Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                

Aw60 40le Zip in

Download as pdf or txt
Download as pdf or txt
You are on page 1of 10

AISIN AW 60-40LE (AF-13)

ZIP KIT
PART NUMBER AW60-40LE-ZIP

Valve Body Identification

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

60-40LE (AF-13) Valve Body

Has a
Short TCC
Solenoid

Has a
Long TCC
Solenoid

60-41SN (AF-17) Valve Body

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.

Check which step the retainer location sleeve


is on, to determine how many shims (if any) are
required for Sonnax replacement assembly.

Front Control
Valve Body

7
9

Checkballs
10 Small
1 Large

Rear Control Valve Body

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

Aisin AW 60-40LE ZIP KIT

Quick Guide

Zip Kit Contents & Installation Steps


Step 1 Replace OE Reverse
Boost Assembly

Step 6 R
 eplace OE Solenoid
O-Rings

Observe the step location of the retainer on OE sleeve prior to removal.


If set at the lowest step, do not use the Sonnax shims. If set at middle
step, use one Sonnax shim. If set at the highest step, use two Sonnax
shims. Shims should be place on inboard sleeve diameter.

Packaging Pocket 6

O-Rings, Small (4)

1 extra

Packaging Pocket 1

Valve Sleeve Shims (3)

Step

1 extra

7 Replace OE Lockup Control


Step 
Plunger Valve Assembly

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

End Plug, Large O-Rings, Large (2)

1 extra

Discard OE retainer and use replacement pin to retain lineup.

Step 9 Replace OE Checkballs

Packaging Pocket 3

Valve Sleeve Retaining Pin

Checkballs
Packaging Pocket 9

Checkballs, Small .218" dia. (10) Checkball, Large .250" dia.

Step 4 Replace OE End Plugs


Packaging Pocket 4

End Plugs, Medium (2) O-Rings, Medium (4)

2 extra

Step 5 Replace OE End Plug


Packaging Pocket 5

End Plug, Large O-Rings, Large (2)

1 extra

2015 Sonnax Industries, Inc.


800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

AW60-40LE-ZIP-Guide02-11-15
Page 2

AISIN AW 60-40LE (AF-13)


ZIP KIT
PART NUMBER AW60-40LE-ZIP

INSTALLATION & TESTING BOOKLET

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

Valve Body Identification

Manual Shift Lever Nut


60 in-lb

Front Valve Body


Cover Bolt
18 ft-lb

Front-Valve-Body-toRear-Valve-Body Bolt
60 in-lb

Rear Valve Body


Cover Bolt
96 in-lb

Solenoid-to-ValveBody Bolt
60 in-lb

Valve-Body-toTransaxle Bolt
90 in-lb

60-40LE (AF-13) Valve Body: Use this kit.


No
Number 2
Rear Control
Body

Fluid Chart

Has a
Short TCC
Solenoid

Recommended Capacities: Dexron-III ATF


Approximate Capacity,
Complete Overhaul
6.0 qt (5.7L) - 1.6L
6.2 qt (5.9L) - 1.8L

Approximate Capacity,
Drain and Fill
2.9 qt (2.7L) - 1.6L
2.9 qt (2.7L) - 1.8L

60-40LE (AF-13) Valve Body

60-40LE (AF-13) Valve Body

60-41SN (AF-17) Valve Body: Use AW60-41SN-ZIP kit.


Has a
Number 2
Rear Control
Body

Has a
Long TCC
Solenoid
60-41SN (AF-17) Valve Body

60-41SN (AF-17) Valve Body

Component Apply Chart


Position

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

2015 Sonnax Industries, Inc.


800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

X
X

X
X

AW60-40LE-ZIP-Booklet02-11-15
Page 1

TIME TESTED INDUSTRY TRUSTED

Aisin AW 60-40LE ZIP KIT

Installation & Testing Booklet

Solenoids

Solenoid Apply Chart

This 60-40LE unit uses four solenoids (Figure 1).


