, codes 35 & 38

Secondary Complaints: Excess hub to bushing clearance causes lower pump output and
Cause front seal leakage
• Various switch codes
This pump bushing will restore the clearance required for proper
• Reduced cooler flow Correction operation and this close tolerance bushing can reduce oil loss.
• Lower pump volume IMPROVED FRONT PUMP BUSHING
Part No. 12502-01

5 Front Pump Bushings
Pump Body Bushing
41TE 42LE Part No. 92835-07
Complaint High line pressure, erratic converter apply pressure

Cause A worn pressure regulator reducing sleeve allowing oil leakage
• Poor lube control
This replacement pressure regulator sleeve prevents excessive wear,
• Harsh shifting Correction restores hydraulic integrity, and reduces oil loss.
P R E S S U R E R E G U L AT O R R E D U C I N G S L E E V E
Part No. 92835-07
1 Pressure Regulator Sleeve
Note: The '89-'91, #33 separator
plate design had a steel sleeve and Spring
plugs. The Sonnax hard anodized Low/Reverse
Boost Valve
sleeve has increased durability and Valve Body
compatibility when used with OEM Pressure
steel plugs. Regulator Valve Inner
Sleeve
Pressure
Regulator Sleeve
milled slot eliminates
circuit cut off by End Plug
end plug
Low/Reverse Orifice
Line Balance Plug

41TE 42LE Part Nos. 92003-01K & -TL
Complaint Premature underdrive clutch failure

Leaks in the Underdrive circuit caused by excessive input clutch hub
Cause bushing to support clearance
Part No. 92003-01K Replace the input clutch hub bushing with this
1 Bushing
O
TO L
Correction tighter-fitting bushing.
R
D
E
QUIRE
INPUT CLUTCH HUB BUSHING & TOOL
Part No. 92003-TL Input Clutch Hub
1 Bushing Tool
3 3 1/2” Hex Bolts Bushing
Stator Support
41TE 42LE Part Nos. 92004-L & -SP
Complaint Planetary failure, shaft breakage

Poor tolerancing of the OEM bushings allows critical lube
Cause to exhaust
Part No. 92004-L
5 Bushings - late design, .937”Dia. These unique one-piece bushings restore the desired fit with the
Correction Underdrive shaft to prevent excessive radial movement.
Part No. 92004-SP
5 Bushings - early design, .959”Dia. OVERDRIVE CLUTCH HUB BUSHING
Note: Bushing 92004-SP is for the Steel Backed

early design (1995 & earlier), 41TE Bushing
and 41TE; Bushing 92004-L is for
the later design (1996 & up), 41TE
and 42LE.
Underdrive Clutch
Early Design: OD Ø 1.142" Hub
Later Design: OD Ø 1.162"
Overdrive
Clutch Hub

41TE 42LE Part No. 92835-02K
Complaint Erratic or no TCC, 2nd gear starts

Cause Solenoid switch valve plugs cocking in the bore
• Low reverse
switch code This replacement switch valve plug kit has a
Correction thru-hole that guides the stem on the mating plug.
Part No. 92835-02K S O L E N O I D S W I T C H VA LV E P L U G S

2 Replacement Plugs
Replacement Plugs
Plug
Solenoid Switch Valve
41TE 42LE Part No. 92834-03K
Complaint 1-2 shudder, coastdown clunk

Cause Scuffed and worn accumulator bores resulting in a poor seal
• High CVI’s due
to worn bores Correction
This accumulator piston and sleeve kit restores hydraulic integrity,
refurbishes worn bores, and saves valuable cases.
• Slide shifts
A C C U M U L AT O R P I S T O N & S L E E V E K I T
Part No. 92834-03K

1 Sleeve Sleeve
o-rings installed
1 Piston
2 O-rings
2 Teflon® Seals Piston
Teflon® seals installed
Valve Body
Note: Also works on all 3

accumulator case bores.
Springs

41TE 42LE Part Nos. 92836-03K, -02 & -03
Complaint Intermittent pressure switch codes (21, 22, 23 & 24)

Worn switch contacts and leaking switch seals or replacement seals
Cause that are too thick
Part No. 92836-03K
Solenoid Repair Kit Replace worn diaphragm and switch contact with properly
3 Diaphragms Correction dimensioned parts.
3 Brass Contacts
SOLENOID PACK RUBBER DIAPHRAGM &/OR BRASS CONTACT REPAIR
Part No. 92836-02

9 Diaphragms
Cover
Part No. 92836-03
9 Brass Contacts
Diaphragm
Solenoid Pack
Switch Contact
(Brass)
41TE 42LE(‘94-‘97 w/internal bypass valve) Part No. 92836-01K
Complaint Lock-up shudder

Cause The cooler bypass valve may be stuck open, reducing converter
• Erratic switch codes apply pressure
This bypass plug disables the OEM bypass valve and directs all fluid
• Soft, long 1-2 shift Correction through the cooler.
• Erratic coast down B Y PA S S P L U G
bumps
Case
• Converter clutch On the 41TE case
slippage, and code 38 which has a
bypass, there is a
casting bulge
• Converter pressure above the right
fitting.
drop due to excess
Case Fitting
fluid bypass re-installs over plug
Part No. 92836-01K

2 Bypass Plugs OEM Bypass Valve
Bypass Plug
installs into case
Note: This Bypass plug prevents having to remove
the unit when the OEM design is stuck open.

41TE Part Nos. 92965-Z5, -30, -37, & -45
Complaint Bearing failure, gear train noise

Setting the preload and endplay of transaxle output shaft and transfer
Cause shaft bearings, rebuilders may exhaust popular spacer sizes
Part No. 92965-Z5
10 Shims .005” thick These spacer and shim kits allow more accurate setting of preload
Correction and endplay, and may be used with leftover OEM selective spacers.
Part No. 92965-30
10 Spacers .030” thick T R A N S F E R / O U T P U T S H A F T G E A R S PA C E R S & S H I M S
Part No. 92965-37 Transfer

Shaft
10 Spacers .037” thick Gear
Part No. 92965-45 Spacer

10 Spacers .045” thick 92965-45
Spacer
Output 92965-37
Shaft Shim Kit
Gear 92965-Z5
Spacer
92965-30
A904 42RE Part No. 12780-Z
Complaint Excessive total transmission endplay

Cause Worn gear, snap ring, and/or spline
Part No. 12780-Z
10 Shims .010” thick
This shim allows for adjustment of the total and rear unit endplay
Correction and works with both 3 and 4 tanged thrust washers.
R E A R P L A N E T E N D P L AY S H I M
Ring Gear
Rear Planet Shim

Assembly for 3 or 4 tanged
Driving Shell
with Sun thrust washers
Gear
Assembly
Thrust Washers,
3 or 4 tangs

42RE 42RE Part Nos. 12962N-01K & -02K
Complaint Reverse drum, retainer & planet failure

Secondary Complaints: U P G R A D E D P I S T O N R E TA I N E R S
• Loss of lube oil to

the gear train
• High replacement
cost of the reverse
drum
Cause
Kit includes
Case plugs to allow
Excessive clearance use in electroni-
between the overdrive pis- cally controlled
ton retainer and interme- units.
diate shaft reduces lube

Piston Retainer
flow to the gear train
Seal compensates for

S onnax is now offering an upgraded standard replacement 12962N-01K
and an oversized 12962N-02K piston retainer to allow rebuilders to sal-
vage the expensive reverse drum. The
variations in the case I.D. oversize version requires only boring
and oil is delivered to the I.D. of the drum using a lathe and
maximum load points on then installing as normal.
shaft. OEM and oversized 5 1. O-ring prevents loss of lube oil.
drum contact surface
Many OEM supports do not seal
allows salvage of drum. well here.
2
2. Two O.D. oil delivery grooves
3 repositioned at high load areas.
Part No. 12962N-01K
6 Bolt Piston Retainer (OEM) 3. Two I.D. oil delivery grooves run
full length of load bearing surface.
4. Band drum diameter, (standard

Part No. 12962N-02K and oversized) allows drum I.D.
INI
CH
6 Bolt Piston Retainer A
to be turned.
N
M
(Oversized)
R
E
QUIRE
5. Higher quality aluminum to
Note: Requires machining of resist gauling.
reverse drum.
1
4

Designed for Durability
BY BOB WARNKE
hroughout this material we have described insulates electrical current flow.
T improvements Sonnax has made to valves, The coating results in a polished

bushings and various other parts. All of surface finish 30-50% more
these items have been upgraded in some form, dense than the aluminum itself.
whether in tolerance, material, or design. Due to the anodizing process,
O-rings on the sleeve O.D. are required when the the surface is ten times harder Figure 4: Sonnax
valves have a much
effects of fluid and spring cycles etch away the bore than the internal aluminum and harder surface than
(Figure 1, C-6). A seal at the outside diameter of a can be assembled with bronze, most OE valves, mak-
ing them less likely
sleeve insures that the con- steel or brass without etching to score. The radial
grooves also help
trolled oil supply works fully the material. reduce side loading.
on the valve. Air testing, Dyno Making valves of steel vs alu-
testing and isolated valve body minum is an application and engineering concern.
testing equipment can prove Hard-anodized valves have many benefits over steel,
this. The o-ring grooves are but there may still be applications best for steel
Figure 1: Often times
the bore for the boost cut into sleeves that have the design. For example, going to a heavier steel valve
valve sleeve is scored. If same O.D. as the original part; eliminated the Chrysler pressure regulator buzz
scored badly, use a
boost valve sleeve with the seals are not used to com- (Figure 5, P.Reg.s). The opposite can also be true; a
o-rings.
pensate for loose tol- heavier steel valve delivers more impact as
erances. Knowing it comes to a stop
this, be assured that and takes more
using a sleeve with- force to initiate
Figure 3a: If
out the o-rings will ring design sleeve,using the o- movement. Using Figure 5: Sonnax makes
not detract from make sure to lube the o- steel valves in an replacement valves out
ring before installing it of steel any time steel
original perform- into the valve body. The aluminum-housing offers an advantage.
ance, but will not Sonnax Slippery Stick is can double the leak- Steel is often a pre-
ferred material for pres-
perfect for this.
gain either. Sonnax age, because alu- sure regulator valves to
Figure 2: Sonnax manu-
factures boost valve supplies many boost minum expands at reduce
buzzing.
oscillations and
sleeves, both with and sleeves with or with- twice the rate of
without o-rings.
out o-rings (Figure steel.
2) for installer’s preference. Sleeves with radial porting reduce side
An o-ring sleeve assembly procedure is loading on the valve spool. Pressure on
shown in Figure 3. only one side of a valve can force the spool
Annular grooves are not added to the Figure 3b: Hone the to wear into the casting. Radial porting
sleeve bore of the valve
Sonnax valves for appearance (Figure 4, body. This will smooth distributes the load
AOD-E). The grooves hold oil to support any rough edges that and reduces wear.
might cut the o-rings.
the valve, which then reduces the scrub- High silicon,
bing action against the bore. This increas- Deltalloy® 4032 alu-
es bore life, improves valve response and minum sleeve con- Figure 6: Some valve
sleeves have radial port-
reduces hung valves. struction further ing to reduce side load-
Hard anodizing on the aluminum increases bore life ing of the valve: another
Sonnax innovation.
Sonnax valves is an electro-chemical coat- (Figure 6).
ing, which penetrates into the valve and Once the Sonnax Development Team
leaves an outside layer as hard as tool Figure 3c: Before recognizes the cause of failure, redesigning
steel. Ordinary anodizing is a thin surface installing the sleeve, roll
it against a smooth for durability is simply part of the process,
layer often used for appearance (Figure 4, clean surface. This will not part of the cost.
slightly flatten the o-
AOD-E). The hard coat resists heat, adds rings, and make it easier
to lubrication, reduces corrosion and to install the sleeve.

A904/A727 42RE, 46RH & 47RH
Part Nos.12229-01K
& 22229-01K
Complaint Slippage in reverse

Secondary Complaints: R E G U L AT O R VA LV E A N D P R E S S U R E P L U G K I T S
• Poor cooler charge

at idle
• Poor line control
Valve Body
• Poor forward and
reverse engagement
Spring
Throttle pressure plug
Cause 22
22
Plug
Sleeve
9-0
1K
(fo
rA
Excessive wear at the 72
7/4
2R
regulator valve pressure 12
H/
46
RH
22 /47
sleeve and low reverse 9-0
1K
RH
)
(fo
boost pressure rA
90
Spring 4)
Correction Throttle pressure plug
Plug End plates
These upgraded sleeve and Sleeve
plug kits restore the

hydraulic integrity of
the circuit SONNAX PART SUMMARY
Part No. 12229-01K

1 Plug
V ehicles with A904, A727, 42RH, 46RH & 47RH transmissions may have
problems with slippage in reverse, poor cooler charge at idle, and high or
low line control. These complaints are often due to excessive wear at the line
1 Sleeve pressure plug and sleeve. When this sleeve and plug wears, leakage past the plug
prevents the pressure regulator valve from properly controlling line pressure.
For A904 units, Sonnax has now made available 12229-01K regulator valve
Part No. 22229-01K pressure sleeve and 22229-01K for A727, 42RH, 46RH & 47RH. For
1 Plug 22229-01K, the plug diameter has been reduced by 25% to increase reverse
1 Sleeve with O-ring boost and an o-ring has been added to the sleeve to prevent line pressure cross leaks.

A727 46RH, 47RH & A904 Part Nos. 22912, 22912A & -B
Complaint Burned bands, poor reverse

Cause Leaks caused by pin wear do not apply band sufficiently
• Pin bore wear
This billet aluminum piston resists breakage; rounded seal ridges
• Rear servo piston Correction prevent the piston from sticking in the case bore.
sticking/breakage
SERVO PISTON
Part No. 22912
(A727/46RH)
Part No. 22912A Servo Piston

(A904/A999/42RH)
Part No. 22912B

(47RH, ‘94-up with Split Band)
Each includes the following: Retainer Inspect for
scored pin
1 Rear Servo Piston

Seal
Spring
Piston Plug
46RH 42RH, 47RH, A727 & A904 Part No. 22771-01K
Complaint Shift timing concerns & throttle buzz

Cause Throttle valve and sleeve wear
• Poor kickdown
This hardened steel throttle valve repair kit salvages the valve body
• Late 2-3 upshifts Correction and restores throttle valve control.
• Oversensitive 3-2
T H R O T T L E VA LV E K I T
downshifts
Part No. 22771-01K Throttle Valve

1 Throttle Valve
1 Throttle Plunger Valve Body Shims
3 Spring Shims
1 Alternative Spring Throttle Plunger
1 Sleeve Inspect for OEM
spool etching here
Sleeve
Alternative Spring
Inspect OEM
for wear

42RH 46RH & 47RH Part No. 22771A-01
Complaint Lock up shudder, overheated converter

Secondary Complaints: U P G R A D E D 4 S P O O L E D S W I T C H VA LV E
• Reduced cooler flow

• Soft TCC apply
Cause Bracket
The OEM valve stroke is

insufficient to control Switch Valve
circuit timing of apply and

release pressures Spring
Valve Body
Correction
Improve timing and flow
to the apply and release SONNAX PART SUMMARY
circuits with this improved
switch valve. T he circuit timing of applied vs. release pressure exhausted is critical for
proper TCC operation. The OEM valve stroke contributes to soft TCC
apply, shudder complaints, and increased damper spring loads. Replace the
Part No. 22771A-01 OEM switch valve with Sonnax’s switch valve 22771A-01. The new Sonnax
1 Switch Valve switch valve improves the timing and flow to the apply and release circuits.
Application Note: For units with
boost tube only.
S O N N A X S W I T C H VA LV E O E M S W I T C H VA LV E
Line Pressure Line Pressure
No TCC Apply Exhausts before TCC is

TCC Apply Exhausts at the same time Pressure applied causing soft apply
Pressure that TCC is applied for firmer and shudder
apply and no shudder
Venting oil from release side of Venting oil from release side of
TCC and converter control valve TCC and converter control valve

A727 46RH Part No. 22700-Z
Complaint Excessive total transmission endplay

Cause Excessive endplay often due to worn gears, snap rings and/or splines
Part No. 22700-Z
10 Shims (.010” thick)
This shim reduces transmission endplay for both 3 or 4 tanged
Correction OEM washers.
R E A R P L A N E T E N D P L AY S H I M
Reverse
Ring
Planet
Gear
Driving
Shell
3 Tanged
Thrust Washer
Shim
for 3 or 4 tanged thrust washers
A727 46RH & 47RH Part No. 22556-BRG
Complaint Expensive case damage

The inner race of the over-running clutch comes in contact with
Cause
Part No. 22556-BRG the case causing damage
INI
CH
3 Bearings A
N
M
This case repair bearing saves expensive cases and prevents further
Requires machining of Correction case damage.
R
E
QUIRE
transmission case.
C A S E R E PA I R B E A R I N G
Case
Repair Bearing

46RH 46RE, 47RH & 47RE Part Nos. 22754N-01K & 22754N-02K
Complaint Reverse drum, retainer & planet failure

Secondary Complaints: U P G R A D E D P I S T O N R E TA I N E R
• Loss of lube oil to

the gear train
• High replacement
cost of the reverse
drum
Cause
Kit includes plugs
Case to allow use in
Excessive clearance electronically-
between the overdrive pis- controlled units.
ton retainer and interme-
diate shaft reduces lube
Piston Retainer
flow to the gear train
Seal compensates for

S onnax is now offering an upgraded standard replacement 22754N-01K
and an oversized 22754N-02K piston retainer to allow rebuilders to sal-
vage the expensive reverse drum.
variations in case I.D. and Salvaging the drum requires only bor-
oil is delivered to maxi- ing the I.D. of the drum using a lathe
mum load points on and then installing as normal.
shaft. OEM and oversized 5 1. O-ring prevents loss of lube oil.
drum contact surface
Many OEM supports do not seal
allows salvage of drum. well here.
2
2. Two O.D. oil delivery grooves
3 repositioned at high load areas.
Part No. 22754N-01K
6 Bolt Piston Retainer (OEM) 3. Two I.D. oil delivery grooves run
full length of load bearing surface.
4. Band drum diameter, (standard

