TOYOTA U5E-U50E ZIP KIT PART NUMBER U5E-U50E-ZIP QUICK GUIDE Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents. installation Diagram Upper Valve Body Install with open end out. Medium 5 Small Small 4 Large Large Lower Valve Body 7 Plastic Checkball Shown in places. CAUTION NOTE: Before removing OE boost sleeve, take note of the adjustable step/ pin location and ensure the Sonnax sleeve is installed at the same height/ location. Failure to do so will result in incorrect line pressure. Small 3 Small Cutaway shows a side view of lower valve body with Sonnax boost valve kit installed. 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. 07 Sonnax Industries, Inc. U5E-U50E-ZIP-Guide 0-03-7 800-843-00 80-43-97 F: 80-43-4059 www.sonnax.com
U5E-U50E ZIP KIT Quick Guide Zip Kit Contents & Installation s Packaging Pocket Plunger Valve Plunger Sleeve Packaging Pocket Plunger Valve Plunger Sleeve Replace OE B Plunger Valve & Sleeve Replace OE B Plunger Valve & Sleeve Replace OE Accumulator Piston NOTE: Use in the most worn location. Place O-Ring in deep groove, lubricate with Sonnax Slippery Stick O-LUBE and roll on bench to size. Packaging Pocket 5 Accumulator Piston O-Rings () 5 Replace OE End Plugs Extra Place O-Ring in groove, lubricate with Sonnax Slippery Stick O-LUBE and roll on bench to size. Install all end plugs with the O-Ring outboard. CAUTION 3 Replace OE Boost Valve, Sleeve & Plug NOTE: Ensure Sonnax sleeve is installed at the same height/location as OE boost sleeve. Failure to do so will result in incorrect line pressure. Packaging Pocket 3 Boost Valve Boost Sleeve Boost Valve Plug Packaging Pocket End Plugs, Large (5) O-Rings, Large (7) Packaging Pocket 7 End Plug, Medium O-Rings, Medium () Packaging Pocket 8 End Plugs, Small (4) O-Rings, Small () Extra Extra Extra 7 Replace OE Checkballs 4 Replace OE Lockup Control Plunger Valve & Sleeve Packaging Pocket 9 Plastic Checkballs () NOTE: Reuse OE spring if applicable. Packaging Pocket 4 Plunger Valve Plunger Sleeve 07 Sonnax Industries, Inc. U5E-U50E-ZIP-Guide 0-03-7 800-843-00 80-43-97 F: 80-43-4059 www.sonnax.com
TOYOTA U5E-U50E ZIP KIT PART NUMBER U5E-U50E-ZIP INSTALLATION & TESTING BOOKLET Torque Specifications Pan Filter to Valve Body 8 ft-lb Oil Pan to Transaxle 9 in-lb Component Pack Clearance Forward (C) Clutch U5E & U50E:.039.049" nd (B) Brake U5E:.04.03" U50E:.0.03" Direct (C0) Clutch U5E:.04.033" U50E:.00.033" Underdrive (C3) Clutch U5E & U50E:.059.07" End Play Input Shaft U5E & U50E:.00.049" Direct Clutch Assembly U5E:.00.03" U50E:.008.038" Fluid Low & Reverse (B) Brake U5E:.04.053" U50E:.09.048" Reverse (C) Input U5E & U50E:.04.03" Underdrive (B3) Brake U5E:.07.087" U50E:.05.087" Underdrive Unit U5E:.00.040" U50E:.008.07" Toyota Genuine ATF WS PN: JWS334 or NWS938 Fluid level should be between the hot marks on the stick: Dry Fill: 8.8 liters Drain and Re-fill: 3.5 liters Electronic Cautions Resetting Shift Adapts The ECM (engine control module) has memorized values which must be relearned after transmission repair. Use a scan tool (OE factory tool recommended) to reset the ECM. Post-Adapt Road Test After resetting the ECM, a road test is required. Start the engine and warm it to normal operating temperature. Perform a thorough road test with multiple accelerations from a stop until proper shifting is obtained. Solenoids Solenoids should be cleaned to remove debris that results in sticking and malfunction. Toyota/Lexus