The S1 (shift solenoid no. 1) and S2 (shift
solenoid no. 2) are an on/off style, operated by
the TCM to control the various shifts. These two
solenoids are interchangeable.
The TCC control solenoid is an on/off style
controlled by the TCM to operate the converter
clutch.
The throttle pressure control liner solenoid is
modulated by the TCM to regulate line pressure.

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

On only when TCC is operating.

Zip Kit Instructions


Figure 1

1. Valve Body Disassembly


NOTE: See color charts for bolt lengths.

a. Remove the 13 bolts (Figure 2).


b. Remove the small cover, TCC control solenoid,
throttle pressure control solenoid (Figure 1) and
brackets.
c. Remove the two bolts (Figure 3), two shift solenoids (Figure 1) and front valve body cover,
separator plate and gasket.
d. Remove the three checkballs, two oil filters, one
check valve and spring, four bolts and one bracket (Figure 4).

No. 1
TCC Solenoid
1115 ohm

No. 2

Test all four solenoids at


20C/68F.

Throttle Pressure
Control Solenoid
35 ohm

Shift Solenoids
(interchangeable)
1115 ohm

Figure 2

Bolt installation torque specifications are 60 in-lb.

02-11-15AW60-40LE-ZIP-Booklet
Page 2

Figure 3

Bolt installation torque specifications are 60 in-lb.

2015 Sonnax Industries, Inc.


800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

Aisin AW 60-40LE ZIP KIT

Installation & Testing Booklet

1. V
 alve Body Disassembly
(continued)

TIME TESTED INDUSTRY TRUSTED

Figure 4

e. Flip valve body over and remove five bolts. Lift


rear valve body and separator plate off of front
valve body (Figure 5).
f. Remove 11 bolts to access valves retained under
the two rear valve body covers (Figure 6).

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.

3. Valve Body Assembly


a. 
Reinstall the two rear valve body covers and
loosely install the 11 bolts (Figure 6), then torque
to 96 in-lb.
b. Reinstall the separator plate, gasket and rear valve
body onto the front valve body (first ensuring all
checkballs, check valves and filters are in proper
locations). Loosely install the five bolts (Figure 5),
then torque to 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.

f. Reinstall the brackets, throttle pressure control


solenoid, TCC control solenoid (Figure 1) and
small cover.
g. Loosely install the 13 bolts (Figure 2) and then
torque all 15 bolts to 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

2015 Sonnax Industries, Inc.


800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

AW60-40LE-ZIP-Booklet02-11-15
Page 3

TIME TESTED INDUSTRY TRUSTED

Aisin AW 60-40LE ZIP KIT

Installation & Testing Booklet

Critical Wear Areas & Vacuum Test Locations


NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to with an arrow.
Springs are not shown for visual clarity. Low vacuum reading indicates wear.

Front Control Valve Body - Separator Plate Side Shown Here

B1 Modulator Valve

1-2 Shift Valve

Shift complaints in 2nd & 4th

1-2 Shift complaints


NOTE: Seal port on opposite side of casting.

Pressure Regulator Valve


Low/High line pressure
Soft/Harsh shifts
Converter complaints
Loss of lube

B1 Modulator
Plunger Valve
Shift complaints in 2nd & 4th
Replace with Sonnax Part No.
19741-03K*

2-3 Shift Valve


2-3 Shift complaints
NOTE: Seal port on opposite side of
casting & solenoid port with thumb.

*Part numbers with an asterisk (*)


are included in this Zip Kit.
02-11-15AW60-40LE-ZIP-Booklet
Page 4

2015 Sonnax Industries, Inc.


800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

Aisin AW 60-40LE ZIP KIT

20

15

Installation & Testing Booklet

TIME TESTED INDUSTRY TRUSTED

10

25

0
30
VACUUM
TEST

Front Control Valve Body - Cover Side Shown Here


3-4 Shift Valve
3-4 Shift complaints
NOTE: Seal solenoid port with thumb.