Part No. 22754N-02K and oversized) allows drum I.D.
INI
CH
6 Bolt Piston Retainer A
to be bored.
N
M
(Oversized)
R
E
QUIRE
5. Higher quality wear-resistant alu-
Note: Requires machining of
reverse drum. 1 minum to resist gauling.
4

46RH A727 Part Nos. 22750L & 22750N
Complaint Worn inner race

Cause OEM races overheat and pit
• Press-on race not
available separately These press-on and slide-on roller clutch races directly replace the
Correction OEM and allow re-use of reverse drums.
• Reverse drum not
salvageable PRESS-ON & SLIDE-ON LOW ROLLER CLUTCH RACES
Reverse Drums
Part No. 22750L

1 Press-on Roller Clutch Race
Part No. 22750N

1 Slide-on Roller Clutch Race
Press-On Roller Clutch Race Slide-On Roller Clutch Race
46RH A727 & 47RH Part Nos. 22900-10 & -15
Complaint No reverse or slip after low/reverse drum resurfacing

OEM strut of insufficient length to adequately hold drum after
Cause resurfacing
Part No. 22900-10
1 Lengthened Band Strut These extended struts compensate for removed drum material,
(.100") Correction salvaging drums and double wrap bands.
Part No. 22900-15 LENGTHENED REVERSE BAND STRUT

1 Lengthened Band Strut
(.150")
Band Strut

Converter Code Blues?
D
o you have a 4L60-E with DTC P1870 that is back for the 2nd, 3rd, or even 4th
time? The converter, solenoids, stator and bushings have all been replaced,
maybe it was even re-flashed, but still the code is haunting you. Along with
intermittent harsh 1-2 shifts, P1870, 740 or 039 can be caused by a worn TCC Regulator
& isolator valve bore or a worn TCC apply valve bore.
Maybe there is a CD4E with code 628 that is back...again! Perhaps the converter
has been changed out, an aftermarket kit has been tried, solenoids, and maybe even the
valve body, but it still "won't go away." Many times this is caused by the Bypass Clutch
Control Valve bore or Bypass Sleeve wear.
We have recognized one of the root causes of these problems and have developed the
following products to help fix these units and get customers happily back on the road.
SONNAX PARTS: HELPS CURE: APPLICATION:

84754-01K TCC Regulator Valve & Isolator Plug (93 - up) • Codes P1870, 740, 39
84754-08K* TCC Regulator Valve & Isolator Valve Kit (91 & 92) • Converter shudder
84754-16K* TCC Apply Valve Kit (oversized) • Blued or burnt converters
• Falling out of lock-up hot 4T60 & E
84754-22K TCC Apply Valve Kit (91-96)
84754-97K TCC Apply Valve Kit (97 and up)
84754-98K* TCC Apply Valve Kit (oversized)
77754-03K* TCC Regulator Valve Kit (93 - non EC3 97) • Codes P1870, 740, 39, 68
77754-04K* TCC Regulator Valve Kit (97 & up EC3 units) • Falling out of lock-up hot 4L60-E
77805-K TCC Apply Valve Kit (4L60 & NON PWM 4L60-E) • Harsh 1-2 (PWM and NON-PWM)
• Converter shudder
77805E-K TCC Apply Valve Kit (4L60-E PWM only)
• Blued or burnt converters
4L80-E
34994-01K TCC Regulator Valve Kit
96201-06K Bypass Clutch Control Sleeve & Plunger Valve Kit • Codes 628 & 1744
96206-01K Bypass Clutch Control Sleeve & Plunger Valve Kit • Converter shudder and overheat AXOD & E, AX4S,
96206-03K Bypass Clutch Control Sleeve & Plunger Kit • Improved converter apply pressure AX4N, AOD-E,
76948-04K Bypass Clutch Control Sleeve & Plunger Kit 4R70W & CD4E
73840-BK* Bypass Pressure Regulator Kit
92835-03K Converter Apply Pressure Regulator Valve Kit • Torque Converter Clutch Failure
92836-06K Bypass Plug • TCC lining in unit 41TE, 42LE,
• Unit overheat
92835-07 Pressure Regulator Sleeve
• High line pressure 42RH, 46RH, 47RH
22771A-01 Upgraded 4-Spool Switch Valve • Poor lube control
* These parts require reamers

So Where’s the Connection?
BY DENNIS MADDEN
or years, the major indicator for normal trans- pressure; it’s called cutback. On the 400, governor
F mission operation (besides seat-of-the-pants

diagnosis) was testing for proper line rise.
Many units only had a line pressure tap. On the man-
pressure works against the modulator valve, oppos-
ing the spring in the modulator. The faster the speed,
the more governor pressure works on the modulator
ufacturing level, the fewer taps on the transmission, valve. The C6 is a bit different. The C6 has an actual
the fewer potential leak points they had to consider. valve that controls cutback called…the cutback valve.
Then too, there was probably an accountant some- Governor pressure works on the cutback valve so
where in the picture looking at the three additional 1⁄2 that after the vehicle gets moving, line pressure drops
cent pressure tap plugs, thinking, “that penny and a to a reduced level. The point is, that in both exam-
half really adds up in a year’s time.” Regardless of ples, we knew that governor pressure worked (at
why many transmissions are conspicuously short on least to some degree) because of the influence it has
pressure taps, the fact remains; at times, all we have on line pressure. This type of diagnosis is available
to work with is line pressure. on a lot of different transmissions, but knowing how
Don’t underestimate the value of a line pressure the system works is crucial in order to take advan-
tap though. On older, governor-controlled units a lot tage of it.
of different systems can be tested. For example, check So what’s the point? Over the years, a lot of tech-
for TV rise in a 4L60, or governor pressure in a 400 nicians have used these scenarios to help diagnose
or C6. How? Simple, as TV pressure in a 4L60 rises, problems. They have not always understood why the
so does line pressure. If the TV cable is system behaves in a certain manner, that is,
pulled and line pressure rises, the not understood the connection
TV pressure is working, though between line rise and pressure
it has to rise to the correct changes in other systems.
maximum level to really be This can lead to misunder-
okay. Keep in mind that standings like, “High line
if line pressure does pressure causes late
not rise during this shifts.” No, high TV
test, it’s no guaran- pressure causes late
tee that the problem shifts, but it also
is TV related. causes high line
For the governor pressure. Sure there
test in the 400 and are anomalies that
C6, once again don’t follow this
have the pressure rule, but as a gener-
gauge attached to al statement it’s cor-
the line pressure rect. And besides,
tap. Now drive the I’m trying to make a
vehicle with the point.
shifter in Drive. As If we take these misun-
vehicle speed increases derstandings, and apply
(keep the throttle steady), them to newer, computer-
line pressure drops. On the controlled transmissions, we
400 it’ll be a steady drop. The C6, can find ourselves in much more
however, will have a quick drop in pres- trouble. For example, line pressure on
sure once it reaches about 15 – 20 mph. In both transmissions that use electronic pressure con-
cases, governor pressure is manipulating line trol do not necessarily change line pressure

based on throttle angle, or even engine load. Some to model. Even the same model car can have different
systems, like Mitsubishi’s 20 and 30 series, maintain line pressure behavior, based on the software level of
a constant high line pressure under all throttle angles the computer.
except during a shift. Once the transaxle makes a
shift, line pressure if fixed; it doesn’t matter what is • If a line rise problem is suspected check the com-
done with the throttle. puter signal to the transmission first. A good service
Other units, some Fords for example, drop line manual for the proper voltage or amperage specifica-
pressure very low (close to idle pressure) once the tions will be necessary.
transmission shifts to second gear or when it reaches
a certain vehicle speed. Again, line pressure doesn’t • To effectively identify line rise problems, keep a
change with throttle, but it changes during the shifts. journal of good working units. Once proper line rise
So where’s the connection? There isn’t one! is recognized, it’s a lot easier to spot incorrect line
One fact that we know is that if enough line pres- rise. The same thing goes for line pressure signals
sure is present to keep the friction components from the computer.
applied; any additional pressure is a waste. In fact,
excess line pressure makes the engine work harder • Don’t rule out the pressure control solenoid as the
and uses more gas. In the old days, engineers didn’t cause of the problem, even if it was replaced with a
have the advantage of making line pressure behave new one. New solenoids have been known to fail.
anyway they wanted. They used cables and vacuum
as the mechanism to influence line pressure. It made • If a line rise problem is determined to be internal be
no difference whether the transmission was shifting sure to look for a worn pressure regulator valve or
or the shift was complete, line pressure was the same pressure regulator valve bore. It’s becoming increas-
for a given throttle angle, or load–not withstanding ingly common to find worn out valve bodies, causing
some governor control mentioned earlier. Because line rise problems. Sonnax manufactures a large line
engineers now have the luxury (better known as of replacement regulator valves, as well as other
technology) of doing whatever they want with line valve body components that commonly wear out.
rise, they often design these systems to have just
enough line pressure to keep the applied friction ele- The following is a list of available valves and valve
ments from slipping. This means there’s no wasted body components, for both computer-controlled and
gas turning a pump that’s putting out more pressure non-computer controlled units.
than necessary.
PART NO. APPLICATION DESCRIPTION
Now let’s take our understanding of older systems
and apply them to these newer computer-controlled 92835-07 41TE Pressure regulator reducing sleeve
34910-03K 400 Pressure regulator valve
transmissions. For example, a 4L80-E that shifts late, 34910-01K 400 Boost valve kit
or not at all. The danger here is in thinking that line 75918-01K 125-C TV & Reverse boost valve
pressure plays any role in shift timing. Too often we 84754-24K & 25K 4T60&E Reverse and modulator line boost valve kits
77917-06 & 07 4L60&E Oversized pressure regulator valves
take rules from the past and try to apply them to K77898 4L60 Reverse boost valve kit
today’s transmissions. Even though we don’t see the 77917-01K 4L60 TV boost valve
same connection between line rise and how other 77898E-K 4L60-E Reverse boost valve kit
34200-03K 4L80-E Reverse boost valve kit
systems work, line pressure–and proper line rise–is 96201-01K AXOD&E, AX4N Reverse boost valve kit
crucial for proper transmission function and longevi- 76990K AOD Boost valve kit
ty. Even though a lot of the rules have changed, some 36946-01K & 02K C6 Reverse boost valve kits
rules are still true: 36424-01K E4OD Reverse boost valve kits
56947-06K A4LD O.S. Pressure regulator valve & boost kits
56947-02K, 04K A4LD Reverse boost valve kits
• Check line pressure with a pressure gauge. The best 73840-RK CD4E O.S. Pressure regulator valve kit
line rise range will occur while the vehicle is station- 71846-01K G4A-EL Reverse boost valve kit
74846-01K GF4A-EL Reverse boost valve kit
ary. 93990 RL4F02A Reverse boost sleeve
89031-01 A540 Reverse boost sleeve
• Do not worry too much about line rise while driv- 89010-01 A130 Reverse boost sleeve
85991-01 ZF4HP14/18 O.S. Pressure regulator valve kit
ing the vehicle. Pressure behavior varies from model

HONDA Part Nos. 88406-SP, B, C
Complaint 2nd gear damage from roller bearing

Secondary Complaint: MAIN SHAFT 2ND GEAR THRUST WASHERS
• Frequent roller
bearing replacement
Main Shaft
2nd Gear
Cause
Axial thrust load of
hardened needle rollers
on softer gear Bronze Thrust Washer
Correction
These high quality bronze
thrust washers are designed
to more effectively with-
SONNAX PART SUMMARY
stand the axial thrust load
of the mainshaft 2nd gear
assembly. O n Honda 4 speed transmissions, the mainshaft 2nd gear wears severely
from contact with the 2nd clutch needle roller bearing. This bearing
and gear also need frequent replacement due to wear. Replace the OEM bear-
ing with Sonnax thrust washer 88406-SP, 88406B, or 88406C. These high
quality bronze thrust washers are designed to more readily withstand the
Part No. 88406-SP
wear and axial thrust load of the mainshaft 2nd gear assembly.
Part No. 88406B
Part No. 88406C
Sonnax No. Application OD Thickness
88406-SP AK, AS, F4, L4, CA, PL 2.028" .084"
1 Bronze Thrust Washer
88406B some G4 2.185" .084"
Note: The gear thrust surface must
be in good condition. A worn gear 88406C G4, K4, L5, PL5X 2.185" .103"
will cause failure.

A131 A130 & A132(L) Part No. 89010-01
Complaint Soft upshifts, delayed reverse

Secondary Complaints: These problems can be caused by severe wear of the boost sleeve,
Cause allowing TV and boost oil leakage
• Higher than normal
pressures in reverse The aluminum replacement boost sleeve restores hydraulic integrity
Correction and prevents cross leaks.
• Repeated clutch
failure BOOST SLEEVE
Part No. 89010-01 Spring
1 Boost Sleeve
Note: For multiple applications,
compare OEM valve dimensions Ø.565"
with dimensions below. Ø.482"
Boost Valve
The exsisting valve must match these
dimensions to fit the sleeve
Boost Sleeve
A540-E Part No. 89031-01
Complaint Soft upshifts, delayed reverse

Secondary Complaints: A worn boost sleeve may allow TV pressure to leak to reverse in
Cause drive ranges; in reverse, reverse boost oil may leak to the TV circuit
• Higher than normal
pressures in reverse This replacement boost sleeve will restore the hydraulic integrity
Correction and prevent cross leaks.
• Repeated clutch
failure BOOST SLEEVE
Part No. 89031-01

1 Boost Sleeve
Note: For multiple applications, Ø.583"
compare OEM valve dimensions
Valve Body Ø.480"
with dimensions below.
Boost Sleeve
Spring
Boost Valve
The exsisting valve must match
these dimensions to fit the sleeve
Retaining Pin
Adjustable Step

F4A-EL GF4A-EL Part No. K74878
Complaint 2-3 shift flare

Secondary Complaints: Insufficient pump flow to pressure regulator valve
Cause
• Low pump output
This pump rebuild kit reduces restrictions & has a specially designed
• Soft shifts Correction & stiffer spring to avoid bore hang-ups & improve pump volume.
PUMP REBUILD KIT
Part No. K74878
1 Discharge Valve
Compression Spring
1 Compression Spring stiffer, oversized spring
avoids bore hang-up
Note: Fits 1 pan style unit and problems & increases
2 pan 7 solenoid style units pump output
Plug
Pump Body
Discharge Valve
restriction removed from valve
to increase pump output
G4A-EL 4EAT Part Nos. 71912-01K & -02
Complaint 2-3 shift flare, low pump volume

Cause The pump is unable to produce sufficient volume
• Severe overheating
This pump rebuild kit and pump vane expander kit increases oil
• Converter burn up Correction pump volume by decreasing internal oil leakage.
• Spool valve and PUMP REBUILD KIT
spring bore hang-up
concerns
Spool Valve
non-restrictive
Part No. 71912-01K Spring

1 Spool Valve designed to avoid hang-
Pump Body
up and raise exhaust
1 Spool Valve Spring volume/psi of pump
1 Pump Vane Expander
Note: Fits 2 pan 4 solenoid style
units.
Pump Vane
Expander
Part No. 71912-02 holds vanes toward
1 Pump Vane Expander slide at low RPM

units.

GF4A-EL G4A-EL Part Nos. 71846-01K & 74846-01K
Complaint Low
?? line rise
Secondary Complaints: B O O S T VA LV E K I T S
• Shudder in reverse
Valve Body
• Delayed reverse
• Poor 1-2 shift
Spring Spring Retainer
Cause Pressure
Regulator Valve
End Plug
Worn boost valve sleeves

that allow EPC, TV boost
Boost Valve
or reverse pressures to G4A-EL
cross leak into exhaust
Boost Sleeve
G4A-EL
Correction Boost Plug
These replacement boost

valve kits are hardened
and anodized to prevent Boost Valve
wear and are tightly toler- GF4A-EL
anced to restore the Boost Sleeve

GF4A-EL
hydraulic integrity of the
circuits.
SONNAX PART SUMMARY
Part No. 71846-01K

(G4A-EL with TV Cable)
V ehicles with a G4A-EL or GF4A-EL transmission may have complaints of
low line rise or low reverse boost. These problems can be caused by worn
boost valve sleeves that allow EPC (GF4A-EL), TV boost (G4A-EL), or reverse
1 Boost Valve
pressures to cross leak or leak to exhaust.
1 Boost Sleeve
1 Boost Plug Sonnax has developed replacement boost valve kits for both the 71846-01K
Note: Fits 2 pan 4 solenoid style (G4A-EL) and the 74846-01K (GF4A-EL). The G4A-EL boost valves and
units. sleeves are made from carbon steel and hardened to prevent wear. The
GF4A-EL boost valve is made from anodized aluminum, and the sleeve is man-
Part No. 74846-01K ufactured from Deltalloy® 4032 to resist wear. These tightly toleranced parts
(GF4A-EL No TV Cable/with Elect.)
will restore the hydraulic integrity of the circuits.
1 Boost Valve
1 Boost Sleeve
units and can be modified to fit 1
pan F4AEL or F4EAT units.

