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Aisin AW 60-40LE Zip Kit® AW60-40LE-ZIP Available for this unit.

TIME TESTED • INDUSTRY TRUSTED

Critical Wear Areas & Vacuum Test Locations 20


25
30
15

0
10
5

NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to VACUUM
TEST

with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.

Front Control Valve Body - Separator Plate Side Shown

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
2-3 Shift Valve
Replace with Sonnax Part No.
19741-03K* 2-3 Shift complaints
NOTE: Seal port on opposite side of
casting & solenoid port with thumb.

Click on Sonnax part numbers to see more information.

©2015 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 03-02-15


800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
Aisin AW 60-40LE Zip Kit® AW60-40LE-ZIP Available for this unit.
TIME TESTED • INDUSTRY TRUSTED

Critical Wear Areas & Vacuum Test Locations 20


25
30
15

0
10
5

NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to VACUUM
TEST

with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.

Front Control Valve Body - Cover Side Shown

Click on Sonnax part


numbers to see more 3-4 Shift Valve
information. 3-4 Shift complaints
NOTE: Seal solenoid port with thumb.

TCC Modulator Valve


• Converter slip/shudder/codes
2-3 Shift Valve • No converter apply
2-3 Shift complaints NOTE: Test using non-orificed 2nd/4th
NOTE: Seal port on opposite side of casting and modulator brake control valve.
seal solenoid port with thumb.

Seal

Seal

Reverse Boost Valve


• Low reverse pressure
• Delayed reverse
Replace with Sonnax Part No.
19741-07K*


 Pressure Regulator Valve
End Plugs • Low/High line pressure
• Soft/Harsh shifts
• Burnt clutches/brakes
• Converter complaints
• Various shift complaints
• Loss of lube
Replace with Sonnax Part No.
19741-13K*
NOTE: Several Locations = 1-2 Shift Valve
1-2 Shift complaints
NOTE: Seal port on
3-4 Shift Valve
opposite side of casting. 3-4 Shift complaints

©2015 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 03-02-15


800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2
Aisin AW 60-40LE Zip Kit® AW60-40LE-ZIP Available for this unit.
TIME TESTED • INDUSTRY TRUSTED

Critical Wear Areas & Vacuum Test Locations 25


30
20
15

0
10
5

NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to VACUUM
TEST

with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.

Rear Control Valve Body - Separator Plate Shown


Solenoid Modulator Valve
Coast Clutch Shift complaints
Modulator Valve Low Coast NOTE: Test using non-orificed 2nd/4th brake
modulator control valve
Burned coast clutch Modulator Valve
NOTE: Test using non-orificed 2nd/4th • Burned 1st & reverse clutch
brake modulator control valve.
• Delayed engagement reverse
or 1st in manual low
Reverse Clutch
NOTE: Test both at the same time.
Accumulator Piston
Lockup • Burned reverse clutch
Control Valve • Delayed reverse
Lockup complaints/codes • Bump in reverse

Secondary
Regulator
Valve
• TCC complaints
• Loss of lube

End Plugs
• Burnt clutches/brakes
• Various shift complaints
2nd/4th Brake & Foward
Replace with Sonnax Part No. 2nd/4th Brake Clutch Accumulator Piston
19741-13K*
NOTE: Several Locations = Modulator • Burned forward clutch • Delayed forward
Control Valve • Burned 2-4 brake • Bump 2nd & 4th gear
• Burned 2-4 brake
Lockup Control Plunger Valve Kit • Shift complaints in
• Burnt converter • TCC codes 2nd & 4th 2-3 Timing Valve & Overdrive
• TCC apply & release concerns Clutch Accumulator Piston
Replace with Sonnax Part No. • 2-3 Shift complaints • Bump in 3rd gear
59954-01K • Burned overdrive clutch
Click on Sonnax part • NOTE: Test one port while sealing the other.
numbers to see more
*Part numbers with an asterisk (*) information.
are included in this Zip Kit.

©2015 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 03-02-15


800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3
Aisin AW 60-40LE Zip Kit® AW60-40LE-ZIP Available for this unit.
TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Front Control Valve Body - Cover Side (Separator Side Inset) Shown Here

106
Front Control Valve Body Descriptions
105
I.D. No. Description 104
Reverse Boost Assembly
101
& Pressure Regulator Valve
107
Accumulator Control Valve
102
& Plunger Assembly
B1 Modulator Valve Check
103
& Plunger Assembly Valve

104 1-2 Shift Valve


105 2-3 Shift Valve
Front Valve Body
106 3-4 Shift Valve (Cover Side)
107 TCC Modulator Valve

Check Valve

Filter

Filter

Front Control Valve Body


(Separator Side)

102

103

101 104
©2015 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 03-02-15
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 4
Aisin AW 60-40LE Zip Kit® AW60-40LE-ZIP Available for this unit.
TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Rear Control Valve Body

212

208 209

211

210

Check
Filter
Checkball, Large .250" dia. Valve
(All 10 others, Small .218" dia.)

Rear Control Valve Body Descriptions Check


Valve
I.D. No. Description
201 Secondary Regulator Valve
2nd/4th Brake Modulator
202
Control Valve
203 Low Coast Modulator Valve
204 Solenoid Modulator Valve
Reverse Clutch Check
205
Accumulator Piston Valve
2nd/4th Brake
206
Accumulator Piston
207 Manual Valve 202
203
Forward Clutch
208
Accumulator Piston 206
204
Overdrive Clutch
209
Accumulator Piston 207 205
210 2-3 Timing Valve 201
211 Coast Clutch Modulator Valve
Lockup Control Valve
212
& Plunger Assembly

©2015 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 03-02-15


800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5

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