TIME TESTED • INDUSTRY TRUSTED

Transmission Report Volume 6, No. 3 October 2015

Sonnax is YOUR SOURCE for

Quality Remanufactured Valve Bodies
Founded in 2002 on the premise that technicians shouldn’t have to choose between a
“good used” or “dealer new” valve body, Valve Body Xpress (VBX) has long been the
leading producer of guaranteed remanufactured valve bodies and solenoids.

In August 2014, Sonnax Industries acquired Valve Body Xpress to better meet the repair
challenges of increasingly sophisticated modern transmissions. In combining the vast
resources and know-how of both organizations, the transmission aftermarket now has
one trusted source of quality solutions for every transmission job.

Whether you want to rebuild it yourself or save time and money with a remanufactured
valve body, Sonnax has you covered. The full line of products is now conveniently listed
alongside transmission components at www.sonnax.com.

6R140, 6R60/80, 6F50

Solenoid Strategies
• Solenoid operation & flow characteristics
• Use scan tools to identify flow rate values
& update/learn new values
• Diagnose & repair solenoid-related problems

Choose to attend any of five sessions:

• Nov. 3 at noon EST & MST
Live webinars with Sonnax Tech Specialist • Nov. 4 at noon CST & PST
Steve Garrett deliver transmission expertise
into your hands! • Nov. 4 at 7 a.m. AEDT (Australia)
• Convenient, 1-hour lunchtime sessions
• Join via computer or phone/tablet Sign up TODAY at www.sonnax.com/webinars
• Ask questions and request additional tech support Can’t make it to the live event? No problem! The recorded
• Download detailed handouts and presentation and slides are posted online after the final
access full webinar after each event session and are freely available anytime you want them.

Contact Sonnax 8:30 a.m. to 5 p.m. ET (800) 843-2600 • fax (802) 463-4059 • www.sonnax.com
 Transmission Tech Bulletin
Introducing Sonnax
Remanufactured
Valve Bodies

Save time and money with

a quality rebuilt valve body
from Sonnax.
Every premium valve body is completely disassembled,
cleaned, updated, solenoids tested and replaced as needed.
Each remanufactured unit is then hydraulically and
electronically tested so it’s ready to bolt up!
• Rebuilds feature genuine Sonnax parts. Ask Your Parts Distributor
• Backed by Limited Lifetime Warranty. for Sonnax Remanufactured
• No tools? No problem. Plug-and-play valve bodies Valve Bodies
save labor and tool costs in your shop.
• Get the job out the door fast. Stock up on off-the-shelf solutions for your in-demand repairs.

Find these & 200+ more remanufactured valve bodies at www.sonnax.com!

Unit Application Details Part No.
01M, 01N, 01P ‘99-Later VW204
Large Cans, Cooler on Case with Switches AW6VWF1
09G, 09K, 09M, TF-60SN
Large Cans, Cooler on Case without Switches AW6VWF3
4R70W, 4R75W ‘01–‘08 F095
4T65-E ‘03-Later GM037
Volvo, Early, No Letter or “A” Casting, No B5 Spring AW55VE
55-50SN, 55-51SN Volvo/Nissan, Late, “B” or “C” Casting, No B5 Spring AW55VL
Volvo/Nissan, ‘05-Later, with B-5 Spring AW55NL
5R55E ‘97-Later with 4.0L F056
5R55S, 5R55W ‘01–‘08 F032
CD4E F7 Casting, without Solenoid Pack FM067
FNR5 F025
JF506E VW VW506
Saturn TAAT Late ‘92-Later SAT005
TF-80SC AW6VF
TF-81SC AW6FMF
‘00–‘05, without Central Lube Feed TOY171
U140E, U140F, U240E, U241E
‘00–‘05, with Central Lube Feed TOY172
U151E, U151F, U250E ‘04–‘14 TOY181
2 Transmission Report • October 2015
 Introducing the Sonnax

48RE Converted Valve Body

The breakthrough solution to the 48RE valve body shortage!
Patent-pending innovation allows Sonnax to convert
plentiful early-model RE Chrysler cores into premium-quality 48REs.

Part No. CHR135

100% Tested to ensure pressure curves and timing match 48RE OE design.
Refurbished and improved with Sonnax parts.
Great for pressure and lockup upgrades in 46/47RE.