G4A-EL Part No. 71400-15
Complaint Difficulty setting endplay

Cause Not enough of the popular 3-tanged selective thrust washer sizes
Part No. 71400-15
This shim kit contains 5 shims to help set endplay and eliminate the
Correction need to carry quantities of all size variations of OEM washers.
FRONT SUPPORT PUMP SHIM

Oil Pump 3-Tanged Selective
Bearing Race
Roller
Bearing
Shim
F4A-EL G4A-EL Part Nos. 71828-TL & 74828-TL
Complaint Difficult to air check for drum leakage

Cause The only way to check for leaks is while the drum is in the case
• Burned clutches
This drum test tool allows bench checking for drum leaks without
• Slips or no 2-3 shifts Correction having to disassemble and reassemble the transmission for testing.
3-4 DRUM TEST TOOL KIT

Part No. 71828-TL
Part No. 74828-TL Weld Area
Each includes the following: Apply Pressure

Orifices Drum Test Tool
1 Drum Test Tool
1 Test Tool Cap Test Here
1 Test Tool Cap Screw When Assembled
3-4 Drum
2 O-Rings
Note: 71828-TL is for G4A-EL
applications and 74828-TL is for
F4A-EL applications.
O-Rings
Test Tool Cap Screw Test Tool Cap

Sonnax Precision Reamers
SONNAX PARTS: FOR USE WITH:
36833-TL C6 Oversized Modulator Valve kit 36833-01K
56947-TL A4LD Pressure Regulator Valve kit 56947-06K
73840-BTL CD4E Bypass CC Valve kit 73840-BK
73840-MTL CD4E Valve Body Master Rebuild kit 73840-MK
73840-RTL CD4E Pressure & TCC Regulator Valve kit 73840-RK
76991-TL AOD Oversized 1-2 Capacity Modulator Valve kit 76991-01K
77754-R2 4L60E TCC Regulator Valve kits 77754-03K and 77754-04K
77754-TL 4L60-E Actuator Feed Limit Valve kits 77754-09K and 34200-16K
77917-TL 4L60 & 4L60-E Oversized Pressure Regulator Valves 77917-06 and 77917-07
77968-RM 4L60 Oversized Throttle Valve kit 77968
84754-RM 4T60-E TCC Regulator Valve kit, 84754-08K ('91 and '92 models)
84754-TL 4T60-E TCC Apply Valve kit 84754-16K
85991-TL ZF4HP14/18 Oversized Pressure Regulator Valve kit 85991-01
96201-BST AXOD-E Forward Control Valve 96201-16K
T36605-03 C6 Oversize Case Bushing 36008A and 36008C

Restoring theValve Body: Reamer Technique
BY MAURA STAFFORD
S
onnax offers various custom reamers and ream- Use a speed handle to spin
er bushings to simplify the repair of worn out the reamer. Use smooth,
steady turns of 1 - 11⁄2 rota-
valve body, pump, and transmission case bores. tions per second.
Each application may require minor adjustments to
reaming speed and feed rate to achieve the proper sur-
face finish and bore size. Some variables that con-
tribute to how a reamer performs and the quality of
the reamed hole are:
• The size of the bore being reamed.
• The type of material being reamed.
• The amount of material being removed.
The basic instruc-
tions and tips below
should help with ream-
ing bores successfully.
The first step is to
adequately prepare the handle to ream the bore in as level a manner as pos-
valve body so that it sible. The reaming action should be clockwise in a
can be worked on smooth and continuous motion, at approximately 1
properly. After remov- to 11⁄2 revolutions per second. The reamer should
ing the valves from the actually pull itself through the bore, so little or no
bore to be reamed, feed pressure should be applied to the reamer or the
Make sure to use a light oil when
clean the valve body reaming, such as Tap Magic or speed handle.
thoroughly with a Kerosene. As a last resort use ATF. Continue reaming until the tip of the reamer bot-
mixture of mineral spirits and degreaser. After it has toms out in the bore. Spin the reamer five to ten
been cleaned, clamp the valve body to the bench with times more after bore bottoming to allow for the
the open circuits up. Next, fill the bore with a cutting
fluid such as Kerosene, Tap Magic™, etc. Continue to lubricate the
reamer throughout the
Most Sonnax reamers are piloted by the existing process.
valve body bore. However, some designs require a drill
jig or reamer bushing to align and guide the reamer in
the bore. Before inserting the reamer, soak the fluted
end of the reamer with cutting fluid. Next, insert the
reamer into the bore until
the reamer tip contacts
the first bore to be cut.
Securely position the
reamer in the for-
ward-cutting direc-
tionto remove any
reamer wobble. The
chamfer at the reamer
tip will help stabilize
Don’t and center the reamer.
use With the reamer carefully
these tools
for reaming. and securely positioned, use a speed

removal of any excess material and for better surface
finish. Using low air pressure, blow the chips free PORTRAIT OF A REAMER
before removing the reamer from the bore. The following conditions will increase as your reamer becomes
To remove the reamer, continue turning while more and more worn:
slowly pulling outward on the reamer. Remove any • The cutting edges become rounded over and worn looking
remaining debris from the bore with low air pressure • The cutting edges also appear jagged and not smooth
and a mixture of mineral spirits and degreaser. • It is harder to ream a hole and requires more force to
Lubricate the replacement valve with ATF and fit it push the reamer into the work piece
into the reamed bore. If it is snug, repeat the reaming • The surface finish becomes rough
procedure with an air drill at 500 RPM. • The finished bore size is undersized
Never turn the reamer backwards, as it will ruin • When these conditions occur, the reamer needs to be
the cutting edges. Do not drop or roll a reamer on a sharpened or replaced
metal surface, either. Pushing with too much forward
force on the reamer while reaming will result in poor
surface finish, inadequate and sporadic material
removal, and material being left behind as the ream-
er exits a bore. Take care to blow the chips free from
Cutting edge
Reaming a valve body produces
a lot of chips. Make sure you
never rotate the reamer
counter-clockwise to
remove the reamer.
Doing so will dam-
age the flutes of
the reamer.
Primary wear zone
Sonnax reamers come with one, two, or three

cutting diameters depending on the application.
It is important to remember that a reamer is a fin-

ishing tool and should be handled carefully. After
use, the reamer should be oiled, especially the cutting
edges, to prevent rusting. Always store the reamer
separately in its plastic tube to prevent the cutting
edges from being nicked or burred.
the reamer after each use of it. Inspect the cutting

edges of the reamer frequently for burrs, and if there
are burrs on the cutting edges remove them with a
hone. A burr left on the cutting edge will cause rough
surface finishes.
It is also important to periodically inspect the ream-
er for signs of wear. Signs of wear to look for include
cutting edges that are worn or rounded, jagged or
rough; increased difficulty and more force required to
ream a hole; a rough surface finish or undersized fin-
ished bore. If the reamer gives a rough surface finish
or cuts undersized, the valve may not fit. At this time
the reamer would need to be sharpened or replaced. Remove as many chips as you can, with the reamer still in place.

KM SERIES (4 SPEEDS) Part No. 41750-03
Complaint Delayed engagement, lube failures

Secondary Complaints: Line pressure exhausting and not charging the converter when the
Cause selector lever is in park
• No cooler flow in
park This redesigned manual valve prevents line circuit oil from exhausting
Correction to the sump resulting in converter charge pressure in park.
• Pump, pump bush-
ing, and converter M A N U A L VA LV E
hub wear
• Bushing spin out
and/or converter Valve Body
overheating
Part No. 41750-03

1 Manual Valve
Manual Valve
JATCO RL4F02A & RE4F02A Part No. 93897S
Complaint Stripped planetary splines, no reverse

Accelerated wear of the internal spline that is stamped from low
Cause
Part No. 93897S carbon steel
INI
CH
1 Planetary Carrier Insert A
N
M
This splined repair insert, welded to the planet, is made of hardened

Correction steel for improved wear resistance and weld-ability.
R
E
QUIRE
S P L I N E D R E PA I R I N S E R T
Planetary
Carrier
Planetary
Carrier Insert

RL4R01A R4A-HL Part No. 69835
Complaint No upshift, low line rise

Secondary Complaint: Cause Worn and scored governor bores
• Costly case
replacement This replacement sleeve allows rebuilders to reuse cases with
Correction worn governor sleeves.
GOVERNOR BORE SLEEVE
Part No. 69835
1 Governor Bore Sleeve Transmission Case Park Gear
Governor Bore Sleeve
RE4R01A RE4R03A & RL4R01A Part No. 69700-01
Complaint Loss of 2nd and 4th gear

The OEM strut splits in half under pressure from the
Cause servo piston
Part No. 69700-01
1 Servo Band Strut This strut is made from higher quality material, has a wider cross-
Correction section and additional material at the corners to reduce stress.
SERVO BAND STRUT
Band
Servo
Strut

L4N71B E4N71B & N4A-EL Part No. 66942-01K
Complaint ??Poor line rise, delayed reverse

Secondary Complaint: B O O S T VA LV E K I T
• Soft 1-2 related to

poor line rise
Cause Valve Body
A worn boost valve allows

TV or reverse oil leakage,
causing poor line pressure
rise during an increased
load
Correction Reverse Orifice
TV Slot
This replacement boost

valve and sleeve assembly
has the same dimensions
as the largest OEM boost Boost Valve
valve to insure maximum
allowable boost pressure. Boost Sleeve
Part No. 66942-01K

1 Boost Sleeve SONNAX PART SUMMARY
1 Boost Valve
V ehicles with a L4N71B transmission commonly have poor line rise, soft
shifts, and/or poor reverse boost. These complaints are often caused by
the reciprocating boost valve wearing the inside diameter of the boost sleeve.
When this occurs, oil that enters the throttle valve slot leaks past the boost
valve and exhausts through the reverse orifice, resulting in poor or no line
rise. Oil entering the reverse orifice will also leak past the worn sleeve to
exhaust, resulting in poor reverse boost.
The Sonnax replacement assembly 66942-01K eliminates the above prob-

lems with a closely-toleranced boost valve and sleeve. The sleeve is manufac-
tured from Alcoa Deltalloy® 4032 aluminum, which is specially designed to
resist wear. The boost valve is manufactured from high quality anodized
aluminum to prevent excessive wear on the inside diameter of the boost
sleeve. These parts are held to extremely tight tolerances, thus restoring the
hydraulic integrity of the assembly. This kit has been manufactured to the
larger (turbo) spool diameters, insuring maximum allowable boost pressure
for all units.

JATCO Part Nos. 69903-01K & 93903-01K
Complaint ??2-3 bind up, high clutch failure

Secondary Complaints: S E R V? O
? PIN
• Overheated band
Servo Pin
• Excess case servo Viton® O-ring installed
pin bore wear
• Drop-in 3rd
clutch oil pressure Spring
Retainer
Spring
• Excess oil loss at
servo release dur-
ing WAT
Servo Piston
Cause Worn Piston
The bore becomes out-of- SONNAX PART SUMMARY

round due to the band
apply force and pin bore
wear; this reduces 3rd
I n many Jatco units common complaints are 2-3 bind up, high clutch failure
and overheated bands caused by a worn servo pin bore. Due to the inherent
problems regarding sealing rings, line rise and shift timing, oil control is criti-
servo release oil and high cal for this unit. Sonnax now offers a servo pin with an o-ring 69903-01K for
clutch apply force RE4R01A & RE4R03A units and 93903-01K for RE4F02A & RL4F02A
units to compensate for egg-shaped wear in the case bore. An o-ring is placed
onto the servo pin, at the location of most bore wear.
Correction
RE4R01A AND 03A RE4F02A AND RL4F02A
Servo pin has Viton seal ®
to eliminate servo release

oil loss.
Part No. 69903-01K

RE4R01A & RE4R03A
1 Servo Pin
1 Viton® O-ring
Part No. 93903-01K No leakage here With servo installed, No leakage, here
during WAT WAT test here. during WAT test
RE4F02A & RL4F02A
1 Servo Pin
1 Viton® O-ring

RL4FO2A RE4FO2A Part No. 93990
Complaint Poor shift timing, insufficient line rise

The regulator boost valve wears the inside diameter of the boost
Cause
Part No. 93990 sleeve
1 Boost Sleeve
This replacement pressure regulator boost sleeve has been tightly
Correction toleranced to restore hydraulic integrity.
P R E S S U R E R E G U L AT O R B O O S T S L E E V E
Pressure
Regulator Boost Valve
Pressure Regulator Boost Sleeve

made from aircraft quality aluminum
to prevent wear
Valve Body Washer/Spring

Seat Retainer
ZF4HP-18 Part No. 85701-01
Complaint Neutralizes on 3-4 shift

A broken cushion washer that gets stuck in the overdrive servo bore,
Cause
not allowing band apply
Part No. 85701-01 Correction Replace the broken cushion washers with these replacement washers.
2 Servo Cushion Washers
SERVO BELLEVILLE CUSHION WASHER
Servo Cushion Washers
Pin
Servo Piston

ZF4HP14/18 Part Nos. 85991-01 & -TL
Complaint Poor line pressure control

Secondary Complaint: O V E R S I Z E D P R E S S U R E R E G U L A T O R V A LV E & T O O L K I T
• Reverse engagement Valve Body

complaints
Cause Reamer Jig

Oversized PR Valve
A worn pressure regulator

bore due to oscillation of Reamer
the aluminum valve
Eliminate excessive leak-

age by reaming the valve
M any vehicles with either a ZF4HP14 or ZF4HP18 transmission
experience poor line pressure control due to a worn pressure regulator
bore. This bore wear can be verified by testing line pressure and/or performing
body bore and installing a Wet Air Test on the valve body. The current fix for this complaint is to replace
the valve body, which is expensive and hard to find. These problems are often
the oversized replacement
caused by wear from the oscillation of the aluminum valve in the valve body
pressure regulator valve. bore. Line/balance, modulated TV, and converter/cooler pressures then leak
past the valve and exhaust to the sump or cross-leaks into other circuits.
Part No. 85991-01 Excessive leakage can be eliminated by installing the oversized Sonnax replacement
1 Oversized PR Valve O
TO L
pressure regulator valve 85991-01. The five spool diameters on this valve are
slightly larger than the OEM valve, allowing the valve body bore to be
R
E
QUIRE
modified to restore the hydraulic integrity of the assembly. The valve body bore
can be made large enough to accept this replacement valve by reaming it with
Part No. 85991-TL
the specially designed Sonnax reamer tool kit 85991-TL. This hand reamer has
1 Reamer three tightly-toleranced cutting diameters that will slightly enlarge the valve
1 Reamer Jig body bore in the area of the pressure regulator valve. The reamer (requires a
Note: Required for installation guide) can be used with a standard speed handle and socket. This is much less
of 85991-01. expensive than replacing the worn valve body!
“E” 3-4 Clutch Reducing (2nd Port)

WET AIR TEST INFO
1. Before removing the valve body Balance Line Line Converter & Modulated Pressure
no leakage no leakage Cooler
end plate, place a small amount of oil
Exhaust
into the drive balance circuit (plug To Mod TV
the opposite side of the valve body
circuit). Follow with low air pressure.
There should be no oil leakage into
the line circuits.
2. With the end plate and springs
removed, firmly hold the PR valve
fully in the bore. Place a small
amount of oil into either of the line
orifices. Follow with low air pressure.
There should be no oil leakage past
the spool diameters or into exhaust
circuits.
Plug Oversized Pressure Valve Body Springs End Plate
Regulator Valve

“Super Hold” Servos
The Sonnax “Super Hold” Series of Servos gives transmissions higher holding
power, hydraulic integrity and cleaner, more positive shifts. From a street driven
muscle car to top fuel dragsters, Sonnax servos cannot be beat.
4L60 & E
4th Gear “Super Hold” Dual Servo
Part No. 77767K
Our patented dual piston servo offers 40% more holding power in 4th gear giving full clamping force on the
band and allowing racers to actually race in overdrive without burning the band.
• Crisper, cleaner 3-4.

Blue PTFE
• Great for Heavy duty applications
Coated,
Viton®
O-Ring
Scarf
Cut
PTFE Scarf Cut
Seal PTFE Seal
Viton® O-Ring
Replacement Seal Kit

Part No. 77767K-SK
4 assorted seals

S
onnax is proud to offer High Performance and Drag Racing transmission rebuilders
a full array of parts for Powerglide and many other High Performance transmis-
sions. We have products ranging from hard-to-find OEM replacement parts to parts
that will make your customers’ drag, street or strip vehicle lighter, faster and
stronger. Many of our High Performance items have been developed with input from cus-
tomers actively involved in racing. Consistency is the most important factor that all racers
need, and Sonnax offers you consistency in all your rebuilds with guaranteed high quality
in all the parts we make.
POWERGLIDE
“No Leak” Dual O-ring Servo Piston
Part No. 28821-01K
“No leak” Dual O-ring servo uses dual o-ring seals for supe-
rior, positive sealing. In applications with a distorted bore
or case flex, O-rings will conform to the bore surfaces, a
feature not possible with metal sealing rings. Precise slip
fit with apply pin to further improve performance.
Replacement Seal
Part No. 28821-OR
1 – O-ring (2 required)
POWERGLIDE
Dual Teflon® Ring
Servo Piston
Part No. 28821-02K
Whether Teflon® Seals, or Metal
rings are your preference, we have the
servo for you. This dual seal servo
accepts both Teflon® Seals or metal
sealing rings. Made with the same
high quality billet aluminum as our O-
ring servo, this servo will give you
the same positive apply needed in
high pressure racing conditions.
Replacement Seal
Part No. 18608T
1 Teflon® Seal (2 required)

F O R D P E R F O R M A N C E S E R V O S
C4 - C RATIO C6 R-RATIO
“Shelby Mustang” Servo Piston Servo Piston Kit
Part No. K13259C Part No. K36528R
As used with Shelby Mustang and other perform- Since its introduction in 1969 with the 428 SCJ, the “R” code servo
ance vehicles, this servo offers maximum holding has remained the trick piece for C6 builders needing additional band
power, giving cleaner, firmer 1-2 and 2-3 shifts. This is apply force. Ford last offered an OEM replacement in 1992. Sonnax
the largest in the servo family and works equally well in is reintroducing this servo kit with our unique “no-leak”servo pin.
Performance C5 applications too. Cleaning up a 2-3 flare was never This pin uses an o-ring and a Teflon® seal to eliminate back pressure
easier than installing this servo. and leakage due to worn case bores. Over 9 square inches of apply sur-
face results in more band apply force. Three selective return springs allow
Replacement seal kit for tuning of the shift quality
Part No. K13259C-SK
– Gasket and seals
C6 - E RATIO
Servo Apply Replacement seal kit
lever Part No. K36528R-SK
Part No. 36916E – Gasket and seals
Previously obsolete, this servo lever is
made from 2014-T6 aluminum E4OD & 4R100
forging that will not distort or
crack like the cast OEM lever. Line Pressure Modulator Valve and
Perfect for firmer cleaner shifts Sleeve Kit
when used with the Sonnax “R”
code servo K36528R. Replaces Part No. 96948-01K
OEM P/N C6AZ-7330-D. Ford Super Duty or Lightning trucks don’t always have the 1-2, 2-3
shift firmness your looking for in a performance or heavy duty truck.
This is easily addressed by Sonnax’s performance Line Pressure
AOD&E Modulator Sleeve and Valve kit. For use with any Heavy Duty or
Performance E4OD and 4R100 transmissions, our valve kit increas-
Elevated Pressure es shift firmness by using a larger .427” diameter valve increasing
Regulator Spring accumulator pressure resulting in a firmer shift.
Part No. 76948-06

Low line pressure on high perform-
ance or heavy duty applications of Ford AOD-E
and 4R70W transmissions result in forward
clutch failure. A stronger pressure regulator
spring is required to bring the line pressure up to
68 psi. Our elevated pressure regulator spring will
insure the proper clutch engagment. A must for
squad and muscle cars and any vehicles requiring
frequent and hard acceleration.

