Aw60 40le Zip Book

A I S I N AW 6 0 - 4 0 L E ( A F - 1 3 ) AI zIp KIt PaRT NUMBER aW60-40LE-ZIP

only. NOTE: This Zip Kit AW60-40LE-ZIP is designed or 60-40LE (AF-13) applications only. A separate Zip Zip Kit AW60-41SN-ZIP is available or 60-41SN (AF-17) applications.

Torque Specifications Transaxle Transaxle Si de Cover Bolt

Manual Detent Spring Bolt

18 t-lb

90 in-lb

Manual Shift Lever Nut

Front Valve Body Cover Bolt

60 in-lb

INsTaLLaTIoN INsTaLLaTIoN & TEsTING Boo KLET

Valve V alve Body Idenifcaion 60-40LE (AF-13) Valve Body: Use this kit.

18 t-lb Front-Valve-Body-toRear-Valve-Body Rear-Valve-Body Bolt

Rear Valve Body Cover Bolt

60 in-lb

96 in-lb

Solenoid-to-ValveBody Bolt

Valve-Body-toTransaxle Bolt

60 in-lb

90 in-lb

No Number 2 Rear Control Body

Fluid Chart

Has a Short TCC Solenoid

Recommended Capacities: Dexron-III ATF Approximate Capacity, Capacity, Complete Overhaul

Approximate Capacity, Capacity, Drain and Fill

6.0 qt (5.7L) - 1.6L 6.2 qt (5.9L) - 1.8L

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

P

X

R

X

N

X

D

2 L

1

X

X

2

X

X

3

X

X

4

X

1

X

X

2

X

X

1

X

X

Brake

Reverse

OD

X

1st-Reverse

1-Way Clutch 2nd-4th

No. 1

No. 0

X

X

X

X

X

X

X

X

©2012 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

X X X X

X X

X

X AW60-40LE-ZIP-Booklet 09-26-12 Page 1

TIME TESTED • INDUSTRY TRUSTED

Aisin AW 60-40LE zIp KIt

Intlltin & Teting Bklet

Solenoids

Solenoid Apply Chart

Tis 60-40LE unit uses our solenoids ( Figure 1). •

•

•

he S1 (shit solenoid no. 1) and S2 (shit solenoid no. 2) are an on/o style, operated by the CM to control the various shits. hese two solenoids are interchangeable. he CC control solenoid is an on/o style controlled by the CM to operate the converter clutch. he throttle pressure control liner solenoid is modulated by the CM to regulate line pressure.

Solenoid

Position

Bolt Color Code

Yellow

10mm

Red

16mm

Orange

20mm

Green

38mm

Blue

50mm

P

X

R

X

N

X

D

Bolt Length

No. 1

1

X

2

X

No. 2

X X

3

L

X1 X1

4 2

TCC

1

X

2

X

1

X

X

1

On only when TCC is operating.

zi Ki Insrucions Figure 1

1. Valve Body Disassembly NOTE: See color charts or bolt lengths.

a. Remove the 13 bolts ( Figure 2). b. Remove the small cover, CC control solenoid, throttle pressure control solenoid ( Figure 1) and brackets. c. Remove the two bolts ( Figure 3), two shit solenoids (Figure 1) and ront valve body cover, separator plate and gasket.

No. 1 TCC Solenoid 11–15 ohm

d. Remove the three checkballs, two oil lters, one check valve and spring, our bolts and one bracket (Figure 4).

No. 2

Test all our solenoids at 20˚C/68˚F.

Throttle Pressure Control Solenoid 3–5 ohm

Shit Solenoids (interchangeable) 11–15 ohm

Figure 2

Bolt installation torque specifcations are 60 in-lb.

09-26-12 AW60-40LE-ZIP-Booklet Page 2

Figure 3




Intlltin & Teting Bklet TIME TESTED • INDUSTRY TRUSTED

1. Valve Body Disassembly (coninued)

Figure 4

e. Flip valve body over and remove ve bolts. Lit rear valve body and separator plate of o ront valve body (Figure 5). . Remove 11 bolts to access valves retained under the two rear valve body covers ( Figure 6).

2. Insallaion Install Zip Kit parts as shown on diagram o separate quick guide sheet included in this Zip Kit.


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 ront valve body (rst ensuring all checkballs, check valves and lters are in proper locations). Loosely install the ve bolts ( Figure 5), then torque to 60 in-lb.

Figure 5

c. Flip the valve body over. d. Loosely install the our bolts ( Figure 4), and torque the our bolts to 60 in-lb. e. Place the ront valve body cover, gasket and separator plate onto the ront valve body. Reinstall the two shit solenoids and loosely install the two bolts ( Figure 3).