OE remanufactured valve bodies – while competitively priced – undergo only minimal restoration.
The Sonnax 48RE provides far more value and durability. Each valve body is carefully refurbished
in critical areas to restore proper function and prevent future wear.
• Upgraded Manual Valve • Oversized 4-Spool Switch Valve
• Oversized Throttle Valve Kit • Patented Pressure Curve Components
• Valve Body Detent Ball & Sleeve Kit • Patented Lockup Conversion Components
• Oversized Lube Reg. PR Valve • 3-4 Accumulator Spring
& Line/TV Pressure Plug Kit • New Governor Pressure Solenoid & Sensor

©2015 Sonnax Industries, Inc. 3

 2
3
Transmission Tech Bulletin
5

Upper
Valve Body

Lower
Valve Body

Mercedes 722.9 Valve Body Repairs

Symptoms Description Part No. Tooling
• Low cooler & lube pressure
• Harsh TCC apply & release 1 Oversized Lubrication PR Valve Kit 88740-09K F-88740-TL9 & VB-FIX
• Erratic TCC apply pressure
• Erratic line pressure
2 Oversized Working PR Valve
• Poor shift quality 88740-01 F-88740-TL & VB-FIX
Replaces early- & late-style OE valves.
• Burnt clutches
• Bump shifts
• 2-3 Flare/Harsh 3 Oversized K1 Regulator Valve 88740-08 F-88740-TL8 & VB-FIX
• 5-6 Flare/Harsh
• Harsh engagement
• Delayed Forward & Reverse 4 Oversized B2/BR Regulator Valve Kit 88740-04K F-88740-TL4 & VB-FIX
• 4-5 Flare/Harsh
• K3 clutch burned
• 4-5 Flare/Harsh 5 Oversized K3 Shift Valve Kit 88740-06K F-44892-TL3 & VB-FIX
• No Forward
• Solenoid codes
6 Oversized Solenoid Regulator Valve
• Wrong gear starts 88740-02 F-88740-TL2 & VB-FIX
Fits either of two locations.
• Burnt clutches

4 Transmission Report • October 2015

Sneak Peek at Sonnax - Powertrain Expo 2015
Talk shop with the Sonnax team and get the scoop on the hottest
new transmission products at the industry’s biggest tradeshow,
Oct. 29 to Nov. 1 at the Rio All-Suite Hotel & Casino in Las Vegas.
• Remanufactured valve bodies
• Dodge diesel performance & heavy-duty upgrades
(grab the new catalog at the show or request one online)
• 6R140, 722.9 & U660E rebuild components
• Vacuum testing & reaming demos

Get your FREE Tradeshow Pass to the Oct. 30 and 31 Exhibit Hall
Days by visiting the Expo event on the Sonnax Facebook page.

ZF6HP & 6R80 Precision Bushings

Restore Critical Clearances without Machining
ZF6HP and Ford 6R80 OE bushing material is soft and prone to premature wear, a critical flaw
that leads to bushing failure and loss of pressure, resulting in gear ratio or solenoid codes.
To address this weakness, Sonnax ZF bushings are made from an upgraded bimetal material
that prevents premature wear. An innovative manufacturing process delivers a finished-in-place
tolerance for easy, press-in installation.

6R80 ZF6HP19 ZF6HP21 ZF6HP26 Bushing Type Fits Journal Dia. Part No.

ü ü Rear Stator Support 25.97mm/1.022" Input 95030-01

ü ü Rear Stator Support 29.96mm/1.180" Input 95030-02

ü ü “A” Drum Front 59.77mm/2.353" 95030-03

ü ü “A” Drum Rear 49.97mm/1.967" 95030-04

ü ü ü Input/Output 16.98mm/.669" 95030-05

ü ü Sun Gear 24.17mm/.952" 95030-06

ü ü “B” Direct Clutch 33.97mm/1.337" 95030-07

ü ü Front Stator Support 24.17mm/.952" 95030-09

©2015 Sonnax Industries, Inc. 5

 Transmission Tech Bulletin
Missed It by “That Much”
Measure the TCC Plunger Valve to Avoid RE5R05A Pressure Problems
Do you remember the old show Get Smart, with Agent 86 (aka Maxwell As solenoid pressure ramps up, it allows line
Smart)? One of his more famous lines was “Missed it by that much!,” pressure to be regulated into TCC apply
typically stated when he had missed something by a considerable pressure. Some of this TCC apply pressure
bit. Sometimes it can be like that with valve bodies, when details are also is routed to the small TCC control sleeve
important, but easily overlooked. Unfortunately, the consequences in and plunger valve to help properly balance the
the shop of missing some details don’t result in canned laughter, but a control valve and set the TCC apply pressure.
potential comeback.
Looking at this small plunger valve assembly
Recent examination of early and late RE5R05A 1st through 4th design in the noted Jatco/Nissan valve bodies, it
valve bodies as well as an RE7R01A highlight how small variations in might be easy to assume they are all the same.
critical valve dimensions can impact functionality. In these valve bodies, In fact, the plunger valves vary in diameter,
the TCC control valve is stroked by the TCC solenoid (Figure 1). which has a significant impact on TCC apply
pressure between the different applications.
TC Return Figure 2 shows what the pressures should be
Pressure for each design, assuming a 65 psi pilot valve
Figure 1 Line Pressure TCC Solenoid
feed pressure to the TCC solenoid. With
Pressure Pressure
the RE7R01A being similar in size to the
TCC Apply TCC Apply TC Charge later RE5R05As, it stands to reason that the
Pressure Pressure Pressure pressures would be similar as well.