U5E/F, U50E Typical Solenoid Firing Order Gear SL SL SL3 S4 SR DSL/TCC SLT st ON ON Off Off Off ON/M nd Off ON Off Off Off Off 3rd ON Off Off Off ON ON 4th Off Off ON Off ON ON 5th Off Off ON ON ON ON Modulates based on engine load. Toyota/Lexus U5E/F, U50E Component Application Chart Reverse Input Clutch C Low & Reverse Brake B No. One Way Clutch F No. One Way Clutch F Gear Range Forward Clutch C Direct Clutch C0 Underdrive Clutch C3 nd Brake B Underdrive Brake B3 Park ON Reverse ON ON ON Neutral ON D-st Gear ON ON ON ON D-nd Gear ON ON ON ON D-3rd Gear ON ON ON High Ratio D-3rd Gear ON ON ON ON Low Ratio D-4th Gear ON ON ON ON D-5th Gear ON ON ON 07 Sonnax Industries, Inc. U5E-U50E-ZIP-Booklet 0-03-7 800-843-00 80-43-97 F: 80-43-4059 www.sonnax.com Page
TIME TESTED INDUSTRY TRUSTED U5E-U50E ZIP KIT Figure Zip Kit Instructions. Valve Body Removal from Case Remove the 9 bolts indicated (Figure ).. Valve Body Disassembly: NOTE: See Figure for bolt locations. Bolt Color Code Black Red Green Yellow Lt Purple Bolt Length mm.75mm.50mm 5.00mm.50mm Valve Body Removal from Case Figure Solenoids can be put into the wrong location in the valve body. Ensure each of them are put back in their correct location. Solenoid designs have changed over the years, see Figure 3 for the most common configuration. Olive Purple White Lt Blue a. Remove bolt # and locking plate. Remove shift Blue solenoid SL3 and the SLT solenoid. Orange b. Remove bolt # and shift solenoid S4, then SR solenoid. c. Remove bolt #3 and shift solenoid DSL. d. Remove bolt #4 and locking plate. Remove shift solenoid SL. e. Remove bolt #5 and locking plate. Remove shift solenoid SL. 30mm 35.50mm 4.00mm 4.50mm 57.00mm.50mm 3 f. Remove the seven # bolts. g. Remove the #7 bolt. 4 3. Valve Body Disassembly: NOTE: See Figure 4 for bolt locations. a. Remove the light blue # bolt, retaining bracket and checkball. 7 b. Remove the seven remaining light blue bolts. c. Remove the purple bolt. 5 Valve Body Disassembly: Figure 3 Figure 4. DSL (TCC) Solenoid, 5 Ohms. SL Solenoid, 4.5.0 Ohms 3 3. S4 Solenoid, 5 Ohms 4. SR Solenoid, 5 Ohms 4 5 7 5. SL3 Solenoid, 4.5.0 Ohms. SLT Solenoid, 4.5.0 Ohms Solenoid Locations and Resistance 7. SL Solenoid, 4.5.0 Ohms Valve Body Disassembly: 0-03-7 U5E-U50E-ZIP-Booklet 07 Sonnax Industries, Inc. Page 800-843-00 80-43-97 F: 80-43-4059 www.sonnax.com
U5E-U50E ZIP KIT TIME TESTED INDUSTRY TRUSTED 4. Installation Install Zip Kit parts as shown on diagram of separate quick guide sheet included in this Zip Kit. When installing the lockup control plunger valve and sleeve kit in 4, reuse the OE spring between the new valve and sleeve. The Sonnax O-ringed end plugs in must be installed with the O-ring outboard. 5. Valve Body Assembly: NOTE: See Figure 5 for bolt locations. a. Loosely install the purple bolt. b. Loosely install the seven, unnumbered light blue bolts. c. Loosely install the light blue #8 bolt, retaining bracket and checkball. d. Torque all bolts to 90 in-lb.. Valve Body Assembly: NOTE: See Figure for bolt locations and torque specifications. a. Loosely install bolt #. b. Loosely install the seven # bolts. c. Install shift solenoid SL and locking plate. Loosely install bolt #3. d. Install shift solenoid SL and locking plate. Loosely install bolt #4. e. Install shift solenoid DSL. Loosely install bolt #5. f. Install the SR solenoid, then shift solenoid S4. Loosely install bolt #. g. Install shift solenoid SL3 and the SLT solenoid. Install the locking plate and loosely install bolt #7. h. Torque all bolts as indicated in chart (Figure ). 