G E N E R A L M O T O R S
4L60
Full Throttle Upshift TV Boost Valve Kit Pressure Regulator
Sleeve and Valve Kit Spring Shim
Part No. 77917-500
Part No. 77966-94MK Commonly the OEM TV Boost sleeve is Part No. 77917-RV
The Sonnax Throttle Plunger Sleeve and worn and either you will have insufficient This spring shim easily installs under the
Valve kit allows performance vehicles wide- line rise and/or experience burned 3-4 pump slide springs to preload the springs
open-throttle (WOT) 3-4 upshifts. Unlike clutches or burned band. Our o-ringed increasing pump output and stabilizing
other kits on the market, ours includes the sleeve and valve are made from hardened pressure. This will not compensate for areas
Plunger Valve with annular grooves to pre- steel, restore hyrdaulic integrity and pre- of pump leakage. Kit includes 10 spring
vent premature wear. The sleeve is made vent cross-leaks between the sleeve and shims
from aircraft quality aluminum and has the pump bore. No 4L60 rebuild should be
part-throttle orifice removed. The sleeve without this kit.
and plunger also improve detent down-
shifts.
4L60 4L60 & E 4L60 & E, 200-4R

Performance Throttle Enhanced Performance High Output Pump
Valve Spring 1-2 Accumulator Spring Slide Spring
Part No. 77968-01K Part No. 77704S Part No. 77722-01K
The OEM throttle valve (TV) spring Typically the OEM 1-2 accumulator spring When engine speed exceeds 5800 RPM, the
is a bit weak resluting in low line pressures is too weak for high performance rebuilds. centrifugal force on the pump vanes acts to
and insufficient throttle pressure for high Our enhanced performance spring provides center the pump slide and reduce the pump
performance applications. Our a firmer 1-2 shift and may even cure the volume. In high performance applications,
stronger TV spring helps to main- “thunk” sound during the shift. This spring it is critical to maintain maximum pump
tain higher line pressure and achieves the same effect as the common volume in order to hold line pressure and
improved TV performance. shop practice of using avoid 3-4 clutch failure.
This spring may be used with a 350 direct accu- Our high output single
the OEM valve configura- mulator spring, in spring is stiffer than the
tion or the Sonnax Upshift which our spring
dual OEM springs and is
Sleeve and Plunger kit may also be used.
able to hold the pump
77996-94MK.
slide in a maximum vol-
ume position despite the
MOST GM UNITS - AUTOMATICS & STANDARDS
high engine RPM.
Speedo Plug
Part No. 35922-01K
During high performance rebuilds, the speedometer
is often removed, and replaced by a freeze plug. However,
the speedometer gear, besides being used for driving the
speedometer, is also critical to lubricating the rear output
shaft bushing. This new speedo plug supports the speedo
gear and allows lube to flow as the original design intended.
The gear shaft has to be cut to 1.320” long.

P E R F O R M A N C E P A R T S
OUTPUT SHAFT SUPPORT STATOR SUPPORT SHAFT
Part No. 28080K Part No. 28154S
Application: Powerglide Associated Parts
Bored to accept bushing 35007 for ”Turbo” applications.
Application: Powerglide
High strength Powerglide Output Shaft Support, made from 6061-T6 High quality heat treated alloy steel, provides added strength to give solid
billet aluminum, with pre-installed roller bearing in place of the bushing. support to the torque converter stator. Roller burnish finish in the seal bore
This part is purpose built for drag racing, eliminating the provisions for increases sealing for improved pressure. Spline and knurl areas induction
the governor. This true "bolt-on" modification for the Powerglide lowers hardened for wear resistance, and more pronounced knurl ensures more
weight dramatically, and keeps friction losses to a minimum. positive press fit. Specially designed for severe duty race applications.
BAND ADJUSTMENT SCREW “NO FLEX” REVERSE SPRING RETAINER

Part No. 28612K Part No. 28709
Application: Powerglide Associated Parts
28320A reverse spring
Application: Powerglide
Prevents deflection and bending that causes band slippage and trans- Resists deflection caused by stiffer-than-OEM springs in transbrake-
mission case breakage. Made of hardened and tempered alloy steel and equipped Powerglides. Stamped from high strength, roll tempered steel.
yellow zinc plated for protection against corrosion. Features extra thread Resists deflection better than used OEM retainers made of mild steel.
length to accommodate undersized clutch drums.
FORWARD CLUTCH HUB FORWARD CLUTCH HUB W/O HOLES

Part No. 28304 Part No. 28304-SP
Application: Powerglide Application: Powerglide
Designed for extra duty requirements of drag racing Powerglides. An extra strong alternative for 28304. Built to give extra strength in drag
Machined from high quality medium carbon steel forging. Accepts five racing Powerglides where weight is not a consideration. Machined from
friction discs for added load capacity. All splines and thrust surfaces pre- high quality medium carbon steel forging. Accepts five friction discs for
cision machined. Unique lube hole pattern designed to reduce drag on added load capacity. All splines and thrust surfaces are precision machined.
friction discs in low gear. Hub also features five lightening holes to reduce Unique lube hole pattern designed to reduce the drag on the friction discs
weight without compromising strength. in low gear.
SHIFT LEVER MODULATOR PLUG KIT

Part No. 28431 Part No. 28738-01K
Our shift lever is designed to work with competition type shifters and When building a racing Powerglide, it is necessary to plug the hole left by
requires no modification to the case. It can be installed so that the lever is the vacuum modulator. Our vacuum modulator Plug kit is made from
positioned up or down. Plated with Zinc Chromate for corrosion protection. anodized aluminum and includes the necessary gasket.
BORG WARNER “RACE ONLY” BAND 28314K – KEVLAR® LINED BAND

Part No. 28314 Part No. 28314K
Borg Warner Powerglide “Race Only” Band is a “no-holds-barred” Our Borg Warner Kevlar® lined band is specially engineered for muscle, street
approach to the design of a race-only band. Features the latest in friction and strip applications. Similar to our 28314 “Race Only” band, this is all
materials, and “all new” construction. This "Race Only" Band is not new construction and features the latest development in Kevlar® materials.
intended for highway use. Band application upon transmission down-shift
with vehicle in motion is not recommended and can result in band failure.

D I R E C T R E P L A C E M E N T S
PRECISION CASE BUSHING "FIP" CLUTCH DRUM BUSHING DIR. CLUTCH RETURN SPRING
Part No. Part No. Part No.
28002 28005X 28320
Made to correctly Save worn Made from high ten-
locate the carrier- Powerglide pump sile spring wire, cad-
output shaft assem- covers with “Finish In mium plated. Spring
bly. Direct OEM Place” Clutch Drum ends are close-
replacement. Bushing. Use of this wound and match
Application: Application: bushing allows Application: ground to uniform
Powerglide Powerglide rebuilders to refinish Powerglide length. Reliable
journal diameter up replacement of OEM
to .012" undersize. direct clutch return
springs.
24 per kit.
DIR. CLUTCH DRUM REAR SUN GEAR CARRIER THRUST BEARING

THRUST WASHER THRUST WASHER
Part No.
Part No. Part No. 28438
28406C 38208 Direct OEM replace-
Made of lead-bronze Made from self-lubri- ment for the hard-
on steel backing, cating sintered to-find carrier-to-
lead-tin plated. bronze material. case Powerglide
Designed with four Direct replacement thrust bearing.
of hard-to-find OEM Application:
oil grooves for Application:
Application: increased surface thrust washer. Powerglide
Powerglide Powerglide
lubrication. .078"
thick, can be
shimmed for precise
clearance.
Designed for racing
applications.
REV. CLUTCH RETURN SPRING SUN GEAR THRUST BEARING STATOR SHAFT BUSHING
Part No. Part No. Part No.
28320A 28321 35007
High tensile springs, Allows replacement of Bronze lined, bimetal
with ends close- obsolete part. bushing with 1.0"
wound and match Hardened bearing I.D. Directly replaces
ground for uniformi- assembly comes com- Turbo 350/400 and
ty. Specifically made plete with a premium 700R4 OEM stator
Application: for transbrake Application: quality Torrington Application: bushings. Designed
Powerglide equipped Powerglide bearing. 350/400 for Sonnax
Powerglides. Powerglide Stator
17 per kit. Support Shaft
28154S with
"Turbo" style input
shafts.
SUN GEAR BUSHING 1.76 PINION PIN KIT ALTO “RED EAGLE” CLUTCH
Part No. Part No. PLATES/STEELS
8436 28435K Sonnax is an author-
Direct OEM replace- High strength bear- ized distributor of
ment for “wedding ing grade pinion pin Alto “Red Eagle”
band” bushing. with unique key pin clutch rings.
Restores alignment locking device for Available for all
between front sun hassle free installa- applications.
gear and input Application: tion. 28435K con-
Application: shaft. Powerglide tains 6 each: pinion
Powerglide pins, hardened thrust
washers and steel
retaining bolts.

PARTS FOR REBUILDING POWERGLIDE PLANETARY GEARS
8413 Needle Rollers – 1.82

Pinion
28435K
1.76:1 Pinion Assembly 28413 Needle Rollers – 1.76
8415 Pinion Thrust Washer – 1.76 Front
8415A Pinion Thrust Washer – 1.82
8415B Pinion Thrust Washer – 1.76 Rear
Needle Rollers
28413 K 2 8 4 1 4 Pinion Roller Spacer Kit – 1.76
Rear Thrust
8 4 1 5 A K Pinion Thrust Washer Kit – 1.82
Front Washer
Thrust 8415B 8 4 1 5 B K Pinion Thrust Washer Kit – 1.76
Washer
8415 2 8 4 3 5 K Washer, Bolt & Pinion Pin Kit – 1.76
Roller Spacers
K28414
Washer & Bolt

28435K
TV Cable Correctors
EDLEBROCK (GM APPLICATIONS WITH TV CABLE)
TV Cable Corrector
Part No. AS3-03K
The position of the TV cable stud hole used on the Edelbrock carburetors offers far too much pull on the TV
cable through the full range of throttle positions. If you adjust the TV cable at full throttle, line rise is too low,
and the shift points are too early. If you adjust the TV cable for normal-throttle upshift timing the TV cable
bottoms out before you reach full throttle which results in the TV cable falling out of adjustment after a few
kickdowns. The end result is poor shift quality, timing and repeat clutch and band failure. Our TV cable cor-
rector provides the proper TV geometry, resulting in correct TV rise at all throttle openings.
HOLLEY CARBURETORS (WITH GM AND FORD AOD TRANSMISSIONS)

Holley Carburetor TV Cable Corrector
Part No. AS2-02K
With many GM transmissions with cables and most Ford AOD transmissions, it is common for the TV cable
detent to be pulled out of adjustment at wide-open throttle (WOT). This is caused by the inaccurate geom-
etry of the carburetor linkage plate. Our cable corrects adjusts the geometry of the TV linkage and allows
WOT with pulling the TV out of adjustment.
MOST GM & FORD AOD TRANSMISSIONS

TV Cable Corrector
Part No. AS1-01K
This simple TV Cable corrector allows true wide open throttle (WOT) without pulling the TV cable out of
adjustment. Very similar to our Holley Carburetor TV Cable corrector, but for use on stock carburetors. A quick
and inexpensive fix for any transmission with a TV cable.

W e have recognized the need for
replacement clips, retainers, pins
and others “doo-dads” that are commonly
broken or lost. No longer will you have to
dig through a pile of cores, attempt to rob
a valve body or crawl under the bench to
get that “invisible” part. We are now
offering a variety of these helpful items so
they will be conveniently within arm’s
reach with our new Small Parts Program
start up kit SSPP-01. The kit includes a
variety of small parts for GM, Ford, Chysler
and some foreign applications. Each part is
© also available separately and we are adding
parts weekly. To keep up on the newest
ones, watch out ads, visit our web site
www.sonnax.com or ask your distributor
for the latest Small Parts Program items.
PART NUMBER DESCRIPTION TRANS. APPLICATION
34910-06K* End Plug, O-Ringed, PR Valve Bag/5 GM 400
34994-07 Spring Pin, Coiled, Valve Body Bag/10 GM 4L80-E
34994-09 Spring Pin, Small, Pump, Bag/10 GM 4L80-E
34994-10* Snap Ring, .625" TCC Valve, Bag/10 GM 4L80-E
34994-11 TCC Valve Bore Plug, Bag/5 GM 4L80-E
34994-12* Retaining Pin, Lo/Rev Checkball, Bag/10 GM 4L80-E
34994-13 End Plug, Small, TCC Valve, Bag/5 GM 4L80-E
34994-14K End Plug, .684"Dia., TCC Valve, Bag/5 GM 4L80-E
34994-15* Snap Ring, TCC Valve, Bag/10 GM 4L80-E
77754-08* Clip, 3-2 Control Solenoid & Misc. Locations, Bag/10 GM 4L60 & 4L60-E
84754-26* Hair Pin Clip, 4-3 Manual TV Valve, Bag/10 GM 4T60 & 4T60-E
84754-27* E Ring, Rev. Boost Valve, Bag/10 GM 4T60 & 4T60-E
84754-28 Retainer, Boost Sleeve, Bag/10 GM 4T60 & 4T60-E
84754-29 Spring Pin, Coiled, Fwd/Rev Servo, Bag/10 GM 4T60 & 4T60-E
34200-05K* End Plug, TCC & PR Valves, Bag/5 GM 4L80-E
* included in SSPP-01 Small Parts Kit


©
(continued)
PART NUMBER DESCRIPTION TRANS. APPLICATION
36946-05KSPP*Springs, Inner & Outer, 1-2 Accum., Bag/5 of each Ford C6
56947-11* Retaining Pin,Valve Body, Bag/10 Ford A4LD
56947-12* Retainer Disc For Valve Body, Bag/10 Ford A4LD
56947-13* Retainer, Rectangular, Valve Body, Bag/10 Ford A4LD
76811-01KSPP*Retainer Rings, Direct Drum/Shaft, Bag/5 Ford AOD & AOD-E
76948-08* Spring, 1-2 Accumulator, Bag/10 Ford AOD & AOD-E
86940-02* Spring, Throttle Control Valve, Bag/5 Ford ATX
86940-04SPP* Spring, 1-2 Accumulator Valve, Bag/5 Ford ATX
96201-09* Retainer, 3-2 Timing Valve, Bag/10 Ford AXOD & AXOD-E
96201-10 Clip, 1-2 Capacity Modulator Valve, Bag/10 Ford AXOD & AXOD-E
96201-11 Clip, Backout Valve, Bag/10 Ford AXOD & AXOD-E
96945RSPP* Clip, 1-2 Servo Spring Retainer, Bag/5 Pairs Ford AXOD & AXOD-E
10000-03K* E-Ring, Shift Linkage, Bag/10 Chrysler 46RE, 31TH
92836-02* Solenoid Diaphragm, Bag/9 Chrysler 41TE
97855-01* Retainer, Rectangular, .654" X .236", Bag/10 Chrys/Toyota AW4/A340

97855-02* Retainer, Rectangular, .592" X .198", Bag/10 Chrys/Toyota AW4/A340
97855-03 Retainer, Rectangular, .572" X .198", Bag/10 Chrys/Toyota AW4/A340
97855-05 Retainer, Rectangular. .645" X .203", Bag/10 Chrys/Toyota AW4/A340
97855-07 Pin, Downshift Plug, Bag/10 Chrys/Toyota AW4/A340
97855-08 Stop, Throttle Valve, Bag/10 Chrys/Toyota AW4/A340
10000-08 Check Ball, .250", Torlon, Bag/10 Misc.

