Sonnax Industries, Inc. Ford 4R44E ZIP KIT Installation & Testing Booklet Download

Page: 6 / 8

4R44E-5R55E ziP KiT

installation & Testing Booklet

01-26-12 4R44E-5R55E-ZIP-Booklet

Page 6

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

TIME TESTED • INDUSTRY TRUSTED

Solenoid & Bolt Locations

Install bolts in sequence indicated by numbers. Colors indicate bolt lengths, see chart for details.

Bolt

Color Code

Bolt Lengths

No. Bolts

Required

Red

20mm

Green

30mm

Yellow

35mm

Blue

40mm

Orange

45mm

Purple

55mm

Bore Valve Springs

O.D.

Wire

Dia.

Free

Length Coils

Color

101

Forward Control

.338" .032"

.665"-

-.775"

6.5

White

102

Pressure Regulator, Outer

.745" .055"

1.065"

Plain/Lt. Purp.

102

Pressure Regulator, Inner

.412" .032"

1.135"

9.5

Lt. Green

103

Forward Modulator

.236" .026"

.738"

White

103

EPC Boost

.293" .040"

1.210"

Orange

105

Reverse Modulator, Outer

.210" .018"

1.080"

10.5

Plain

105

Reverse Modulator, Inner

.210" .018"

1.080"

10.5

Plain

106

2-3/3-4 Shift

.275" .030"

1.052"

Plain

107

1-2/2-3 Shift

.284" .033"

.730"

Lt. Purple

108

Solenoid Regulator

.218" .030"

.830"

8.5

Yellow

109

TCC Regulator, Inner

.187" .028"

.720"

White

Shift Solenoid B (SSB) 22–48 ohms

EPC Solenoid 3.1–5.7 ohms

Coast Clutch Solenoid

(CCS/SSD) 22–48 ohms

TCC Solenoid 8.9–16 ohms

Shift Solenoid C (SSC) 22–48 ohms

Shift Solenoid A (SSA) 22–48 ohms

Bore Valve Springs

O.D.

Wire

Dia.

Free

Length Coils

Color

109

TCC Regulator, Outer

.285" .040"

.787"

9.5

Orange

109

Coast Clutch. Bottom Bore .222" .023"

.840"

9.5

Red

110

TCC Modulator

.238" .023"

1.230"

11.5

White/Yellow

111

Thermal Outer, Big

.575" .042"

1.045"

4.5

White

111

Thermal, Middle

.264" .026"

1.232"

13.5

Lt. Green

111

Inner Limit (smallest)

.200" .018"

.840"

Blue

112

3-4/4-5 Shift

.280" .032"

1.162"

Plain

113

Throttle Downshift

.263" .028"

.700"

6.5

Orange

114

Manual Low

.320" .032"

.985"

7.5

Yellow

115

Kickdown

.262" .028"

.670"

Orange

N/A

Steel EPC Relief Tee

.292" .040"

.982"

13.5

Plain

N/A

Plastic TCC Relief Tee

.292" .040"

.982"

13.5

Plain

OE Spring identification Chart

Summary of Contents for Ford 4R44E ZIP KIT

Page 1: ...re Air dry then drip a small amount of Loctite 609 or 3M 04732 sealant into the L pin opening This must have a cure time to hold properly Epoxy is not suggested as it is permanent Loctite can be heated to allow removal To remove plugs once sealed heat the area until the sealant melts then air dry Flat stone the valve body surface and clean well to remove surface imprints 4 Replace OE End Plugs a M...

Page 2: ...eter and uses two large O rings 5 Replace OE Checkballs EPC Limit Valve Lube Orifice Plug Replace the four OE checkballs with the new Torlon balls included ensuring prop er location Replace the OE lube orifice Replace the OE EPC relief valve with the Sonnax domed relief reusing the OE spring The TCC relief and the EPC relief springs are interchangeable Two replacement L pins are included in case o...

Page 3: ...he vehicle has line rise as reverse will not engage until line is 120 psi Delayed Reverse Forward The separator plate must be aligned with pins If not the bolt threads will separate the case from the plate causing a line pressure leak Servo Covers Blown Out of Case Inspect for causes of high line psi such as pressure regulator bore or boost sleeve wear or line booster valve stuck inboard Servo Rub...

Page 4: ...sure No Lockup Control If TCC modulator valve sticks EPC will only obtain about 65 psi Flare on 2 3 Shift 4R 3 4 on 5 Speed The servo pin bore is worn on the intermediate servo or the spring on the piston is too strong No 3rd or 4th The 2 3 shift valve spring is missing or installed wrong Also the 1 2 shift valve should stroke during wet air test WAT at the rectangular circuit five openings in fro...

Page 5: ... FRS FRS FS FR FRS RP Figure 8 A Applied H Holding OR Overrunning Applied TCS on Ineffective TCS on FRS Front Sun Gear FS Forward Sun Gear RP Reverse Planet Assembly FR Forward Ring Gear Apply Component Chart Key Solenoid Apply Chart Transmission Range Selector Lever Position Powertrain Control Module PCM Gear Commanded Shift Solenoids SSA SSB SSC SSD CCS 4R44E 4R55E 5R55E Park Neutral Park Neutra...

Page 6: ... 3 3 4 Shift 275 030 1 052 13 Plain 107 1 2 2 3 Shift 284 033 730 7 Lt Purple 108 Solenoid Regulator 218 030 830 8 5 Yellow 109 TCC Regulator Inner 187 028 720 12 White 27 13 10 1 20 28 23 16 8 4 5 9 17 19 21 11 7 6 14 22 12 24 26 25 15 18 2 3 Shift Solenoid B SSB 22 48 ohms EPC Solenoid 3 1 5 7 ohms Coast Clutch Solenoid CCS SSD 22 48 ohms TCC Solenoid 8 9 16 ohms Shift Solenoid C SSC 22 48 ohms ...

Page 7: ...onverter fill High Low line pressure Low cooler flow at idle Overheated converters Replace with Sonnax Part No 37947 05K TCC Modulator Valve No TCC apply Code 1741 Low cooler flow Poor converter fill delayed engagements Engine stall on forward engagement Replace with Sonnax Part No 37947 07K Boost Valve Assembly Soft shifts Delayed reverse Low line pressure Poor modulator control Replace with Sonn...

Page 8: ...e 103 EPC Boost Valve Forward Modulator Valve 104 Manual Valve 105 Reverse Modulation Valves 106 2 3 or 3 4 Shift Valve 107 1 2 or 2 3 Shift Valve 108 Solenoid Regulator Valve 109 Coast Clutch Valve Converter Regulator Valve 110 Converter Clutch Modulator Valve 111 Cooler Limit Valve Bypass Valve Thermostat Bypass Valve 112 3 4 or 1 2 4 5 Shift Valve 113 Throttle Downshift Control Valve 114 Manual...

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