7. Valve Body Reinstallation to Case NOTE: See Figure 7 for bolt locations. a. Loosely install all 9 bolts. Reference the color chart on previous page for bolt lengths. b. First tighten the two # positioning bolts to 8 ft-lb. Torque the remaining bolts to the same 8 ft-lb. Figure 5 8 Valve Body Assembly: Figure 5 4 7 3 Valve Body Assembly: Bolt ID & Color Code Installation Torque Specs Bolt # 90 in-lb Bolt # 90 in-lb Bolt #3 58 in-lb Bolt #4 8 ft-lb Bolt #5 8 ft-lb Bolt # 8 ft-lb Bolt #7 58 in-lb Figure 7 Valve Body Reinstallation to Case 07 Sonnax Industries, Inc. U5E-U50E-ZIP-Booklet 0-03-7 800-843-00 80-43-97 F: 80-43-4059 www.sonnax.com Page 3
TIME TESTED INDUSTRY TRUSTED U5E-U50E ZIP KIT 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 and Sonnax parts noted for replacement. Lower Valve Body Bottom Side U50E Shown Here 4-5 Shift Valve Delayed 3rd UD/C3 Clutch burned Delayed or no 5th gear B (Low/Reverse) Switch Valve B Brake clutches burned Delayed Reverse Loss of engine braking in manual low B (Low/Reverse) Apply Control Plunger B Brake clutches burned Delayed Reverse No engine braking in manual low 774-0K* B (nd) Apply Control Plunger B Brake clutches burned -3 or 4-3 Bind-up Harsh upshifts 774-04K* NOTE: Seal port on opposite side when testing. Boost Valve Low line rise in Drive Soft shifts High line pressure in Reverse 774-0K* Clutch Apply Control Valve Flare shifts and bind-ups Burnt Forward/C Clutch, Direct/C0 Clutch and nd/b Brake 774-8K Requires F-774-TL8 & VB-FIX NOTE: Stroke valve to ensure it is not stuck. *Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately. 0-03-7 U5E-U50E-ZIP-Booklet 07 Sonnax Industries, Inc. Page 4 800-843-00 80-43-97 F: 80-43-4059 www.sonnax.com
U5E-U50E ZIP KIT TIME TESTED INDUSTRY TRUSTED 5 0 0 5 5 30 0 VACUUM TEST For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com. Lower Valve Body Top Side U50E Shown Here End Plugs, Multiple Locations Shift concerns Clutch failure 774-0K* NOTE: Two Locations = B (Low/Reverse) Switch Valve B Brake clutches burned Delayed Reverse Loss of engine braking in manual low Pressure Regulator Valve Low/High line pressure Soft/Harsh shifts Clutch & brake failures High line pressure in Reverse Low converter pressure 774-08K Requires 5797E-TL8 Clutch Apply Control Valve Flare shifts and bind-ups Burned Forward/C Clutch, Direct/C0 Clutch & nd/b Brake 774-8K Requires F-774-TL8 & VB-FIX NOTE: Stroke valve to ensure it is not stuck. B (nd) Apply Control Plunger B Brake clutches burned -3 or 4-3 Bind-up Harsh through 4 maneuver shifts 774-04K* NOTE: Seal this port and test on opposite side. Items without part numbers are valid vacuum test locations for indicated drivability complaints, but do not have corresponding Sonnax parts due to low percentage of bore wear. 07 Sonnax Industries, Inc. U5E-U50E-ZIP-Booklet 0-03-7 800-843-00 80-43-97 F: 80-43-4059 www.sonnax.com Page 5