10000-12 Check Ball, .218", Torlon, Bag/10 Misc. * included in SSPP-01 Small Parts Kit

©
(continued)
PART NUMBER DESCRIPTION BRAND APPLICATION
AS1-01KSPP* Cable Corrector Kits, Stops & Springs, Bag/5 Kits Misc. AOD, AXOD & GM
O-LUBE* Slippery Stick, O-Ring Lubricant Misc.
* included in SSPP-01 Small Parts Kit
Part No. SWAT-P1

Part No. SSPP-01 Wet Air Test Plate
Sonnax
Small Parts
“Start-up” Kit
This convenient Sonnax kit, with

15 Viton® o-rings and 4 seals in
bags of 25 each, will aid
Part No. OR-MK rebuilders when servicing valves
or replacing o-rings damaged
Sonnax during installation. The kit
includes o-rings for all currently
O-Ring Master Kit available Sonnax sleeves and
additional space for future o-
rings that will be offered.
APPLICATION O-RING KIT APPLICATION O-RING KIT APPLICATION O-RING KIT

34200-03K OR-014-25 73840-FWD OR-214-25 77898E-K OR-77898E-25
34910-01K OR-36946-25 73840-LR OR-214-25 77917-01K OR-16-15-25
34910-03K 34910-S-25 76833 OR-012-25 77917-471 OR-16-15-25
34910-03K OR-76989-25 76833E OR-012-25 77917-500 OR-16-15-25
34994-01K 34994-S-25 76989K OR-014-25 92834-03K 92834-S-25
36424-01K OR-36424-25 76990K OR14X1MM-25 92834-03K OR-92834-25
36946-01K OR-77898E-25 76999-LRG OR-017-25 96201-01K OR-017-25
36946-02K OR-77898E-25 76999-SML OR12X1MM-25 96945S OR-013-25
36948-03K OR-017-25 76999-MED OR12X1MM-25 96948-01K OR-017-25
36948-05K OR-017-25 77767K OR-214-25
56947-02K OR17.5X1-25 77805E-K 77805-S-25
56947-04K OR17.5X1-25 77805-K 77805-S-25
73840-24 OR-214-25 77898E-4K OR-77898E-25

Sonnax Shims
SONNAX PARTS: APPLICATION: USE FOR:
75410-10 4T60 & 4T60-E Differential endplay
84733-10 & -20 4T60 & 4T60-E Input clutch hub endplay
75890-30 4T60 & 4T60-E Differential side gear
77406-10 4L60, 4L60-E & 350/C Rear unit endplay
77409-15 4L60 & 4L60-E Front unit endplay
34500-Z 400 & 4L80-E Front & rear unit endplay
36428-Z C6 Total unit endplay (6-slot type)
36428-AZ C6 Total unit endplay (4-slot type)
36414-01K C6 Salvage of worn sunshell
36402-Z E4OD Total unit endplay
86539-Z5 ATX Preload for idler gear
73251-01K CD4E Total unit endplay
12780-Z A904 & 42RH Total unit endplay
22700-Z A727 & 46RH Total unit endplay
32539-Z5 A404, A413, A470 & A670 Preload and endplay
35539-Z5 A404, A413, A470 & A670 Output shaft endplay
39539-Z5 A404, A413, A470 & A670 Differential Preload
92965-Z5 41TE Transfer/output shaft gear endplay
71400-15 G4A-EL Total unit endplay
Sonnax has developed these shims to aid technicians in maintaining proper

pre-load or unit endplay for many transmissions. Many times, OEM
washer/shim kits are only partially used leaving piles of un-usable and
unwanted shims. Or sometimes simple drivetrain wear will prevent OEM kits
from properly setting endplay. The Sonnax shim kits help rebuilders make use
of un-usable shims and allow accurate setting of endplay.

Sonnax offers a full line of high
quality ISO 9002 ring gears for use
on flexplates, flywheels and converters.
We can handle your needs from a
single gear to full containers.
• GM • Caterpillar
• Ford • Cummins
• Chrysler • Perkins
• Toyota • Mercedes
• Honda • Borg Warner
• Mazda • International
• Mitsubishi • John Deere
• VW • Massey Ferguson
• Case
Sonnax offers manual clutch

components for agricultural, industrial,
and high-performance applications.
All of our manual clutch hubs are
made from Chrome-Moly steel forgings,
which greatly improves fatigue
resistance and service life. Components
available include hubs, pins, springs,
levers, and bushings.
• International Harvester • Kubota

• John Deere • White
• Allis Chalmers • Oliver
• Ford New Holland • Gleaner
• Massey Ferguson • Case
Also available are high performance clutch hubs for Chrysler, Ford, G.M., Mitsubishi, Toyota,
Honda, Volvo, Acura, and Nissan applications.

Allison Replacement Products
SONNAX ALLISON
PART NUMBER PART NUMBER SERIES DESCRIPTION/APPLICATION
GOVERNORS & GEARS

425 8624939 Glass filled nylon Governor Gear Kit (2 Nails,
6883938 Roll Pin, Bagged) Fits Governors #460-5
426 643742 VH-VS Phenolic Governor Insert
460 6881466 AT Governor
461 6885570 AT, MT, HT Governor
462 6885571 AT, MT, HT Governor
V700
463 6885572 MT, HT, CLT Governor
CLBT
465 6881471 MT Governor
734 6882734 MT Brass Gear Sleeve Assy (Sleeve, Gear,
Stampings, 2 Nails)
738 6882737 MT Governor, Brass Gear
739 6882736 MT Governor, Brass Gear
740 For 738, 739 Gov Brass Gear, Roll Pin in Box
717180 VH-VS Governor, Partial Assembly
SUN & PINION GEARS

S6835936 6835936 AT Center Sun Gear
S6884902 6884902 AT Rear Sun Gear
S6883901 6883901 MT Rear Sun Gear
SHAFTS & GROUND SLEEVES

S6835937 6835937 AT Center Sun Shaft
S23014304 23014304 AT Ground Sleeve (w/ Bushing & Bearing)
S23014527 23014527 MT Ground Sleeve (w/ Bearing)
S23014306 23014306 MT Ground Sleeve (w/ Bearing)
DRIVE HUBS
S6834221 6834221 MT Fourth Clutch Driving Hub
S6834222 6834222 MT Forward Clutch Hub
S23017267 23017267 MT Fourth Clutch Driving Hub
TURBINE SHAFT
S23019222 23019222 MT, 644, 654 Turbine Shaft
GASKETS, OIL PANS, FILTER KITS & PAN PLUG

S29501160 29501160 AT, MT Pan Gasket (Armstrong TS-9003) 1 Piece
SP6883044 6883044 AT, MT Oil Filter, Deep Pan (Made/Sealed Power)
SP6438326 6438326 AT Oil Filter, Shallow Pan (Made/Sealed Power)
SP23019201 23019201 AT, MT Deep Pan Filter Kit (w/ 1 Piece Gasket)
(Contains Sealed Power Filter, O-Rg, Gskt)
SP23019201-2 23019201 AT, MT Deep Pan Filter Kit (w/ 2 Piece Gasket)
S23045906 23045906 Deep Oil Pan, Ribbed with Heater Hole
S29501358 29501358 Deep Oil Pan, Dual Fill Tube Locations
S9436642 9436642 AT, MT Plug for Deep Pan Heater Hole
STEEL PLATES
56711 23047771 HT700 Steel, First Clutch, 38 Tooth, .103 Thick
56711A 23047772 HT700 Steel, First Clutch, 38 Tooth, .120 Thick
56713 6834679 HT700 Steel, Forward Clutch, 14 Tooth
56715 6834488 HT700 Steel, 2nd Clutch, 16 Tooth, .103 Thick
56715A 6834720 HT700 Steel, 2nd Clutch, 16 Tooth, .120 Thick
LOCK-UP CLUTCH LINING

MI-F-3060K* 3060 World Series Friction Ring-Kevlar®
MI-F-HDB500K* 3060 World Series Friction Ring-Kevlar®
* Sonnax offers a relining service for these lock-up converter clutches.

Torrington Bearing Kits from Sonnax
SONNAX TORRINGTON TRANSMISSION QTY. DESCRIPTION SONNAX TORRINGTON TRANSMISSION QTY. DESCRIPTION
KIT KIT KIT KIT
SBK-F1 TBK-F1 FORD 1 REV CL/FORWARD CLUTCH SBK-G11 TBK-G11 GM 1 FD CARRIER/CASE

AOD 1 DIRECT CL/OUTPUT RING 440-T4 (4T60) 1 REAC SUN/FD INT
1ST DESIGN 1 CARRIER RING/CASE 4T60-E PARTIAL 1 CHANNEL PLATE/4TH HUB
1980-1992 EARLY 1 OUTPUT/RING CASE 1984-UP 1 FD INT/PARK GEAR
2 FWD CL/LONG SUN & 1 GOVERNOR
LONG/SHORT RUN 1 FD SUN/CARRIER
1 INT CL/REV CL 1 IN CARRIER/REAC CARRIER
1 SPROCKET SUPPORT/IN SHAFT
SBK-F2 TBK-F2 FORD 1 REVERSE CL/FORWARD CL 1 REAC CARRIER/RAC SUN
AOD-E 1 DIRECTCL/OUTPUT RING 1 INPUT SHAFT TO 3RD CLUTCH
2ND DESIGN 1 CARRIER/DIRECT CLUTCH
1992-UP 1 OUTRING/CASE in '92 only SBK-G12 TBK-G12 GM 1 STARTOR SHAFT/FR CLUTCH
1 OUTPUT RING/CAS not used in '92 700-R4 (4L60-E) 1 FRONT CL/IN SUN
2 FWD CLUTCH/LONG SUN; 1982-UP 2 Output carrier/ring;
LONG/SHORT SUN Output shaft/case
1 INT CLUTCH/REVERSE CL 1 REAC CARRIER/SUPPORT
SBK-F3 TBK-F3 FORD 1 INT CLUTCH/PUMP SBK-G13 TBK-G13 GM 1 DRIVEN SPKT/CASE
ATX 1 DIRECT CLUTCH/INT CL GM 3T40 (125) 2 SUN GEAR/REACT INPUT
w/o Shims 1 OUTPUT GEAR/STATOR SUPP 1965-UP & SINL DRV
1981-1994 1 OUTPUT GEAR/TRANS HOUSING 1 FINAL DR SUN INTERNAL
1 CARRIER/RING GEAR 1 DIFF CARR/CASE
1 SPEED0/GOVERNOR GEAR
SBK-F4 TBK-F4 FORD 1 REAR SUN/FINAL DRIVE RING 1 FINAL DRIVE SUN/DIFF CARR
AXOD & AXOD-E 2 CLUTCH HSG/CL HUB;
(AX4S) CL HUB/INPUT SUN SBK-G15 TBK-G15 GM 1 REV CARRIER/LO ROLLER CL
1986-up 1 GOVERNER ASSY SUPPORT 200/200C/235 1 FRONT INT/FRONT SUN
1 FINAL DRIVE CARRIER/CASE 1981-1989 1 REAR SUN/REAR INT
1 FINAL DRIVE SUN/CARRIER 1 FRONT CARRIE/FRONT SUN
1 FINAL DRIVE RING/PARK GEAR
1 FRONT SUPPORT/CLUTCH HSG SBK-C14 TBK-C14 CHRYSLER 1 #1 IN A606/ #1 & 7 IN A604
1 FRONT CARRIE/RR CARRIER 41TE & 42LE 2 #2 Replaces: 4431962 & in
1988-UP A604 #7 use as sub for 4412209
SBK-F5 TBK-F5 FORD 2 CL HUB/INPUT CARRIER;INPUT- 1 #6
CARRIER&SUN 1 #7 in A606 only
E40D 1 FRONT SUPPORT/OD SUN
1989-UP 1 OD CARRIER/OD RING SBK-C16 TBK-C16 CHRYSLER 1 OD PISTON/HUB BRG
1 CTR SUPPORT/CL HUB 42RH/46RH 1 CAM/OUTPUT BRG
2 OD RING/CTR SUPPORT; 1988-UP 1 BACKING PLATE/PLANET BRG
RR RING & RR SUPP.
SBK-F6 TBK-F6 FORD 1 FWD CLUTCH/LONG SUN
4R70W 1 CARRIER/DIRECT CLUTCH
1993-PRESENT 1 INT CLUTCH/REVERSE CL.
1 DIRECT CL/OUTPUT RING
1 OUTPUT RING/CASE
1 REVERSE CL/FORWARD CL
1 LONG/SHORT SUN
SBK-F7 TBK-F7 FORD 1 CL HUB/INPUT CARRIER
C6 INPUT CARRIER/IN SUN
1966-1994 1 RR RING/RR SUPPORT
SBK-G8 TBK-G8 GM 1 REV CARRIER/LO ROLLER COL
200-4R 1 FRONT INT/FRONT SUN
1976-1985 1 REAR SUN/REAR INT
2 OVERDRIVE SET
1 FRONT CARRIE/FRONT SUN
SBK-G9 TBK-G9 GM 2 INT CL/OIL PUMP-use as a sub for

350 FB-42313 (9428664) from '69-'83
1969-1985 1 OUTPUT RING/REAC CAR '84-'85
1 OUTPUT SHAFT/CASE
1 BUICK FR RING/OUTPUT CARRIER
SBK-G10 TBK-G10 GM 1 SUN/INTERNAL GEAR

400/3L80 1 SUN/INTERNAL GEAR
(4L80 Partial) 1 SUN/INTERNAL GEAR
1965-1995 1 INT GEAR/OUTPUT SHAFT
2 CTR SUPPORT/SUN, RACE/RACE
2 CENTER SUPPORT/SUN GEAR
1 CENTER SUPPORT/SUN GEAR

transmission replacement parts SHOWCASE
SONNAX NO. INDUSTRY NO. DESCRIPTION APPLICATION
GOVERNORS & SPEEDO PARTS
200 65410 GOVERNOR, 76-79, 1 SPRING 200

203 65440 GOVERNOR COVER KIT WITH O RINGS 200
203B GOVERNOR COVER- COVER ONLY 200
204 GOVERNOR GEAR KIT 79-87 13 TOOTH (GAS & DIESEL) 200
207 K65411 GOVERNOR GEAR KIT, 76-79, 14 TOOTH 200
213D 65410B GOVERNOR, 79-87, 13 TOOTH, 1 SPRING, DIESEL 200
213G 32410A GOVERNOR, 79-87,13 TOOTH,, 2 SPRINGS, GAS 200
350 35410 GOVERNOR 350
352 K35411 GOVERNOR GEAR KIT -350 350
400 34410 GOVERNOR, 2ND DESIGN 400
402 K34411 GOVERNOR GEAR KIT -400 400
425 K34411A GOVERNOR GEAR KIT (NAILS & ROLL PIN) 425, ALLISON AT & MT SERIES
702 K77411 GOVERNOR GEAR KIT 4L60
729 77410D GOVERNOR, DIESEL 4L60
730 77410A GOVERNOR, GAS, CORVETTE & OTHERS 4L60
731 77410 GOVERNOR, 250,305 & 350 GAS ENGINES 4L60
3187 66411P GOVERNOR GEAR, 75-80, 11 TOOTH, GLASS SUBARU
3188 66411M GOVERNOR GEAR, 80-84 12 TOOTH, STEEL SUBARU
3189 83411 GOVERNOR GEAR, 19 TOOTH, GLASS FILLED NYLON NISSAN
3190 79980 GOVERNOR GEAR, 18 T.FITS 010-325-041 &041A GOV. VW
3191 K79411 GOV. GEAR, 13T. GLASS FITS 089-325-041 &041B GOV AUDI
3192 79988C GOV. GEAR,HOLLOW VERSION 16T. GLASS FITS 087-325-041 GOV AUDI
3193 K79983 GOV. GEAR, SHANK VERSION, 16T.GLASS, FITS 087-325-305B GOV AUDI
4067 86444 SHIM, R:E3FZ-4067-A USE WITH 418A ATX
418A 57225A SPEEDO/GOVERNORDRIVE GEAR ATX
419A 86413 GOVERNOR GEAR KIT ATX
57415X 57415X SPEEDO/GOVERNORDRIVE GEAR, 2 LUG, SPLIT ATX - 2 Lug Split

SHAFTS
68917 68917 SHAFT, STATOR SUPPORT W4B025, SNAP RING, 4" MERCEDES
68918 68918 SHAFT, STATOR SUPPORT, W4B025 PRESS IN MERCEDES
68919 68919 SHAFT, STATOR SUPPORT, W3A040, SNAP RING, 4.6" MERCEDES
75876 75876 PUMP DRIVE SHAFT,LATE, 15TOOTH, 82 & UP, LOCKUP 125
75877 75875 PUMP SHAFT, 15T,(REPLACES 80-81, 20T) NON LOCKUP 125
82810 STATOR SHAFT ZF 4HP22
84874 84874 SHAFT,OIL PUMP DRIVE 4T60
96855 96855 SHAFT, PUMP DRIVE, AXOD
65917S 65917S SHAFT,STATOR SUPPORT 200-R4
FASTENERS & HARDWARE
B41 CONVERTER BOLT M10 X 1.5mm MITSUBISHI/KM 4SPD

B42 CONVERTER BOLT M10 X 1.25mm MITSUBISHI/KM 4SPD
B61 CONVERTER BOLT RWD APPLICATIONS CHRYSLER
B62 CONVERTER BOLT, FWD APPLICATIONS CHRYSLER
B63 CONVERTER BOLT 3/8 -24, 9/16 350
B78 CONVERTER BOLT RWD METRIC APPLICATIONS GM
B79 CONVERTER BOLT FWD METRIC APPLICATIONS GM
N61 CONVERTER NUT M10 X 1mm AXOD, AXOD-E & CD4E
TO-FN-1 CONVERTER BOLT M8 X 1.25mm TOYOTA
TO-FN-2 CONVERTER BOLT M9 X 1.25mm TOYOTA
26761 26761 CONVERTER NUT 3/8 X 24 FLANGED AOD, AOD-E, 4R70W, C6 & E4OD

PUMP PARTS
1280 75926 PUMP VANE R:8631280 125, 200-4R & 4L60

1937 PUMP VANE RING,R:8631279 125
4662 VANE, PUMP, R: 8644662 4T60
4734 65929A VANE GUIDE,10-VANE, R:8654734 200-4R
96925 96925 PUMP VANE AXOD
56201A-K PUMP GEAR SET A4LD & C3
BEARINGS & BUSHINGS
FD-B-1 86001 BUSHING, STATOR SUPPORT E1EP-7N805-A ATX

FD-B-2 96001 BUSHING, STATOR SUPPORT E6SP-7N805-AA AXOE & AXOD-E
GM-B-2 75005A BUSHING, STATOR SUPPORT 125 & 4T60
GM-N-14H 35400C THRUST BEARING DIR CLUTCH TO PUMP COVER 350
GM-N-16 35403B THRUST BEARING, INPUT RING GEAR SUPPORT 350
R16 R16 BALL BEARING, CTR SUPPORT C6 & E4OD
12860-01K PLATE & PLATE, OVERDRIVE 42RH, 46RH, 47RH
35007 3075 BUSHING, STATOR SUPPORT SHAFT 350, 400 & 4L60
56008 56008 BUSHING, OUTPUT SHAFT PILOT E4OD
65405 65405 BEARING, THRUST 78-87 FRONT INT GEAR TO CARRIER 200
76427A 76427A BEARING DIR. CLUTCH OUTER AOD
96423 96423 BEARING,THRUST LOW SPRAG INNER RACE C6 & E4OD
FLEX PLATES
CH-FP-1 12971 10 3/4 OFFSET HOLES CHRYSLER