. Reinstall the brackets, throttle pressure control solenoid, CC 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 specifcations are 96 in-lb. Bolt Color Code

Bolt Length

Yellow

10mm

Red

16mm

Orange

20mm

Green

38mm

Blue

50mm


AW60-40LE-ZIP-Booklet 09-26-12 Page 3




Criical Wear Areas & Vacuum tes Locaions 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 or visual clarity. Low vacuum reading i ndicates wear.

Fron Conrol Valve Body - Searaor plae Side Shown Here

2nd/4h Brake Modulaor Valve

1-2 Shi Valve

Shit complaints in 2nd & 4th

NoTE: Seal port on opposite side o casting.

1-2 Shit complaints

pressure Regulaor Valve Low/High line pressure Sot/Harsh shits Converter complaints Loss o lube

• • • •

2nd/4h Brake Modulaor plunger Assembly Shit complaints in 2nd & 4th

2-3 Shi Valve 2-3 Shit complaints NoTE: Seal port on opposite side o casting & solenoid port with thumb.





15 20

10 5

25 30

0

VACUUM TEST

Fron Conrol Valve Body - Cover Side Shown Here 3-4 Shi Valve 3-4 Shit complaints NoTE: Seal solenoid port with thumb.

tCC Modulaor Valve Converter slip/shudder/codes No converter apply

•

2-3 Shi Valve

•


NoTE: Test using non-orifced 2nd/4th modulator brake control valve.

NoTE: Seal port on opposite side o casting and seal solenoid port with thumb.

Seal

Seal

Reverse Boos Assembly Low reverse pressure Delayed reverse

• •

1-2 Shi Valve

pressure Regulaor Valve


•

NoTE: Seal port on opposite side o casting.

•

Low/High line pressure Sot/Harsh shits Converter complaints Loss o lube

• •

Shi Valve End plugs Shit complaints

3-4 Shi Valve 3-4 Shit complaints






Criical Wear Areas & Vacuum tes Locaions

20

15 10 5

25

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

30

0

VACUUM TEST

to with an arrow. Springs are not shown or visual clarity. Low vacuum reading indicates wear.

Rear Conrol Valve Bod y - Searaor plae Side Shown Here Coas Cluch Modulaor Valve Burned coast clutch NoTE: Test using non-orifced 2nd/4th brake modulator control valve.

Solenoid Modulaor Valve Shit complaints NoTE: Test using non-orifced 2nd/4th brake modulator control valve

Low Coas Modulaor Valve Burned 1st & reverse clutch Delayed engagement reverse or 1st in manual low

• •

NoTE: Test both at the same time.

tCC Conrol Valve

Reverse Cluch Accumulaor pison Burned reverse clutch Delayed reverse Bump in reverse

•

Lockup complaints/codes

• •

Secondary Regulaor Valve TCC complaints Loss o lube

• •

2nd/4h Brake Modulaor Conrol Valve Burned 2-4 brake Shit complaints in 2nd & 4th

• •

2-3 timing Valve & Overdrive Cluch Accumulaor pison 2-3 Shit complaints Burned overdrive clutch Bump in 3rd gear

•

2nd/4h Brake & Foward Cluch Accumulaor pison Burned orward clutch Burned 2-4 brake Delayed orward Bump 2nd & 4th gear

• • • •

• •

NoTE: Test one port while sealing the other.





OE Exloded View Fron Conrol Valve Body - Cover Side (Searaor Side Inse) Shown Here 106 Fron Conrol Valve Body Descriions

I.D. No. 101 102 103 104 105 106 107

Description Reverse Boost Assembly & Pressure Regulator Valve Accumulator Control Valve & Plunger Assembly 2nd/4th Brake Modulator Valve & Plunger Assembly 1-2 Shit Valve 2-3 Shit Valve 3-4 Shit Valve TCC Modulator Valve

105

104

107

Check Valve

Front Valve Body (Cover Side)

Check Valve

Filter Filter Front Control Valve Body (Separator Side)

102 103

101 ©2012 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com





OE Exloded View Rear Conrol Valve Body

212

208

209 211 210

Check Valve

Filter

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

Rear Conrol Valve Body Descriions

I.D. No. 201 202 203 204 205 206 207 208 209 210 211 212

Description Secondary Regulator Valve 2nd/4th Brake Modulator Control Valve Low Coast Modulator Valve Solenoid Modulator Valve Reverse Clutch Accumulator Piston 2nd/4th Brake Accumulator Piston Manual Valve Forward Clutch Accumulator Piston Overdrive Clutch Accumulator Piston 2-3 Timing Valve Coast Clutch Modulator Valve TCC Control Valve & Plunger Assembly


Check Valve

Check Valve

203 206 207

202

204 205 201


Aw60 40le Zip Book

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