Aw60 40le Zip in
Aw60 40le Zip in
Aw60 40le Zip in
ZIP KIT
PART NUMBER AW60-40LE-ZIP
QUICK GUIDE
NOTE: This Zip Kit AW60-40LE-ZIP is designed for 60-40LE (AF-13) applications only.
A separate Zip Kit AW60-41SN-ZIP is available for 60-41SN (AF-17) applications.
No
Number 2
Rear Control
Body
Has a
Number 2
Rear Control
Body
Has a
Short TCC
Solenoid
Has a
Long TCC
Solenoid
Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents.
installation Diagram
3
OE Assembly Shown
Shim
Location
Lowest of three OE
sleeve steps.
Front Control
Valve Body
7
9
Checkballs
10 Small
1 Large
In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum testing
and additional repair options for higher mileage units or for repairing specific complaints which are beyond the scope of this kit.
2015 Sonnax Industries, Inc.
800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com
AW60-40LE-ZIP-Guide02-11-15
Page 1
Quick Guide
Step 6 R
eplace OE Solenoid
O-Rings
Packaging Pocket 6
1 extra
Packaging Pocket 1
Step
1 extra
Replace OE Accumulator
Plunger Valve Assembly
Packaging Pocket 7
Valve Sleeve
Packaging Pocket 2
Valve Sleeve
Step
Step 8 R
eplace OE Secondary
Regulator Valve End Plug
Replace OE B1 Modulator
Plunger Valve Assembly
Packaging Pocket 8
1 extra
Packaging Pocket 3
Checkballs
Packaging Pocket 9
2 extra
1 extra
AW60-40LE-ZIP-Guide02-11-15
Page 2
Torque Specifications
NOTE: This Zip Kit AW60-40LE-ZIP is designed for 60-40LE (AF-13) applications only.
A separate Zip Kit AW60-41SN-ZIP is available for 60-41SN (AF-17) applications.
Transaxle Side
Cover Bolt
18 ft-lb
Manual Detent
Spring Bolt
90 in-lb
Front-Valve-Body-toRear-Valve-Body Bolt
60 in-lb
Solenoid-to-ValveBody Bolt
60 in-lb
Valve-Body-toTransaxle Bolt
90 in-lb
Fluid Chart
Has a
Short TCC
Solenoid
Approximate Capacity,
Drain and Fill
2.9 qt (2.7L) - 1.6L
2.9 qt (2.7L) - 1.8L
Has a
Long TCC
Solenoid
60-41SN (AF-17) Valve Body
Clutch
Forward
Coast
X
X
2
L
OD
1st-Reverse
1-Way Clutch
2nd-4th
No. 1
No. 0
Brake
Reverse
X
X
X
X
X
X
X
X
X
X
AW60-40LE-ZIP-Booklet02-11-15
Page 1
Solenoids
Solenoid
Position
No. 1
Bolt Color
Code
Bolt
Length
Yellow
10mm
Red
16mm
Orange
20mm
Green
38mm
Blue
50mm
No. 2
X
1
X
X
4
2
L
TCC
X1
X1
No. 1
TCC Solenoid
1115 ohm
No. 2
Throttle Pressure
Control Solenoid
35 ohm
Shift Solenoids
(interchangeable)
1115 ohm
Figure 2
02-11-15AW60-40LE-ZIP-Booklet
Page 2
Figure 3
1. V
alve Body Disassembly
(continued)
Figure 4
2. Installation
Install Zip Kit parts as shown on diagram of
separate quick guide sheet included in this Zip Kit.
Bolt installation
torque specifications
are 60 in-lb.
Figure 5
c. F
lip the valve body over.
d.
Loosely install the four bolts (Figure 4), and
torque the four bolts to 60 in-lb.
e.
Place the front valve body cover, gasket and
separator plate onto the front valve body.
Reinstall the two shift solenoids and loosely
install the two bolts (Figure 3).
Bolt installation
torque specifications
are 60 in-lb.
Figure 6
Bolt installation
torque specifications
are 96 in-lb.
Bolt Color
Code
Bolt
Length
Yellow
10mm
Red
16mm
Orange
20mm
Green
38mm
Blue
50mm
AW60-40LE-ZIP-Booklet02-11-15
Page 3
B1 Modulator Valve
B1 Modulator
Plunger Valve
Shift complaints in 2nd & 4th
Replace with Sonnax Part No.
19741-03K*
20
15
10
25
0
30
VACUUM
TEST
Seal
Seal
Reverse Boost
Assembly
Low reverse pressure
Delayed reverse
Replace with Sonnax Part No.
19741-07K*
End Plugs
Burnt clutches/brakes
Various shift complaints
Replace with Sonnax Part No.
19741-13K*
NOTE: Several Locations =
AW60-40LE-ZIP-Booklet02-11-15
Page 5
20
15
10
25
NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed
to with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.
0
30
VACUUM
TEST
Low Coast
Modulator Valve
Burned 1st & reverse clutch
Delayed engagement reverse
or 1st in manual low
NOTE: Test both at the same time.
Lockup
Control Valve
Reverse Clutch
Accumulator Piston
Burned reverse clutch
Delayed reverse
Bump in reverse
Lockup complaints/codes
Secondary
Regulator
Valve
TCC complaints
Loss of lube
End Plugs
Burnt clutches/brakes
Various shift complaints
Replace with Sonnax Part No.
19741-13K*
NOTE: Several Locations =
2nd/4th Brake
Modulator
Control Valve
Burned 2-4 brake
Shift complaints in
2nd & 4th
OE Exploded View
Front Control Valve Body - Cover Side (Separator Side Inset) Shown Here
106
Front Control Valve Body Descriptions
I.D. No.
105
Description
101
102
103
B1 Modulator Valve
& Plunger Assembly
104
105
106
107
104
107
Check
Valve
Check Valve
Filter
Filter
Front Control Valve Body
(Separator Side)
102
103
101
2015 Sonnax Industries, Inc.
800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com
AW60-40LE-ZIP-Booklet02-11-15
Page 7
OE Exploded View
Rear Control Valve Body
212
208
209
211
210
Check
Valve
Filter
I.D. No.
201
202
203
204
205
Reverse Clutch
Accumulator Piston
206
2nd/4th Brake
Accumulator Piston
207
Manual Valve
208
Forward Clutch
Accumulator Piston
209
Overdrive Clutch
Accumulator Piston
210
211
212
02-11-15AW60-40LE-ZIP-Booklet
Page 8
Check
Valve
Description
Check
Valve
203
206
207
202
204
205
201