CH-FP-2 12970 10 3/4 EVEN SPACED HOLES CHRYSLER
CH-FP-3 22980 11 3/4 OFFSET HOLES CHRYSLER
CH-FP-4 22981 11 3/4 EVEN SPACED HOLES CHRYSLER

MISCELLANEOUS
125RA RIGHT AXLE STAB - 1 1/32" 125

13236 SERVO COVER GASKET C6
2178 SEAL,INPUT HOUSE TO OUTPUT SHAFT, R:8642178 4L60
22960 22960 OVERRUN CLUTCH SPRING & ROLLER KIT TF6 & TF8 APPLICATIONS
35354 35354 CASE SAVER, 4 PER 350
36429A RACE, LOW/REVERSE SPRAG C6/1970-87
36429E 36429E RACE, LOW/REVERSE SPRAG C6 & E4OD
36429E-K K36429E LOW/REVERSE SPRAG RACE/BRNG KIT C6 & E4OD
36743H 36743 HUB,CTR SUPPRT,USE W/ R16 BRG C6 & E4OD
420A BALL & SPRING KIT,FORD E5AZ-7A205-A AOD, AOD-E & 4R70W
75785 75785 SLEEVE, CASE COVER, 125C
77731-08 REAR PLANET OIL DEFLECTOR 4L60
8041 CHANNEL PLATE SLEEVE, 4T60
8368 84989 LUBE DAMPNER, R:8658368 4T60
84812 84812 SPRING, ANTI-SHUDDER 4T60
ANCILLARY ITEMS
31295 LUBE, ASSEMBLY, 1 LB TUB All

31295-CASE LUBE,ASSY.,CASE/12 1-LB TUBS All
O-LUBE SLIPPERY STICK ORING LUBRICANT All
ZERO-1 ZERO CLEANER, 1/2 GAL All
MI-AC-180 ABRASIVE CLOTH ROLL 50YDS, 180 GRIT STD All
MI-AC-180HD ABRASIVE CLOTH ROLL 50YDS, 180 GRIT H/DUTY All
MI-AC-320 ABRASIVE CLOTH ROLL 50YDS, 320 GRIT STD All
MI-AC-320HD ABRASIVE CLOTH ROLL 50YDS, 320 GRIT H/DUTY All
MI-DI-FD1 M10-1 RETHREAD DIE AXOD & CD4E
MI-DI-FD2 3/8 - 24 UNF RETHREAD DIE FORD RWD
MI-TP-CH1 5/16 -24 UNF BOTTOMING TAP RWD CHRYSLERAPPLICATIONS
MI-TP-GM1 3/8 - 16 UNC BOTTOMING TAP GM APPLICATIONS

Sealing the Seals, Bore Prep is More
BY DENNIS MADDEN
eaks, whether they’re inter- itude for sanding small grooves or scratches in the
L nal or external, have

always been a source of
aggravation for transmission
ring bore. If the original ring was Teflon®, Vespel®,
or rubber, and is replaced with cast, sand the
ring bore a bit; 220-280 grit works fine. This
rebuilders. Especially when will help the ring hold onto the bore
the unit doesn’t leak when surface.
it goes out, but comes back Now let’s look at rings
with a leak. Sometimes it’s and seals that
a parts problem. Many times work in a piston,
though, the problem relates to such as an accu-
surface preparation. Surface mulator or servo.
preparation varies based on Surface prep here is a bit
the type of seal that is used different because the seals and
and where the seal works or rings slide, or scrape against the seal-
lives. Sometimes, surface preparation is as simple as ing surface. The type of rings to seals here
cleaning all the gunk, like old silicone, dirt or varnish are cast, Teflon®, and rubber. The rubber seals
off the sealing surface. Other times the sealing surface vary from lathe-cut, O-ring, D-ring, to lip seals. Sure,
must be sanded or honed. And then there’s the ‘ol every now and again there’s an oddity like the dou-
Scotch-Brite™ routine, which has its own set of chal- ble-lip seal, but essentially rubber seals come
lenges, but we’ll save that for last. in these four varieties. The rules for these
Let’s first talk about sealing rings for rotating seals are different than the rings we covered
components like drums and shafts. There are four earlier. Teflon® still rides on a smooth surface.
basic types of sealing rings used here: cast, which Cast rings also ride on a smooth surface but
can be iron, or some type of alloy; Teflon®, there is some latitude for sanding the bore for
which can also have different materials added to small scratches and scrapes if the piston contact-
it for specific applications; Vespel®, which is a ed the bore wall. Rubber, however, works differ-
plastic material; and rubber. With the exception of ently in this application than it does as a sealing ring,
the cast ring, all of these rings are designed to run working with a rotating part. Here, the seal works like
on a very smooth surface. On some applications, a squeegee, wiping the oil from the seal’s point of con-
the ring does not rotate in its groove, it either rotates tact. The problem comes when replacing a Teflon®
with the shaft or remains stationary with the support. seal, which rides on a smooth surface, with rubber.
Indeed, some rings, like the second clutch rings on a This squeegee effect can tear away at the rubber seal.
4T60-E have locking tabs to prevent them from rotat- The first real problem I recall with this change was
ing. It’s easy to see why a smooth ring bore with these the accumulator seals on the 440-T4. The idea of
rings is desirable. For all three of these rings, no bore using rubber seals was great because the Teflon® seals
prep is necessary; just keep the bore used at first didn’t work very well. The pistons went
smooth. Cast rings, on the other hand, in fine, the transmission worked
rotate in their groove. If they’re on a great, and everyone was happy…
shaft, like a turbine shaft for for about a month. What we
example, the rings hold onto found was that the seals had
the stator support. If the what looked like little
ring groove is in a station- bite marks on them
ary part like a 400 center (not to mention all the
support, then the ring will debris in the pan from
rotate with the drum. the second clutch).
Here, there is more lat- The industry learned

than Elbow Grease and Sandpaper
through trial and error that the accu- sive material will break off, embedding
mulator bores were too smooth. To fix itself into the metal or falling loose on
the problem, simply rough up the seal the surface. Unless the accumulator
surface of the bore. We all tried a bore is cleaned well enough, little cut-
bunch of different products, and most ting edges are now working against
everyone agrees that the Scotch-Brite™ the rubber seals. Even if the bore were
pads work the best. End of the story, cleaned out well, where’d the abrasive
right? Not quite. After years of using this debris go? On the bench? On a rag that
product we’re finding more and more problems will be used for some other part of the transmis-
associated with using these pads than we did fifteen sion? In the solvent tank were valve
years ago. Why? Two bodies are cleaned? Could this
reasons. First, any for- explain some of the valve
ward-thinking company body hang-ups
wants to increase their product line to cover a wider we’ve been see-
range of customer needs. Consequently, 3M, the ing lately? Some
maker of Scotch-Brite™ has increased the types of rebuilders are now using a
materials out of which they make their abrasive pads. separate cleaning area for bore-
A small list of materials includes: emery, garnet, alu- prep operations, leaving all the grit they accumulate
minum oxide, silicon carbide, alumina-zirconia, dia- in one area. Another consideration is to do the final
mond and Cubitron™ Ceramic cleanup with an aerosol solvent like Brake-Kleen.
Aluminum Oxide Mineral (I threw This insures that parts are not being cleaned with
in all these fancy words so any contaminated solvent.
engineers reading this would As with many problems, when it comes right
feel at home). Some of down to it, the answer to bore preparation
these products are for rings and seals is very simple. Use an
less suited for abrasive pad that offers the right finish for
our needs and the seal and the surface it’s working on, and
may not offer the make sure it’s clean when the job is finished.
right finish for rubber Naturally, with a Sonnax bore sleeve, bore
seals. After all these years, prep isn’t an issue. Each bore is finished to
we’re still finding that the simple accept the type of seal with which it’s used.
green pad still works the best. The green Sonnax offers a wide range of bore sleeves and
pad is a polyester fiber with a urethane pistons, which include:
resin. In the resin is aluminum oxide miner-
34989-02K 4L80-E Intermediate Servo Sleeve and Piston
al, which is the abrasive material. It offers abrasive Page 45
characteristics close to using 280 grit emery. It offers 35709-01K 350 Intermediate Servo Sleeve and Piston
a finish of about 20µ in (Micro- Page 10
inches), depending on how hard 56532-01K A4LD, C3, Reverse sleeve
the pad is pressed while working Page 65 4R44E,
4R55E,
the bore. The official name 3M uses for this 5R55E
pad is #96. They also have a pad that is thinner, so it’s 77998-01K 4L60, 3-4 Accumulator Sleeve and Piston
easier to handle, yet offers the same abrasive proper- Page 34 4L60-E
ties of #96. They call it #07521. 96511K, AXOD, Accumulator Sleeves and Pistons
The second part of this problem deals with nothing 12K, AXOD-E,
more than cleanliness. Any time an abrasive pad is 13K, AX4S
123K
used for prepping a metal surface, some of the abra- Page 91

PRODUCT
sonnax
INDEX NO. APPLICATION DESCRIPTION
RED
RED SONNAX
SONNAX PART
PART NUMBERS
PROBLEM SOLVED
NUMBERS DENOTE
DENOTE NEW
NEW PRODUCTS
PRODUCTS IN
IN THIS
THIS CATALOG
CATALOG
PAGE
GENERAL MOTORS
34006-SP 4L80-E, 400 BUSHING, CASE, No Walk Out Flanged bushing will not walk out 12
34016-W 4L80-E BUSHING, FRONT Reduces leakage by minimizing
STATOR SUPPORT journal clearance 48
34105-01K 400 OVERSIZED ACCUMULATOR Eliminates cross leaks, 2-3 shift slide
PIN KIT & burned bands 13
34105-02K 400 OVERSIZED ACCUMULATOR Start-up kit includes reamer,
PIN & REAMER KIT 10 pins & 10 retaining rings 13
34200-01K 4L80-E BOOST VALVE & SLEEVE KIT, Eliminates high line pressure
w/ Balance Plug & O-Rings & buzzing noises 46
34200-03K 4L80-E FACTORY STYLE BOOST Eliminates high line pressure
VALVE KIT, w/bal. Plug & buzzing noises 46
34200-16K 4L80-E ACTUATOR FEED LIMIT Reduces wrong gear starts, no 4th,
VALVE KIT 3-neutral condition 47
34301-078 4L80-E FORWARD CLUTCH Corrects front unit endplay
34301-094 DRUM WASHERS 45
34500-Z 400, SHIMS, FRONT UNIT Reduces end-play and prevents burned
4L80-E END-PLAY, (.010" Thick) forward clutches 12
34910-01K 400 REVERSE BOOST Reduces delayed reverse
VALVE KIT & modulated drive 11
34910-03K 400 PRESSURE REGULATOR Reduces high line pressure
VALVE KIT to insure pressure control 11
34910-05K 400 FACTORY STYLE REVERSE Reduces delayed reverse
BOOST VALVE KIT 11
34989-02K 4L80-E FRONT SERVO PISTON & Reduces delayed engagement and low line
SLEEVE KIT pressure 45
34994-01K 4L80-E TCC REGULATOR VALVE KIT Reduces converter shudder,
reduces burned converters 49
34994-02K 4L80-E 1-2 SHIFT VALVE SPRING Reduces 2nd gear starts, no 3rd or 4th 48
35012S 4L60 & E OVERSIZED REAR Saves cases with spun bushing surface
CASE BUSHING 16
35410-T 350, 400, 4L60 GOVERNOR CIRCUIT Tests for worn governor bore & leakage in
TEST TOOL governor circuit 16
35709-01K 350 INTER. SERVO SLEEVE KIT Reduces delayed engagement 10
35718-01K 350 OVERSIZED ACCUMULATOR Eliminates cross leaks, 2-3 shift slide
PIN KIT & burned bands 13
35718-02K 350 OVERSIZED ACCUMULATOR Start-up kit includes reamer,
PIN & REAMER KIT 10 pins & 20 retaining rings 13
65754-01K 200 THROTTLE VALVE SLEEVE KIT Prevents poor line rise and no detent
downshifts due to oil loss 9
65754-02K 200 THROTTLE VALVE SLEEVE KIT Eliminates sticky and erratic throttle valve operation 9
65754-03K 200 THROTTLE VALVE SLEEVE KIT Annular cleaning grooves added to valve 9
6578-01 200/ C NYLON BUSHING, Eliminates oil leakage and premature
325-4L Intermediate band failure 16
65797 4L60 & E, 200-4R PUMP SLIDE PIVOT PIN Reduces high line pressure at idle 25
74926 4L60 & E 1-2 ACCUMULATOR SPRINGS Restores OEM 1-2 shift 25
75410-10 4T60 & E DIFFERENTIAL CARRIER Corrects differential endplay
TO CASE SHIM and improves planetary life 37
75890-30 4T60 & E HARDENED SIDE GEAR Allows differential to be services when side gear
THRUST WASHER thrust washers wear out 37
75918-01K 125-C TV & REVERSE BOOST Improves line pressure rise and upshift quality
VALVE KIT 8
77000-HBK 4L60-E TORX PLUS BIT Allows removal of bell housing bolts without
w/ 2 piece case striping bolt head 10
77406-10 4L60 & E, 350/C REAR UNIT END PLAY SHIM Corrects excessive rear unit end play;
reduction of drivetrain noise 26
77409-15 4L60 & E FRONT UNIT END PLAY SHIM Allows proper adjustment
of front unit endplay 26
77701-076 4L60 & E CHECK VALVE Extends 3-4 clutch life and improves 2-3 shift feel 21
77704S 4L60 & E FIRMER 1-2 ACCUMULATOR Firms up soft 1-2 shift
SPRING 25

PRODUCT
sonnax
RED SONNAX PART NUMBERS DENOTE NEW PRODUCTS IN THIS CATALOG
PROBLEM SOLVED PAGE
GENERAL MOTORS (continued)
77731-01 4L60 & E PINION GEAR, Replaces worn planetary gear

REAR PLANET 17
77731-02K 4L60 & E PINION PINS, Replaces gauled pinion pins in
REAR PLANET Rear Planetary Assemblies 17
77731-03 4L60 & E NEEDLE ROLLER BEARINGS Replaces worn needle roller bearings 17
77731-04 4L60 & E ROUND WASHER, REAR PLANET Replaces worn washers 17
77731-05 4L60 & E BATWING WASHER, REAR PLANET Replaces worn batwing washers 17
77731-08 4L60 & E OIL DEFLECTOR, REAR PLANET Replaces damaged deflector and can update early
planets to late 17
77731-RK 4L60 & E REAR PLANETARY REBUILD KIT Parts necessary to rebuild
Rear Planetary Assemblies 17
77754-01K 4L60-E OVERSIZED ACCUMULATOR Prevents burned forward clutch, or
PIN KIT delayed engagement 13
77754-02K 4L60-E OVERSIZED ACCUMULATOR Start-up kit includes reamer & 10 pins
PIN & REAMER KIT 13
77754-03K 4L60-E TCC REGULATOR Improves converter apply pressure to reduce
VALVE KIT '92-'97 (NON EC3) code 1870, Reduces harsh 1-2 shift 29
77754-04K 4L60-E TCC REGULATOR Reduces code P1870 & intermittent
VALVE KIT '97 (EC3) harsh 1-2 shift 29
77754-09K 4L60-E ACTUATOR FEED LIMIT Reduces wrong gear starts, solenoid codes
VALVE KIT 3-4 clutch failure 27
77754-R2 4L60-E REAMER, TCC Required for use with 77754-03K &
REGULATOR VALVE KIT 77754-04K 29
77754-TL 4L60-E TOOL KIT FOR AFL VALVE KIT Required for use with 77754-09K & 34200-16K 27,47
77767K 4L60 & E PISTON, SERVO, 4TH GEAR, Increases holding power by 40% over OEM
“The Sonnax Super-Hold Servo” 26
77767K-SK 4L60 & E SEAL REPLACEMENT KIT Seals for 77767K 26
77777K-K 4L60 & E, ACCUMULATOR VALVE Improves accumulator control and reduces
200-4R TRAIN ASSEMBLY harsh 1-2 shift, Light Weight Cars 24
77777L-K 4L60 & E, ACCUMULATOR Improves accumulator control and reduces
200-4R VALVE TRAIN ASSEMBLY harsh 1-2 shift, Medium Weight Cars 24
77777M-K 4L60 & E, ACCUMULATOR Improves accumulator control and reduces
200-4R VALVE TRAIN ASSEMBLY harsh 1-2 shift, Heavy Vehicles 24
77805E-K 4L60-E TCC APPLY VALVE Falling out of lock up hot, code 1870
(PWM ONLY) 28
77805-K 4L60 & E TCC APPLY VALVE Improves lock-up control
(NON-PWM) 28
77872-01 4L60 SHORTENED TV LINK Insures readjustment of throttle cable
by installer 20
77898E-3K 4L60-E FACTORY STYLE BOOST Improves line rise and shift firmness
VALVE KIT, .490" dia. 32
77898E-4K 4L60-E REVERSE BOOST VALVE & Corrects insufficent line-rise and
SLEEVE KIT, .470" dia. 3-4 clutch failure 32
77898E-6K 4L60-E FACTORY STYLE BOOST Corrects insufficent line-rise and
VALVE KIT, .470" dia. 3-4 clutch failure 32
77898E-K 4L60-E REVERSE BOOST VALVE & Improves line rise and shift firmness
SLEEVE KIT, .490" dia. 32
77911-01 4L60 & E 2ND APPLY SERVO Increases servo apply areas to improve
SAVER SLEEVE 1-2 shift 17
77911-02 4L60 & E METAL CLAD VITON Restores hydraulic seal at
SEALS, Press-in 2nd apply servo piston 17
77917-01K 4L60 TV BOOST VALVE Eliminates clutch/band failure due to TV
KIT, .423" Bore dia. pressure oil leakage 18
77917-02K 4L60 FACTORY STYLE TV BOOST Eliminates clutch/band failure due to TV
VALVE KIT, .423" Bore dia. pressure oil leakage 18
77917-06 4L60 OVERSIZED PRESSURE Corrects pressure regulator valve leakage
REGULATOR VALVE & REAMER KIT 33
77917-07 4L60-E OVERSIZED PRESSURE Corrects pressure regulator valve leakage
REGULATOR VALVE & REAMER KIT 33

