Toyota/Lexus 40E, 40F 00-LTER, V6 & V8 ZIP KIT PRT NUMER 40-LTE-ZIP QUIK GUIDE NOTE: Type 4 EP-style valve body is shown. Parts will fit in the same locations in a throttle cable-style and Type EP-style valve body except where noted. Parts are labeled here in order of installation. See other side of sheet for details on kit contents. 9 installation Diagram * Not used on Type valve bodies. * Upper Valve ody Type 4 Shown 9 0 These checkballs may or may not belong! 0 0 UTION! Note the location of OE checkballs during disassembly! Usage of checkballs vary greatly! 5 UTION: If replacing an OE 6 sleeve with NO dot or three dots, use Sonnax EP valve with flat on large spool diameter. Flat on large spool diameter. Lower Valve ody Type 4 Shown If replacing an OE sleeve with two dots, use Sonnax EP valve with flat on small spool diameter. Flat on small spool diameter. 8 6 6 8 4 If replacing an OE sleeve with two or three dots, do NOT add shims. Discard the Sonnax EP valve that is not used. 7 If replacing an OE sleeve with no dots, add shims. NOTE: Detailed instructions are included on page 8 of installation and testing booklet. 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. 08 Sonnax Transmission ompany, Inc. Marmon / erkshire Hathaway ompany 40-LTE-ZIP-Guide 06--8 866-4-889 856-848-0908 F: 856-848-080 www.sonnax.com Page
Toyota/Lexus 40E, 40F 00-LTER, V6 & V8 ZIP KIT Quick Guide Kit ontents & Installation s Packaging Pocket Replace OE End Plugs Secondary Regulator Valve, Reverse ontrol Valve* *(Type 4 Valve ody Only) End Plugs, Large () O-Rings (4) extra Packaging Pocket Replace OE End Plugs -, - & -4 Shift Valves End Plugs, Medium () O-Rings (5) extra Packaging Pocket Replace OE End Plug nd oast Modulator Valve End Plug, Small O-Rings () extra Packaging Pocket 4 Replace OE End Plug ccumulator ontrol Valve End Plug, Extra Large O-Rings () extra Packaging Pocket 5 Valve 4 5 6 Replace OE Lockup ssembly Sleeve Select orrect Replacement EP oost Valve Look at end of the OE boost sleeve for number of identification dots. If replacing an OE sleeve with NO dots or three dots, use the Sonnax EP boost valve with flat on large spool diameter. If replacing an OE sleeve with two dots, use the Sonnax EP boost valve with flat on small spool diameter. (See page 8 of Installation & Testing ooklet for more details.) Packaging Pocket 6 EP oost Valve EP oost Valve Flat on Large Spool Dia. (for no/three ID dots) Flat on Small Spool Dia. (for two ID dots) ssemble oost ssembly Place small reverse valve into sleeve. Place selected EP boost valve from step 6 into sleeve, smaller diameter first. Place cutback boost valve into sleeve with longer stem facing outboard. Packaging Pocket 7 oost Sleeve Reverse oost Valve utback oost Valve Pressure Regulator Valve Shims Look at the end of OE boost sleeve for the number of identification dots. If replacing an OE sleeve with two or three dots, do NOT add shim. If replacing an OE sleeve with no dots, add both shims. Shims should be added, if used, between the OE washer and pressure regulator valve. (See page 8 of installation and testing booklet for more details.) Packaging Pocket 8 Shim,.05" thick Shim,.0" thick Replace OE Large heckballs See checkball caution notes on page. Packaging Pocket 9 heckballs, Large.50" dia. () 7 8 9 0 Replace OE Small heckballs See checkball caution notes on page. Packaging Pocket 0 heckballs, Small.8" dia. (9) NOTE: These items also are available separately; s,, & 4 Part No. 9774-9K s 6, 7 & 8 Part No. 9774-0K The parts listed here may be protected by patent number 8,955,5. 08 Sonnax Transmission ompany, Inc. Marmon / erkshire Hathaway ompany 40-LTE-ZIP-Guide 06--8 866-4-889 856-848-0908 F: 856-848-080 www.sonnax.com Page