TIME TESTED INDUSTRY TRUSTED U5E-U50E ZIP KIT 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 and Sonnax parts noted for replacement. Upper Valve Body Bottom Side U50E Shown Here Solenoid Modulator Valve Harsh/Flare upshifts TCC slip or cycling Low cooler flow/overheating 774-3K Requires F-774-TL3 & VB-FIX End Plugs, Multiple Locations Shift concerns Clutch failure 774-0K* NOTE: Eight locations = B (Low/Reverse) Control Valve B Brake burned Delayed Reverse Delayed engagement in manual st B3 Orifice Control Valve UD/B3 Brake clutches burned Shift concerns 774-K Requires F-574-TL8 & VB-FIX NOTE: Stroke valve to ensure it is not stuck. Accumulator Control Valve Shift concerns Burnt clutches & brakes C0 (Direct) Control Valve C0 Clutch burned Slipping/Flares in 3rd, 4th & 5th C0 (Direct) Accumulator Piston C0 Clutch burned Slipping/Flares in 3rd, 4th & 5th 5797E-9K* B (nd) Accumulator Piston B Brake clutches burned Slipping/Flares in nd, 4th & 5th 5797E-9K* Solenoid Relay Valve Shift concerns *Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately. One accumulator piston kit included in Zip Kit, choose most worn location. 0-03-7 U5E-U50E-ZIP-Booklet 07 Sonnax Industries, Inc. Page 800-843-00 80-43-97 F: 80-43-4059 www.sonnax.com
U5E-U50E ZIP KIT TIME TESTED INDUSTRY TRUSTED 5 0 5 0 30 0 VACUUM TEST 5 For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com. Upper Valve Body Top Side U50E Shown Here Lockup Relay Valve TCC apply & release concerns TCC codes Burnt converter overheating Lockup Control Valve TCC apply & release concerns TCC codes Burnt converter 774-5K Requires F-774-TL5 & VB-FIX Lockup Control Plunger Assembly Burnt converter TCC apply & release concerns TCC codes 5797E-03K NOTE: Vacuum testing of lockup control plunger assembly not possible while in casting. Perform visual inspection to identify wear. NOTE: Place clay here to isolate circuit. B (nd) Control Valve B Brake clutches burned Slipping/Flares in nd, 4th & 5th Secondary Pressure Regulator Valve Harsh lockup Converter apply/release complaints Burnt converter 5797E-K Requires F-5797E-TL & VB-FIX C (Forward) Control Valve C Clutch burned Delayed engagement Slipping/Flares in st, nd & 3rd NOTE: Seal these ports and test on opposite side. C (Forward) Accumulator Piston C Clutch burned Delayed engagement Slipping/Flares in st, nd & 3rd 5797E-9K* C (Forward) Control Valve C Clutch burned Delayed engagement Slipping/Flares in st, nd & 3rd NOTE: Seal ports on opposite side when testing. Items without part numbers are valid vacuum test locations for indicated drivability complaints, but do not have corresponding Sonnax parts due to low percentage of bore wear. 07 Sonnax Industries, Inc. U5E-U50E-ZIP-Booklet 0-03-7 800-843-00 80-43-97 F: 80-43-4059 www.sonnax.com Page 7
TIME TESTED INDUSTRY TRUSTED U5E-U50E ZIP KIT OE Exploded View Upper & Lower Valve Body U50E Shown Here Upper Valve Body Descriptions I.D No. Description 0 Lockup Relay Valve 0 Lockup Control Valve & Plunger Valve Assembly 03 B Control Valve 04 Secondary Regulator Valve 05 C Control Valve 0 Solenoid Relay Valve 07 C0 Control Valve 08 Accumulator Control Valve 09 B3 Orifice Control Valve 0 B Control Valve Solenoid Modulator Valve C0 Accumulator Piston 3 B Accumulator Piston 4 C Accumulator Piston 09 07 0 08 Installed on Top Side 0 Accumulator Pistons Installed on Top Side Upper Valve Body Bottom Side Shown 05 0 0 03 04 3 4 Lower Valve Body Descriptions Installed on Bottom Side 0 Lower Valve Body Top Side Shown I.D. No. Description 0 Manual Valve 0 B Switch Valve & Plunger Valve 03 4-5 Shift Valve 0 03 04 04 B Switch Valve & Plunger Valve Assembly 05 05 Main Pressure Regulator Valve & Boost Valve Assembly 0 0 Clutch Apply Control Valve 0-03-7 U5E-U50E-ZIP-Booklet 07 Sonnax Industries, Inc. Page 8 800-843-00 80-43-97 F: 80-43-4059 www.sonnax.com