PRODUCT
sonnax
RED
RED SONNAX
SONNAX PART
PART NUMBERS
PROBLEM SOLVED
NUMBERS DENOTE
DENOTE NEW
NEW PRODUCTS
PRODUCTS IN
IN THIS
THIS CATALOG
CATALOG
PAGE
77917-471 4L60 TV BOOST VALVE Eliminates clutch/band failure due to TV

KIT, (.471" Bore dia.) pressure oil leakage 18
77917-TL 4L60 & E REAMER AND GUIDE for Reduces pump scrap rate
PR Valves 33
77918S-K 4L60 & E STATOR SUPPORT SHAFT Eliminates sleeve rotation by
KIT, with 4 bushings mechanical fastening 21
77966-93K 4L60 TV SLEEVE & PLUNGER Increases line rise and prevents
KIT (for 93) no direct downshift 20
77966-94K 4L60 TV SLEEVE & PLUNGER Increases line rise and prevents
KIT (for 94) no direct downshift 20
77966-94MK 4L60 TV SLEEVE & PLUNGER Increases line rise and prevents
Heavier duty no direct downshift 20
77968 4L60 OVERSIZED Eliminates excessive leakage in worn
THROTTLE VALVE valve body bore 19
77968-RM 4L60 REAMER TOOL Required reamer for 77968 19
77998-01K 4L60 & E 3-4 ACCUMULATOR SLEEVE KIT Saves cases with worn 3-4 accumulator bores
4L60-E 34
77999 4L60 & E, OVERSIZED ACCUMULATOR Eliminates cross leaks, 2nd gear starts
200-4R, 325-4L PIN KIT & burned bands 13
77999-02K 4L60 & E, OVERSIZED ACCUMULATOR Start-up kit includes reamer and 10 pins
200-4R, 325-4L PIN & REAMER KIT 13
84573-01K 4T60 & E OVERSIZED Allows re-use of original, worn piston
ACCUMULATOR PINS 13
84573-02K 4T60 & E OVERSIZED ACCUMULATOR Includes 10 Accumulator Pins and Reamer
PIN & REAMER KIT 13
84733-10 4T60 & E INPUT CLUTCH HUB SHIMS Corrects endplay, extends bearing & bushing life 36
84733-20 4T60 & E INPUT CLUTCH HUB SHIMS Improves seal life by reducing drum travel,
adjusts for component wear 36
84754-01K 4T60-E TCC REGULAR VALVE Helps eliminate Code 740 & 1870,
(PWM-'93 & Up) & ISOLATOR VALVE KIT Converter Shudder 40
84754-08K 4T60-E TCC REGULATOR VALVE Helps eliminate Code 740,
(PWM-'91-'92) & ISOLATOR VALVE Converter Shudder 40
84754-12K 4T60 & E MODULATED LINE Improves line rise
BOOST VALVE KIT 42
84754-14K 4T60 & E REVERSE BOOST VALVE KIT Reduces soft shudder 42
84754-16K 4T60 & E TCC APPLY VALVE KIT, Reduces 1870,converter shudder, overheat, and
(91 through '96) oversized codes 39, 740 & 1870 41
84754-17K 4T60 & E MODULATED LINE BOOST Updated valve spool stability
VALVE KIT 42
84754-19K 4T60 & E REVERSE BOOST VALVE KIT Reduces reverse delay or shudder 42
84754-22K 4T60 & E TCC APPLY VALVE KIT Reduces 1870, falling out of lock up, overheat,
(91 through '96) (OEM SIZE) and codes 39, 740 & 1870 41
84754-23K 4T60-E 1-2 SHIFT VALVE Reduces 1-2 shuttle shift 35
84754-24K 4T60 & E REVERSE & MODULATED LINE Reduces 2nd & 3rd clutch distress
BOOST VALVE KIT 43
84754-25K 4T60 & E REVERSE & MODULATED LINE Salvages valve body cores
BOOST VALVE KIT 43
84754-30K 4T65-E BOOST VALVE & SLEEVE KIT Reduces harsh engagement 44
84754-97K 4T60-E TCC APPLY VALVE KIT, Reduces 1870, converter shudder, overheat, and
(97 & up) oversized codes 39, 740 & 1870 41
84754-98K 4T60-E TCC APPLY VALVE KIT Reduces 1870, falling out of lock up, overheat,
(97 & up) (OEM SIZE) and codes 39, 740 & 1870 41
84754-DJ2 4T60-E REAMER GUIDE Required for 84754-97K 41
84754-RM 4T60-E (PWM-'91-'92) REAMER TOOL Required for 84754-08K 40
84754-TL 4T60 & E REAMER AND GUIDE Required tool for 84754-16K & 84754-97K 41
84881 4T60 & E PUMP SLIDE PIVOT PIN Reduces low or high line pressure 35
84881A 4T60 & E PUMP SLIDE PIVOT PIN Reduces low or high line pressure 35
84995-01 4T60 & E REPAIR PLATE, Eliminates oil leakage; easy
Channel Plate Side Cover installation 36

PRODUCT
sonnax
PROBLEM SOLVED PAGE
95200-01 SATURN TAAT PRESSURE REGULATOR Reduces erratic line pressue due to spring breakage
SPRING 49
K77898 4L60 REVERSE BOOST VALVE Reduces delayed reverse or shudder in reverse
KIT 18
K77898A 4L60 FACTORY STYLE REVERSE Reduces delayed reverse or shudder in reverse
BOOST VALVE KIT 18
K84956-SP 4T60-E SPRING, ACCORDIAN, Prevents 1-2 roller clutch failure
(1993 & Up) Heavy Duty Roller Clutch 34
FORD
36008A C6, E4OD REAR CASE BUSHING, Increases lubrication and bearing area
Oversized O.D. 55
36008B C6, E4OD REAR CASE BUSHING, Increases lubrication and bearing area
Standard O.D. 55
36008C C6, E4OD OVERSIZED REAR CASE 4 Saves cases with spun bushing surface
GROOVE BUSHING, late model 55
36008D C6, E4OD REAR CASE BUSHING, Increased lubrication and bearing area
late model 55
36402-Z E4OD SHIMS, REVERSE PLANET Allows precise end-play adjustment,
END-PLAY reduces wear 64
36414-01K C6 SUNSHELL SAVER SHIM Prevents unwanted forward planet/sunshell contact 52
36424-01K E4OD, 4R100 BOOST VALVE & SLEEVE KIT Eliminates poor reverse boost
w/Plug, Sleeve & 2 O-Rings and soft shifts 56
36424-03K E4OD, 4R100 FACTORY STYLE REVERSE Eliminates poor reverse boost
BOOST VALVE KIT and soft shifts 56
36428A-Z C6 SHIMS, REVERSE PLANET Allows precise end-play adjustment,
END-PLAY, 4 slots reduces wear 52
36428-Z C6 SHIMS, REVERSE PLANET Allows precise end-play adjustment,
END-PLAY, 6 slots reduces wear 52
36438A-01K & E4OD PUMP GEARS Improves low line pressure and
36438AX-01K reduces excessive pump noise 59
36440-01 C6, E4OD FORWARD PLANETARY Repair E4OD/C6 planetary carriers with a
REPAIR SLEEVE worn or damaged pilot dia. 54
36743G E4OD CENTER SUPPORT GASKET Eliminates leakage between
Silicone Printed center support and hub 64
36833-01K C6 OVERSIZED MODULATOR Salvages worn cases while still in vehicle;
VALVE & REAMER SYSTEM Improves line rise response 54
36833-TL C6 DRILL JIG & REAMER Drill jig and reamer for 36833-01K 54
36946-01K C6 REVERSE BOOST VALVE Prevents cross leakage, which causes
& SLEEVE KIT, gas ratio insufficient line rise 53
36946-02K C6 REVERSE BOOST VALVE Prevents cross leakage, which causes
& SLEEVE KIT, diesel ratio insufficient line rise 53
36946-03K C6 FACTORY STYLE REVERSE Increases line pressure rise; reduces erratic
BOOST VALVE & SLEEVE KIT shift timing (diesel ratio) 53
36946-04K C6 FACTORY STYLE REVERSE Eliminates reverse shudder caused by poor
BOOST VALVE & SLEEVE KIT line rise (gas ratio) 53
36948-03K E40D (Late) LINE PRESSURE MODULATOR Improves 1-2 & 2-3 shift firmness
PLUNGER VALVE & SLEEVE 58
36948-05K E40D (Early) LINE PRESSURE MODULATOR Improves 1-2 & 2-3 shift firmness
PLUNGER VALVE & SLEEVE 58
36948-09K E4OD, 4R100 ACCUMULATOR CONTROL Reduces loss of 2nd, 3rd or 4th gear
VALVE KIT 57
36948-12 E4OD, 4R100 BORE SIZING TOOL For use with 36948-09K 57
37947-01K 4R44E BOOST VALVE KIT Improves line rise, engagement, and shift quality 71
56001X A4LD, 4R55E, BUSHING, BELL HOUSING, Eliminates front seal leakage
5R55E Finish-In-Place 68
56250-01K A4LD THRUST WASHER AND Reduces bronze-in-the-pan
SPRAG END CAP KIT 69
56521-K A4LD REAR BAND ANCHOR PIN KIT Prevents 1-2 bind-up created by a dragging band 68
56532-01K A4LD, C3, 4R44E, REVERSE SERVO SLEEVE Reduces forward clutch & reverse band failure
5R55E KIT 65

PRODUCT
sonnax
PROBLEM SOLVED PAGE
FORD (continued)
56600 A4LD REARSPRAG INNER RACE Improved race for 2.8, 2.9, 3.0 cases;
(2.50” Dia.) insures tight fit 69
56600B A4LD REAR SPRAG INNER RACE Improved race for 4.0 cases;
(2.70” Dia.) insures tight fit 69
56600B-01K A4LD LOW SPRAG UPDATE KIT Salvages cases with worn or loose races
(4.0 case) (includes 56600B) 69
56600-DJ A4LD DRILL JIG For installing 56600 and 56600B;
Inner races eliminates risk of damaging case 69
56947-01 A4LD MANUAL VALVE INDEX Eliminates burned forward clutch and delayed
forward engagement 70
56947-02K A4LD LARGE RATIO BOOST Prevents insufficient line rise related to worn
VALVE KIT boost sleeve 66
56947-03K A4LD FACTORY STYLE BOOST Prevents insufficient line rise related to worn
VALVE KIT, Large ratio boost sleeve 66
56947-04K A4LD SMALL RATIO BOOST Prevents insufficient line rise related
VALVE KIT to worn boost sleeve 66
56947-05K A4LD FACTORY STYLE BOOST Prevents insufficient line rise related
VALVE KIT, Small ratio to worn boost sleeve 66
56947-06K A4LD PRESSURE REGULATOR Corrects soft shifts, low line pressure
VALVE KIT 67
56947-TL A4LD PRESSURE REGULATOR The bore must be resized by the reamer
VALVE REAMER KIT 67
56995A A4LD SPRING, ANTI-SHUDDER Eliminates shudder when clutch
does not release 70
73251-01K CD4E ENDPLAY SHIM KIT Reduces excessive endplay 93
73840-24 CD4E O-RINGED ACCUMULATOR Reduces soft/harsh shift complaints caused by
PISTON AND SPRING KITS bore wear and piston sticking 97
73840-BK CD4E BYPASS CLUTCH CONTROL Reduces Code 628/1744, lube failure, and hard part
KIT damages, improves TCC apply and release control 94-96
73840-BTL CD4E BYPASS TOOL KIT Required for 73840-BK 94
73840-FWD CD4E O-RINGED ACCUMULATOR Reduces soft/harsh shift complaints caused by
73840-LR CD4E O-RINGED ACCUMULATOR Reduces soft/harsh shift complaints caused by
73840-MK CD4E MASTER REBUILD KIT Consists of Bypass and Regulator kits
described above 94-96
73840-MTL CD4E MASTER TOOL KIT Reduces Code 628, lube failure, and
hard part damage 94-96
73840-RK CD4E PRESSURE REGULATOR Eliminates high line/converter charge psi, increases
VALVE KIT cooler/lube flow, allows line to lube at rest 94-96
73840-RTL CD4E PRESSUE REGULATOR TOOL KIT Required for 73840-RK 94
76204-01 AOD-E, 4R70W STATOR SUPPORT SLEEVE Prevents converter release oil
circuit leakage 82
76811-01K AOD-E DIRECT DRUM SHAFT Improves lube flow to
Retaining Ring direct drum bushing 77
76833 AOD OVERDRIVE SERVO PIN with Eliminates forward clutch and
Washer and O-Ring overdrive band failure 76
76833E AOD-E OVERDRIVE SERVO PIN Eliminates oil circuit leaks at
with Washer and O-Rings overdrive band 82
76948-01 AOD-E MAIN PRESSURE Prevents low line pressure
(‘95 & Earlier ) REGULATOR VALVE 81
76948-02K AOD-E, 4R70W PRESSURE REGULATOR Prevents poor reverse boost
VALVE & SLEEVE KIT 81
76948-04K AOD-E, 4R70W BYPASS TCC CONTROL Eliminates delayed TCC apply
SLEEVE & PLUNGER VALVE & reduces shudder 80
76948-06 AOD-E, 4R70W ELEVATED PRESSURE Reduces forward clutch failure by raising line
REGULATOR SPRING pressure to 68 lbs. 77
76948-09 AOD-E, 4R70W MAIN PRESSURE Prevents low line pressure
('97 and up) REGULATOR VALVE 81
76970 AOD OVERSIZED THROTTLE VALVE Prevents uncontrollable throttle pressure,
PLUNGER increases line rise 75
76970-RM AOD OVERSIZED THROTTLE VALVE Removes excess material for valve body
BORE REAMER to accept the plunger 75

PRODUCT
sonnax
PROBLEM SOLVED PAGE
FORD (continued)
76989-03K AOD FACTORY STYLE THROTTLE Eliminates uncontrollable

VALVE KIT throttle pressure 72
76989K AOD THROTTLE VALVE PLUG Eliminates uncontrollable
& SLEEVE KIT throttle pressure 72
76990-03K AOD FACTORY STYLE BOOST Increases line rise and reduces clutch failure
VALVE KIT 73
76990K AOD BOOST VALVE & Increases line rise and reduces clutch failure
SLEEVE KIT 73
76991-01K AOD 1-2 CAPACITY MODULATOR Restores line pressure for all shifts and
VALVE KIT salvages valve body 76
76991-TL AOD REAMER & DRILL JIG Reamer and drill jig for 76991-01K 76
76999-04K & AOD VALVE END PLUG KIT Eliminates governor oil leakage
76999-05K 74
76999-SML, AOD VALVE END PLUG KIT, Eliminates governor oil leakage
MED, -LRG with O-Rings 74
86412-01 ATX OVERSIZED Prevents late, erratic, or no 1-2 & 2-3 shift
GOVERNOR PIN caused by pin wear 84
86412-T ATX GOVERNOR CIRCUIT Allows easy testing of governor oil circuit
TEST TOOL 84
86539-Z5 ATX SHIM, SELECTIVE, Special thickness allows proper
Idler Gear Assy, (.005" thick) preload setting 84
86940-01 ATX SLEEVE, THROTTLE PLUNGER Eliminates wear & prevents
Hard Coat Finish excess leakage 83
86940-03 ATX SLEEVE, THROTTLE CONTROL Eliminates wear &
VALVE, Hard Coat Finish prevents excess leakage 83
96201-01K AXOD & E, BOOST VALVE & SLEEVE KIT Eliminates 2-1 down-shift clunk and
AX4N, AX4S with O-Rings, 3.8L clutch/band failure 87
96201-05 AXOD & E MANUAL VALVE, Hard Coat Eliminates delayed forward
Finish, Lengthened Spool Dia. engagement, forward clutch burnout 90
96201-06K AXOD BYPASS CLUTCH CONTROL Improves TCC apply & release
SLEEVE & PLUNGER VALVE KIT oil control 86
96201-08K AXOD & E, FACTORY STYLE BOOST Eliminates 2-1 down-shift clunk and
AX4N, AX4S VALVE KIT, 3.8L clutch/band failure 87
96201-12K AXOD & E, BOOST VALVE & SLEEVE KIT Eliminates 2-1 down-shift clunk and
AX4N, AX4S with O-Rings, 3.0L clutch/band failure 87
96201-13K AXOD & E, FACTORY STYLE BOOST Eliminates 2-1 down-shift clunk and
AX4N, AX4S VALVE KIT, 3.0L clutch/band failure 87
96201-15K AXOD & E, AX4S VALVE SAVER CAP Allows re-use of 3-2 control valve 93
96201-16K AXOD & E, AX4S FORWARD CONTROL VALVE KIT Reduces slipping in forward and reverse 85
96201-BST AXOD & E, AX4S BORE SIZING TOOL Required for 96201-16K 85
96206-01K AXOD-E, AX4S BYPASS CLUTCH CONTROL Improves TCC apply & release
SLEEVE & PLUNGER VALVE KIT oil control 89
96206-03K AX4N BYPASS CLUTCH CONTROL Reduces cooler circuit oil loss and Code 628
SLEEVE & PLUNGER KIT 92
96511K AXOD & E ACCUMULATOR BORE SLEEVE Saves expensive and unit specific
KIT, N-D Accumulator channel castings 91
KIT, Master Kit channel castings 91
KIT, 3-4 Accumulator channel castings 91
KIT, 1-2 Accumulator channel castings 91
96728 AXOD & E PISTON, SERVO, Restores seal integrity of worn
Low - Intermediate OEM servo piston 86
96730-RR AXOD & E RETAINING RING, Prevents retaining ring popping out
Rear Ring Gear 88
96803 AXOD & E, REPAIR SLEEVE, CHANNEL Eliminates internal leakage of
AX4N, AX4S PLATE, Hardened & Ground channel plate 90
96806 AXOD & E SERVO TUBE BRACKET Eliminates tube blow out, which causes
a no forward complaint 88
96945R AXOD & E 1-2 SERVO SPRING Fixes 3-2 neutral/delayed engagement
RETAINER CLIP due to broken clip 86
96945S AXOD & E SERVO PIN Increased length to properly set servo travel 86