Toyota/Lexus 40E, 40F 00-LTER, V6 & V8 ZIP KIT PRT NUMER 40-LTE-ZIP INSTLLTION & TESTING OOKLET Valve ody Identification This Zip Kit 40-LTE-ZIP is designed for 000-later, V6 & V8 applications using Type (valve body casting identification #895) or Type 4 (valve body casting identification #898) style valve bodies. Type (asting ID #895) Valve ody V8 applications, EP style throttle control only. Type 4 (asting ID #898) Valve ody V6 or V8 applications, EP (shown) or throttle cable style throttle control. Valve ody asting ID Valve ody asting ID SLT Type ontour ID SLT Type 4 ontour ID Figure Type, Upper Valve ody Figure Type 4, Upper Valve ody Separator Plate ID Valve ody asting ID T ontrol Valve (visible here if used) Separator Plate ID Valve ody asting ID T ontrol Valve (visible here if used) Pressure Regulator Valve (visible) Pressure Regulator Valve (visible) S Shift S Shift SL Shift S Shift S Shift SL Shift ccumulator Piston ssembly Type ontour ID ccumulator Piston ssembly Pressure Relief heck Valve Type 4 ontour ID lternate onfiguration: May have same lineup as Type, Figure Pressure Relief heck Valve Figure Type, Lower Valve ody Figure 4 Type 4, Lower Valve ody 08 Sonnax Transmission ompany, Inc. Marmon / erkshire Hathaway ompany 40-LTE-ZIP-ooklet 06--8 866-4-889 856-848-0908 F: 856-848-080 www.sonnax.com Page
Toyota/Lexus 40E, 40F 00-LTER, V6 & V8 ZIP KIT Installation & Testing ooklet olt Locations & Torque Specifications Torque Specifications Detent Spring olt 89 in-lbs (0 N.m) Oil Pan olt 65 in-lbs (7. N.m) Type Valve ody to ase olts olt olor ode olt Length Red mm Green 8mm Type 4 Valve ody to ase olts olt olor ode olt Length Purple mm White 8mm Type & 4 Oil Pan Filter olts olt olor ode olt Length Pink 4mm lack 0mm Type & 4 Valve ody Disassembly olts olt olor ode olt Length Lt. Purple 0mm Teal 8mm -to-valve ody olt 89 in-lbs (0 N.m) lue 6mm Torque all to 8 ft-lbs Yellow 6mm Torque all to 8 ft-lbs Orange mm Torque to 7 ft-lbs rown 40mm Torque to 57 in-lbs Type (asting ID #895) Valve ody V8 applications, EP style throttle control only. Type 4 (asting ID #898) Valve ody V6 or V8 applications, EP (shown) or throttle cable style throttle control. Figure 5 Figure 7 Type, Lower Valve ody, ase Removal - olt Locations Type 4, Lower Valve ody, ase Removal - olt Locations Figure 6 Figure 8 Type, Upper Valve ody, Valve ody Disassembly - olt Locations Type 4, Upper Valve ody, Valve ody Disassembly - olt Locations 06--8 40-LTE-ZIP-ooklet 08 Sonnax Transmission ompany, Inc. Marmon / erkshire Hathaway ompany Page 800-84-600 80-46-97 F: 80-46-4059 www.sonnax.com
Toyota/Lexus 40E, 40F 00-LTER, V6 & V8 ZIP KIT Installation & Testing ooklet lutch & and pplication hart Figure 9 Shift hart Figure 0 Selector Position - Gear Park 0 0 F0 F F ON Reverse ON ON ON ON Neutral ON D-st Gear ON ON ON ON D-nd Gear ON ON ON ON ON D-rd Gear ON ON ON ON ON D-Overdrive ON ON ON ON -st Gear ON ON ON ON -nd Gear ON ON ON ON ON ON -nd Gear ON ON ON ON ON Low-st Gear ON ON ON ON ON Low-nd Gear ON ON ON ON ON ON Diagnostic Trouble hart DT P0750 P075 P0755 P0758 P0770 P077 Description Shift S ()/S () Malfunction Shift S ()/S () Electrical Malfunction Shift S ()/S () Malfunction Shift S ()/S () Electrical Malfunction Shift SL (E) Malfunction Shift SL (E) Electrical Malfunction Figure Selector Position - Gear Shift S Shift S D - st Gear ON Off D - nd Gear ON ON D - rd Gear Off ON D - Overdrive Off Off - st Gear ON Off - nd Gear ON ON - rd Gear Off ON Low - st Gear ON Off Low - nd Gear ON ON Shift Strategies The computer (EM) controls the ON/Off combination of the shift solenoids S () and S () to shift between st gear and overdrive (O/D). If an electrical failure occurs in one of these two solenoids, the computer continues to control the other