The Perils of Mismatched Plungers

What would happen if we mistakenly place a
late-design RE5R05A plunger valve assembly
in an early valve body (or vice versa)? What
about if we put an early RE5R05A plunger
in an RE7R01A valve body? Figure 3 shows
the TCC apply pressures that would result:
between a 26 and 34 psi swing for each
Figure 2
application!
Matched TCC Apply
Application Plunger Valve Pressure The consequences of a mismatched plunger
Early RE5R05A (1st & 2nd Design) .239" Dia. 92 psi assembly are detrimental to converter
function, but the problems vary depending
Late RE5R05A (3rd & 4th Design) .282" Dia. 66 psi
on valve body design.
RE7R01A .298" Dia. 62 psi
While in Drive, the TCC in early RE5R05A
truck or sedan applications goes to full lock-up
in 5th gear and is allowed slip lockup in 4th
Figure 3
and 5th gears. So reducing TCC apply pressure
Mismatched TCC Apply
by incorrect assembly in early RE5R05As
Application Plunger Valve Pressure
could result in unintentional slipping, lack of
.282" Dia. complete lockup and a burnt converter clutch
Early RE5R05A (1st & 2nd Design) 66 psi
(Late RE5R05A) leading to loss of fuel economy.
.239" Dia.
Late RE5R05A (3rd & 4th Design) 92 psi
(Early RE5R05A)

.239" Dia.
RE7R01A 96 psi
(Early RE5R05A)

6 Transmission Report • October 2015

To guard against TCC apply pressure problems in
RE5R05A units, verify that the diameter of the TCC
control valve plunger matches the correct application: Measure
Plunger Valve Diameter
• .239" Valve Dia. for Early RE5R05A (1st & 2nd Design)
• .282" Valve Dia. for Late RE5R05A (3rd & 4th Design)

3rd Design

Large N to R
Accumulator

Lockup in Drive is controlled differently in late RE5R05As. Sedans lockup in 5th and have slip lockup
available in 3rd through 5th gears; trucks lockup in 4th or 5th gear and have slip lockup available in
3rd gear. Inadvertently increasing TCC apply pressure in these applications could result in driveability
complaints related to a lack of power and harsh converter apply.

In the RE7R01A, the converter clutch is designed to slip lockup in 2nd through 7th gear, with full lockup
in 7th gear, so increased TCC apply pressure also would cause harsh converter apply and a lack of power.
Other complaints may be related to a lack of engine performance, as the TCC would be applied more than
it should be during TCC slip mode, especially in 2nd through 4th gears.

Although the late RE5R05A and RE7R01A TCC control plunger valve diameters only differ by .016", it’s
best not to inadvertently mix those assemblies. Figure 4 shows the results of swapping these sizes. While
not as startling in overall pressure variance from the OE, the percentage of pressure difference is significant
enough to raise a cautionary flag.

Figure 4
TCC Apply Pressure
Application With Matched Valve With Mismatched Valve % Change
Late RE5R05A (3rd & 4th Design) 66 psi 59 psi -11%
RE7R01A 62 psi 69 psi +11%

So don’t “miss it by that much!" When replacing the TCC control plunger valve for wear or other reasons in
these Jatco/Nissan units, pay close attention to the size of the valve. Visit www.sonnax.com for additional
valve body guides that will help you identify the various RE5R05A design configurations.

©2015 Sonnax Industries, Inc. 7

 Sonnax Industries Inc.
1 Automatic Drive
P.O. Box 440
Bellows Falls, VT
TIME TESTED • INDUSTRY TRUSTED 05101-0440

Transmission Report
Volume 6, No. 3 October 2015

Featured in this issue

• Remanufactured Valve Bodies
• Solenoid Strategies Webinar
• 722.9 Valve Body Repairs
• ZF6HP & 6R80 Precision Bushings
• RE5R05A Pressure Problems
• What’s New for Powertrain Expo 2015

To update your address or request to stop this mailing, Sonnax designs, manufactures, tests and distributes a wide variety of components
please call (800) 843-2600, 8:30 a.m. to 5 p.m. ET, used to remanufacture torque converters, rebuild automatic transmissions, upgrade
or e-mail to [email protected]. driveshafts and protect the driveline from over-torque damage.

Sonnax is a 100% Employee-Owned Company

CASH for Solenoid Cores

Sonnax Makes It FAST & EASY to Return These Solenoid Cores
1. Collect Cores Both OE and remanufactured cores are accepted. Five or more cores is recommended.
2. Contact Sonnax Visit www.sonnax.com OR call (800) 843-2600, Ext. 379, OR e-mail [email protected].
3. S
 hip Your Cores Sonnax pre-pays all shipping charges and provides labels.
4. Get Paid! Sonnax sends you a check in the mail.

45RFE/545RFE/68RFE 45RFE/545RFE 62TE AX4N/4F50N

‘04-Later ‘03-Earlier & AXODE/AX4S E40D/4R100

ZF6HP19/26/32
Honda Dual Linears Aisin AW 5- & 6- Speed Yellow or Blue Capped 5R55W/S

Start a core return online and find purchase program details at www.sonnax.com.