PRODUCT
sonnax
RED
RED SONNAX
SONNAX PART
PART NUMBERS
PROBLEM SOLVED
NUMBERS DENOTE
DENOTE NEW
NEW PRODUCTS
PRODUCTS IN
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THIS CATALOG
CATALOG
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FORD (continued)
96948-01K AX4N, HI-PERF., LINE PRESS. MODULATOR Improves 1-2 & 2-3 shift firmness
E40D, 4R100 PLUNGER VALVE & SLEEVE 58, 92
96995A AXOD & E SPRING, Eliminates delayed forward engagement
INTERMEDIATE, SERVO & downshift clunk 86
T36008A C6, INSTALLATION TOOL, Draws the replacement bushing into place
E4OD Rear Case Bushing 55
T36605-03 C6, REAMER, for Oversized Rear Custom designed 1-5/8" reamer
E4OD Case Bushing Required for use with 36008A 55
T36605-04 C6, REAMER FIXTURE, for Flange can be reversed to
E4OD Oversized Bushing Reamer switch between units 55
CHRYSLER
12229-01K A904 REGULATOR SLEEVE & Reduces slippage in reverse
PRESSURE PLUG KIT 109
12502-01 41TE, 42LE, FRONT PUMP BUSHING Restores clearance for
A670, A904 proper operation 102
12780-Z 42RH, A904 SHIM, END-PLAY, Reduces transmission end-play
(.010" Thick) for 3 or 4 tanged OE washers 106
12962N-01K 42RH, 42RE UPGRADED PISTON Reduces reverse drum, retainer & planet failure
RETAINER 107
12962N-02K 42RH, 42RE OVERSIZE UPGRADED Allows salvage of reverse drum
PISTON RETAINER 107
22229-01K A727, 42RH, 46RH, REGULATOR SLEEVE & Reduces slippage in reverse
47RH PRESSURE PLUG KIT 109
22556-BRG A727, 46RH, 47RH CASE REPAIR BEARING Saves expensive cases; prevents further
case damage 112
22700-Z A727, 46RH SHIM, END-PLAY, Reduces transmission end-play
(.010" Thick) for 3 or 4 tanged OE washers 112
22750L 46RH, 47RH PRESS-ON LOW ROLLER Allows resuse of reverse drums with
CLUTCH RACE worn inner races 114
22750N A727, 46RH SLIDE-ON LOW ROLLER Direct OEM replacement
RACE, 12 elements 114
22754N-01K 46RH, 46RE, UPGRADED PISTON Reduces reverse drum, retainer & planet failure
47RH, 47RE RETAINER 113
22754N-02K 46RH, 46RE, OVERSIZE UPGRADED Allows salvage of reverse drum
47RH, 47RE PISTON RETAINER 113
22771-01K 42RH, 46RH, 47RH THROTTLE VALVE KIT Improves shift timing; salvages valve body
with wornTV plunger 110
22771A-01 42RH, 46RH, 47RH 4 SPOOLED SWITCH VALVE Converter shudder, improved
apply & release control 111
22900-10/15 A727,46RH, 46RE LENGTHENED BAND Allows resurface of drum, available either
47RH, 47RE STRUTS .100" or .150" longer 114
22912 A727, 46RH SERVO PISTON UPGRADED Prevents reverse band slippage;
prevents piston breakage 110
22912A A904, A999, 47RH SERVO PISTON UPGRADED Reduces piston cocking/sticking in bore;
prevents reverse band slippage 110
22912B 47RH, ('94 & up) SERVO PISTON UPGRADED Prevents reverse band slippage;
(w/split band) prevents piston breakage 110
32539-Z5 A404, A413, SHIM, TRANSFER GEAR, .005" thickness allows use with
A470, A670 (.005" Thick) leftover Chrysler kit spacers 100
32710-01 A404, A413, STRUT, Heavy Duty, High quality steel resists strut bending
A470, A670 Reverse Band or breakage 100
35539-Z5 A404, A413, SHIM, PINION, .005" thickness allows use with
A470, A670 (.005" Thick) leftover Chrysler kit spacers 100
39539-Z5 A404, A413, A470, SHIM, DIFFERENTIAL Used to reset preload when
41TE, 42LE, A670 BEARING, (.005" Thick) reworking differential assembly 100
92003-01K 41TE, 42LE INPUT CLUTCH HUB Tighter toleranced bushing prevents leaks in
BUSHING underdrive circuit 103
92003-TL 41TE, 42LE BUSHING INSTALLATION Used with 92003-01K input clutch hub bushings
TOOL 103

PRODUCT
sonnax
PROBLEM SOLVED PAGE
CHRYSLER (continued)
92004-L 41TE (1996 & Up), BUSHING, OVERDRIVE Prevents shaft breakage and lube loss
42LE CLUTCH HUB, Steel-Backed 103
92004-SP 41TE (Up thru 1995) BUSHING, OVERDRIVE Prevents shaft breakage & lube loss
CLUTCH HUB, Steel-Backed 103
92834-03K 41TE, 42LE ACCUMULATOR BORE SLEEVE Reduces 1-2 shudder, coast down clunk, and CVI's
AND PISTON KIT 104
92835-02K 41TE, 42LE SOLENOID SWITCH Reduces erratic TCC operation and
VALVE PLUGS switch valve codes 104
92835-03K 41TE, 42LE TCC REGULATOR VALVE Prevents high converter apply pressure
and lock-up piston failure 101
92835-07 42LE PRESSURE REGULATOR Prevents high line pressure and
SLEEVE improves lube control & shift feel 102
92836-01K 41TE, 42LE BY-PASS PLUG Eliminates fluid loss and
directs fluid through cooler 105
92836-02 41TE, 42LE SOLENOID DIAPHRAGM Replaces worn diaphragms 105
92836-03 41TE, 42LE SOLENOID SWITCH Replaces worn contacts
BRASS CONTACT 105
92836-03K 41TE, 42LE SOLENOID REPAIR KIT Reduces pressure switch codes 105
92965-30 41TE SPACER, OUTPUT & TRANSFER Allows more accurate preload setting
SHAFT, (.030" Thick) 106
92965-Z5 41TE SHIM, OUTPUT & TRANSFER Allows more accurate preload setting
HONDA
88406B Some G4 BRONZE THRUST WASHER, Replaces OEM roller bearing;
Mainshaft 2nd Gear Assy. withstands wear 118
88406C G4, K4, L5 PL5X BRONZE THRUST WASHER, Replaces OEM roller bearing;
Mainshaft 2nd Gear Assy. withstands wear 118
88406-SP AK, AS, F4, L4 BRONZE THRUST WASHER, Replaces OEM roller bearing;
CA,PL Mainshaft 2nd Gear Assy. withstands wear 118
MAZDA
71151-K 4EAT, G4A-HL, G4A-EL, PUMP DRIVE TOOL Enables rebuilders to charge pump and
F4A-EL & F4EAT analyze units on the bench (not catalogued)
71400-15 4EAT / G4A-EL FRONT SUPPORT PUMP Use with selective washer to set
SHIM, (.015" Thick) transmission end play 122
71828-TL G4A-EL 3-4 DRUM TEST TOOL KIT Allows bench checking for drum leaks
w/ Tool Cap, Screw & O-Rings 122
71846-01K G4A-EL BOOST VALVE KIT Improves line rise, reduces delayed reverse, and
prevents soft shifts and shudder 121
71912-01K 4EAT / G4A-EL PUMP REBUILD KIT, Increases oil pump volume
Valve, Spring & Expander by reducing internal oil leakage 120
71912-02 4EAT / G4A-EL PUMP VANE Decreases internal leakage
EXPANDER RING 120
74828-TL F4A-EL 3-4 DRUM TEST TOOL KIT Allows bench checking for drum leaks
w/ Tool Cap, Screw & O-Rings 122
74846-01K GF4A-EL, F4A-EL BOOST VALVE KIT Improves line rise, reduces delayed reverse, and
prevents soft shifts and shudder 121
K74878 F4A-EL,GF4A-EL PUMP REBUILD KIT Improves pump volume and line pressure 120
MITSUBUSHI
41750-03 KM 20 & 30 Series MANUAL VALVE Insures converter charge and cooler flow in park 126
NISSAN
66942-01K L4N71B BOOST VALVE & SLEEVE Reduces delayed reverse 128

PRODUCT
sonnax
RED SONNAX
RED SONNAX PART
PART NUMBERS
PROBLEM SOLVED
NUMBERS DENOTE
DENOTE NEW
NEW PRODUCTS
PRODUCTS IN
IN THIS
THIS CATALOG
CATALOG
PAGE
NISSAN(continued)
69700-01 Jatco Various SERVO BAND STRUT Higher quality material with improved load strength;
reduces cracking of strut 127
69835 RL4R01A GOVERNOR BORE SLEEVE Press in sleeve, no machining required 127
69903-01K RE4R01A, RE4R03A SERVO PIN Reduces 2-3 bind up and high clutch failure 129
93897S RL4F02A SPLINED REPAIR INSERT, Replaces stipped or damaged planetary splines
w/ hardened splines 126
93903-01K RE4F02A, RL4F02A SERVO PIN Reduces 2-3 bind up and high clutch failure 129
93990 RE4F02A PRESSURE REGULATOR Eliminates poor shift timing and poor line rise
BOOST SLEEVE 130
TOYOTA
89010-01 A130, A131, BOOST SLEEVE Helps prevent delayed reverse, reduces soft 1-2
A132(L) or 2-3 shift, and increases line rise 119
89031-01 A540 BOOST SLEEVE Reduces delay shudder, soft 1-2 or 2-3 upshifts,
and increases line rise 119
ZF
85701-01 ZF4HP-18 SERVO CUSHION WASHER, Reduces neutralizing on 3-4 shift
BELLEVILLE TYPE 130
85991-01 ZF4HP14/18 OVERSIZED PR VALVE Reduces high, uncontrollable line pressure;
improves converter charge 131
85991-TL ZF4HP14/18 OVERSIZED PR VALVE TOOL KIT Reduces reverse engagement complaints 131
HIGH PERFORMANCE
35922-01K GM Units SPEEDO PLUG Plug allos lubrications to output shaft

Auto and Standard 135
36916E C6 SERVO APPLY LEVER, E RATIO Will not distort or crack 134
76948-06 AOD-E, 4R70W ELEVATED PRESSURE Reduces forward clutch failure by raising line
REGULATOR SPRING pressure to 68 lbs. 134
77704S 4L60 & E 1-2 ACCUMULATOR SPRING, Firms up soft 1-2 shifts
ENHANCED PERFORMANCE 135
77722-01K 4L60 & E PUMP SLIDE SPRING Maintains pump in high volume
at high RPM 135
77767K 4L60 & E PISTON, SERVO, 4TH GEAR, Increases holding power by 40% over OEM
“The Sonnax Super-Hold Servo” 132
77767K-SK 4L60 & E SEAL REPLACEMENT KIT Seals for 77767K 132
77917-RV 4L60 & E SPRING SPACER Preloads the spring for
increased pump output 135
77966-94MK 4L60 FULL THROTTLE UPSHIFT Increases line rise and prevents
SLEEVE & VALVE KIT no direct downshift 135
77968-01K 4L60 THROTTLE VALVE SPRING Improves and maintains higher line pressure 135
96948-01K E4OD, 4R100 LINE PRESSURE Improves 1-2 & 2-3 shift firmness
MOD. VALVE KIT, .427" dia 134
K36528R C6 R-RATIO SERVO More band apply force, unique servo pin 134
K36528R-SK C6 SEAL KIT Replacement seal kit for K36528R 134
K13259C C4 C-RATIO SERVO Firmer 1-2 & 2-3 shifts 134
K13259C-SK C4 SEAL KIT Replacement seal kit for K13259C 134
OTHERS
36605-01 1356 Transfer CASE SAVER SPACER Eliminates no movement or
neutral condition (not catalogued)
AS1-01K AOD, AXOD & GM TV CABLE CORRECTOR KIT Prevents TV cable out of adjustment at
wide-open throttle 138

PRODUCT
sonnax
PROBLEM SOLVED PAGE
OTHERS (continued)
AS2-02K GM & AOD TV CABLE CORRECTOR KIT Prevents TV cable out of adjustment at
(w/cables) (w/ Holley Carburetor) wide-open throttle 138
AS3-03K EDLEBROCK TV CABLE CORRECTOR KIT Prevents TV cable out of adjustment at
wide-open throttle 138
FM-01K ALL AUTOMATICS SONNAFLOW DIGITAL Detects restricted coolers, clogged filters and allows
FLOW METER flow check while driving 78-79
FM-03K ALL AUTOMATICS DIAGNOSTIC LEAD Allows Sonnaflow readings on a lab scope for
advanced diagnostics 78-79
O-LUBE Multiple Applications O-RING LUBRICANT Aids in installation of O-ringed sleeves and general
transmission assembly 141
OR-MK Multiple Applications MASTER O-RING KIT Allows re-servicing of O-ringed boost sleeves 141
SWAT-P1 Multiple Applications WET/AIR TEST PLATE Allow easy isolation of oil circuits when performing
wet/air test 141
SSPP-01 Multiple Applications SMALL PARTS PROGRAM Miscellaneous box of retainers, clips, springs, etc. 139-141
WA R R A N T Y POLICY
Sonnax warrants to the owner that it will repair or replace, at Sonnax’s option, each part manufactured or
supplied by Sonnax, when that part is found to be defective in material or in factory workmanship, under
normal use and service.
The Warranty period shall extend for six (6) months from the date of sale.
Defective or malfunctioning parts must be returned to Sonnax. All returns must be approved by
Sonnax and clearly display the assigned return authorization number (R.A.) on the packaging.
Returns must be accompanied with the purchaser’s copy of the original invoice to validate the
date of purchase.
The Warranty does not cover:

• Removal and replacement-labor costs
• Loss of time, inconvenience or other consequential damage
• Any Sonnax part that has been:
- Subject to misuse, negligence, alteration or accident
- Improperly installed in the judgement of Sonnax, so as to adversely
effect its performance and reliability
THIS WARRANTY IS THE ONLY WARRANTY APPLICABLE TO NEW PARTS MANUFACTURED

BY SONNAX, AND IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE. THERE ARE NO WARRANTIES WHICH EXTEND
BEYOND THE DESCRIPTION ON THE FACE HEREOF.
Sonnax does not authorize any person to create for it any other obligation or liability
in connection with these parts. Sonnax shall not be liable for any incidental or
consequential damage resulting from breach of Warranty.

Innovative Engineered Tested
Buy Genuine Sonnax Parts

Automatic Drive P.O. Box 440 Bellows Falls, VT 05101-0440 U S A
800-843-2600 802-463-9722 fax: 802-463-4059
www.sonnax.com info@sonnax.com

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132 High Performance

PRODUCT CHARTS AND LISTINGS

Symbols used in this catalog:

:Sonnax featured part

:Sonnax part also available

:Tool required for installation

:Machining required for installation

:New Sonnax part introduced in this catalog

© 2001 SONNAX INDUSTRIES

2 sonnax 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com

84754-14K, 19K 42-43 84573-01K 13 75410-10, 37 84733-10 & 20 36

35718-01K 13 35709-01K 10 77406-10 26

36946 Series 53 36428-Z & A-Z 52

96201-01K, 08K, 12K,13K 87 96201-05 90 96511K, 12K, 13K 91

32539-Z5, 35539-Z5, 100

92834-03K 104 39539-Z5, 100 92965-Z5 106

Part number Page number

©2001 Sonnax Industries, Inc.

800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com sonnax 3

E do a job quickly, accurately or with greater

©2001 Sonnax Industries, Inc.

4 sonnax 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com

Which and Wear:

Figure 3: Inspect bore which controls exhaust. Figure 5: Measurement Tools

©2001 Sonnax Industries, Inc.

800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com sonnax 5

Figure 7: Wet Air Test

©2001 Sonnax Industries, Inc.

6 sonnax 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com

must be developed, as well as transmissions, from

©2001 Sonnax Industries, Inc.

800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com sonnax 7

Complaint Delayed reverse engagement

• Poor line pressure

Correction SONNAX PART SUMMARY

©2001 Sonnax Industries, Inc.

8 sonnax 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com

Complaint Soft 1-2 shift, poor detent and up-shift control

Cause Part Throttle Orifice

Correction Throttle Valve Sleeve

SONNAX PART SUMMARY

Sonnax P/N TV Valve Groove TV Plunger Dia.

©2001 Sonnax Industries, Inc.

800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com sonnax 9

Complaint Delayed engagement

Part No. 35709-01K

4L60-E Part No. 77700-HBK

Complaint Stripped bell housing bolt heads

Torx® Plus Bit

©2001 Sonnax Industries, Inc.

10 sonnax 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com

Complaint High line pressure, poor line rise

PR Valve: Teflon® Seal

Modulated Boost Pump Body

Cause halves assembled)

Reverse Orifice Modulated

casting or boost sleeve

Correction Boost Valve

©2001 Sonnax Industries, Inc.

800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com • info@sonnax.com sonnax 11

Complaint Burned forward clutches