solenoid to allow the vehicle to operate as smoothly as possible while in Fail Safe mode. The EM also turns off the SL (E) solenoid during Fail Safe. Should both solenoids S () and S () fail, shifting must be done manually. Figures and give typical solenoid codes and solenoid malfunctioning shift strategies. Figure 4 Malfunctioning Shift Strategies Figure Selector Position - Normal Gear Shift S () Malfunctioning S () S () Gear Shift S () Malfunctioning S () S () Gear oth s Malfunctioning Gear When selector position in manually operated D-st Gear X ON rd ON X st Overdrive D-nd Gear X ON rd Off X O/D Overdrive D-rd Gear X ON rd Off X O/D Overdrive D-Overdrive X Off O/D Off X O/D Overdrive -st Gear X ON rd ON X st rd -nd Gear X ON rd Off X rd rd -nd Gear X ON rd Off X rd rd Low-st Gear X Off st ON X st st Low-nd Gear X ON nd ON X st st Figure To test shift solenoids S (), S () or SL (E) for sticking, force 7 psi of compressed air into the snout (Figure, arrow); it should not leak. Energizing the solenoids should cause them to open and allow air flow. Resistance on these three shift solenoids should be 5 ohm at 68 F, and resistance on the SLT solenoid should be 5.0 5.6 ohm at 68 F. Some valve bodies have an accumulator piston assembly (Figure 4) that can be mistaken for a solenoid. This is actually an accumulator for lockup and should be checked to ensure the piston can move freely. 08 Sonnax Transmission ompany, Inc. Marmon / erkshire Hathaway ompany 40-LTE-ZIP-ooklet 06--8 800-84-600 80-46-97 F: 80-46-4059 www.sonnax.com Page
Toyota/Lexus 40E, 40F 00-LTER, V6 & V8 ZIP KIT ritical Wear reas & Vacuum Test Locations Installation & Testing ooklet 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 and Sonnax parts noted for replacement. Upper Valve ody Type, EP Style Shown Here 9 4. Primary Regulator Valve Low line pressure High line pressure Poor shift quality Low lube oil flow urnt clutches 9774-06K EP valve spool.46 dia.; replaces OE -dot boost sleeve 9774-0K EP valve spool.5 dia.; replaces OE -dot or no-dot boost sleeve 9774-06K & 9774-0K: Requires F-9774-TL6 & V-FIX. oost ssembly Delayed Forward or Reverse Soft shifts Low pressure 9774-0K* 0 5. T ontrol Valve & Plunger ssembly T apply & release concerns T codes Overheated fluid urnt converter 974-0K Lower Valve ody Type, EP Style Shown Here 4. Secondary Regulator Valve T apply & release concerns urnt T apply components Overheated transmission ushing wear 9774-8K Requires F-974-TL8 & V-FIX 5. Lockup Relay Valve & Plunger ssembly T apply & release concerns T codes RPM fluctuation Inadequate lubrication ushing failure Overheated fluid 7774-0K* Lockup Relay ontrol Valve Kit 9774-0K Oversized Lockup Relay Valve Kit 9774-0K: Requires F-9774-TL0 & V-FIX 8 6 7 6. Secondary Modulator Valve Shift concerns codes *Part numbers with an asterisk (*) are included in this Zip Kit. 06--8 40-LTE-ZIP-ooklet 08 Sonnax Transmission ompany, Inc. Marmon / erkshire Hathaway ompany Page 4 800-84-600 80-46-97 F: 80-46-4059 www.sonnax.com
Toyota/Lexus 40E, 40F 00-LTER, V6 & V8 ZIP KIT Installation & Testing ooklet 5 0 5 0 0 0 VUUM TEST 5 For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com. 7. ccumulator ontrol Valve Shift concerns codes Loss of throttle/line pressure Upper Valve ody Type 4, EP Style Shown Here 4 4 8. utback Valve No kickdown Loss of throttle pressure 9. Low oast Modulator Valve urnt st/reverse brake () Loss of manual low 0. nd oast Modulator Valve urnt nd brake () Loss of manual nd. 4 Shift Valve 4 oncerns. Shift Valve oncerns 0 Lower Valve ody Type 4, EP Style Shown Here 5. Shift Valve oncerns 4. Reverse ontrol Valve Delayed Reverse No Reverse 5. End Plugs Soft shifts Low line rise Slips & flares 9774-9K* NOTE: Several Locations = 8 6 7 9 08 Sonnax Transmission ompany, Inc. Marmon / erkshire Hathaway ompany 40-LTE-ZIP-ooklet 06--8 800-84-600 80-46-97 F: 80-46-4059 www.sonnax.com Page 5