TCC Modulator Valve


Converter slip/shudder/codes
No converter apply
NOTE: Test using non-orificed 2nd/4th
modulator brake control valve.

2-3 Shift Valve


2-3 Shift complaints
NOTE: Seal port on opposite side of casting and
seal solenoid port with thumb.

Seal

Seal

Reverse Boost
Assembly
Low reverse pressure
Delayed reverse
Replace with Sonnax Part No.
19741-07K*

End Plugs

Pressure Regulator Valve


Low/High line pressure
Soft/Harsh shifts
Converter complaints
Loss of lube

Burnt clutches/brakes
Various shift complaints
Replace with Sonnax Part No.
19741-13K*
NOTE: Several Locations =

1-2 Shift Valve


1-2 Shift complaints
NOTE: Seal port on
opposite side of casting.

2015 Sonnax Industries, Inc.


800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

3-4 Shift Valve


3-4 Shift complaints

AW60-40LE-ZIP-Booklet02-11-15
Page 5

TIME TESTED INDUSTRY TRUSTED

Aisin AW 60-40LE ZIP KIT

Installation & Testing Booklet

Critical Wear Areas & Vacuum Test Locations

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

Rear Control Valve Body - Separator Plate Side Shown Here


Coast Clutch
Modulator Valve
Burned coast clutch
NOTE: Test using non-orificed 2nd/4th
brake modulator control valve.

Solenoid Modulator Valve


Shift complaints
NOTE: Test using non-orificed 2nd/4th brake
modulator control valve

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 =

Lockup Control Plunger Valve Kit


Burnt converter TCC codes
TCC apply & release concerns
Replace with Sonnax Part No.
59954-01K

2nd/4th Brake
Modulator
Control Valve
Burned 2-4 brake
Shift complaints in
2nd & 4th

2nd/4th Brake & Foward


Clutch Accumulator Piston
Burned forward clutch Delayed forward
Burned 2-4 brake Bump 2nd & 4th gear

2-3 Timing Valve & Overdrive


Clutch Accumulator Piston
2-3 Shift complaints Bump in 3rd gear
Burned overdrive clutch
NOTE: Test one port while sealing the other.

*Part numbers with an asterisk (*)


are included in this Zip Kit.
02-11-15AW60-40LE-ZIP-Booklet
Page 6

2015 Sonnax Industries, Inc.


800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

Aisin AW 60-40LE ZIP KIT

Installation & Testing Booklet

TIME TESTED INDUSTRY TRUSTED

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

Reverse Boost Assembly


& Pressure Regulator Valve

102

Accumulator Control Valve


& Plunger Assembly

103

B1 Modulator Valve
& Plunger Assembly

104

1-2 Shift Valve

105

2-3 Shift Valve

106

3-4 Shift Valve

107

TCC Modulator Valve

104

107

Check
Valve

Front Valve Body


(Cover Side)

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

Aisin AW 60-40LE ZIP KIT

TIME TESTED INDUSTRY TRUSTED

Installation & Testing Booklet

OE Exploded View
Rear Control Valve Body

212

208

209
211
210

Check
Valve

Filter

Checkball, Large .250" dia.


(All 10 others, Small .218" dia.)

Rear Control Valve Body Descriptions

I.D. No.
201

Secondary Regulator Valve

202

2nd/4th Brake Modulator


Control Valve

203

Low Coast Modulator Valve

204

Solenoid Modulator Valve

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

2-3 Timing Valve

211

Coast Clutch Modulator Valve

212

Lockup Control Valve


& Plunger Assembly

02-11-15AW60-40LE-ZIP-Booklet
Page 8

Check
Valve

Description

Check
Valve

203
206
207

202

204
205
201

2015 Sonnax Industries, Inc.


800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

You might also like