OE Exploded View Upper & Lower Valve ody Type, EP Style Shown Here NOTE: Depending upon vehicle application, the OE springs shown may not be present. heckball autions & Notes Toyota/Lexus 40E, 40F 00-LTER, V6 & V8 ZIP KIT Installation & Testing ooklet Upper Valve ody - Type 0 are should be taken during disassembly. Note location of checkballs as usage varies greatly! 06 When determining when a checkball is required, the circuit orifice in the separator plate over that location will be about.090" dia. When no ball is required, the orifice will be about.50" dia..50" dia. 0 ll checkballs are.8" dia. except where noted (.50" dia.). 05 Upper Valve ody Descriptions I.D. No. 0 Description Lockup Relay Valve & Plunger ssembly 0 4 Shift Valve 0 nd oast Modulator Valve 04 Low oast Modulator Valve 05 Shift Valve 06 Secondary Regulator Valve 07 04 Lower Valve ody - Type.50" dia. Orifice 0 Separator Plate.090" dia. Orifice Lower Valve ody Descriptions I.D. No. Description 0 ccumulator ontrol Valve 0 Secondary Modulator Valve 0 utback Valve 04 Primary Regulator Valve & oost ssembly 05 onverter Limit Valve 06 Manual Valve 07 Shift Valve 06 05 0 0 0 04 NOTE: Filters should be installed into the separator plate during assembly. The open end of the filter snaps into the plate opening. 06--8 40-LTE-ZIP-ooklet 08 Sonnax Transmission ompany, Inc. Marmon / erkshire Hathaway ompany Page 6 800-84-600 80-46-97 F: 80-46-4059 www.sonnax.com
Toyota/Lexus 40E, 40F 00-LTER, V6 & V8 ZIP KIT Installation & Testing ooklet Upper & Lower Valve ody Type 4, EP Style Shown Here NOTES: Depending upon vehicle application, the OE springs shown may not be present. Slight wormtrack difference and valve components will vary in throttle cable style valve bodies. Upper Valve ody - Type 4 0 08 Upper Valve ody Descriptions I.D. No. Description 0 Lockup Relay Valve & Plunger ssembly.50" dia. 0 0 4 Shift Valve 0 nd oast Modulator Valve 07 04* heck Valve 06 05* 0 05* heck Valve 06 Reverse ontrol Valve 07 Shift Valve 08 Secondary Regulator Valve 04* *Not in throttle cable style..090" dia. Orifice Please review heckball autions & Notes as well as Filter Note on page 6 as they apply to both Type & Type 4 valve bodies. Lower Valve ody - Type 4 Separator Plate.50" dia. Orifice Lower Valve ody Descriptions Large Filter I.D. No. Description 09 0 ccumulator ontrol Valve 0 Secondary Modulator Valve 08 0 utback Valve 04** T ontrol Valve & Plunger ssembly Teardrop Filter 0 0 0 05 Primary Regulator Valve & oost ssembly 06 onverter Limit Valve 07 Manual Valve 08 Shift Valve 04** 09 Low oast Modulator Valve **Not in all applications 07 Small Filter 05 06 08 Sonnax Transmission ompany, Inc. Marmon / erkshire Hathaway ompany 40-LTE-ZIP-ooklet 06--8 800-84-600 80-46-97 F: 80-46-4059 www.sonnax.com Page 7
Toyota/Lexus 40E, 40F 00-LTER, V6 & V8 ZIP KIT Installation & Testing ooklet Detailed Instructions for s 6 to 8 from Quick Guide For Replacing a No Dot OE oost Valve ssembly Figure 5 dd Sonnax Shims Under OE Washer hoose Sonnax EP oost Valve with Flat on Large Diameter Primary Regulator Valve & oost ssembly ore For Replacing a Dot OE oost Valve ssembly Figure 6 Do NOT add Sonnax Shims Here hoose Sonnax EP oost Valve with Flat on Small Diameter Primary Regulator Valve & oost ssembly ore For Replacing a Dot OE oost Valve ssembly Figure 7 Do NOT add Sonnax Shims Here hoose Sonnax EP oost Valve with Flat on Large Diameter Primary Regulator Valve & oost ssembly ore 06--8 40-LTE-ZIP-ooklet 08 Sonnax Transmission ompany, Inc. Marmon / erkshire Hathaway ompany Page 8 800-84-600 80-46-97 F: 80-46-4059 www.sonnax.com