65797 PART SUMMARY

Vehicles with 700R4, 4L60E and 200-4R transmissions can have low or high line pressure due to a worn pump slide pivot pin. Decreased oil pressure meant to maintain proper line pressures can leak past a worn pin. Sonnax now offers a replacement pump slide pivot pin. This direct replacement pin 65797 will help restore the hydraulic integrity of the pump when replacing a worn pin. This pin is made from through-hardened steel to prevent excessive wear.

77998-01K

# 77998-01K. Sonnax 3-4 Accumulator Bore Repair Sleeve. Fits 700R4 and 4L60E transmissions. Cost $34.00

77998-01K Sonnax Part Summary

The 3-4 accumulator bore on the 700R4 & 4L60E cases can become scored, resulting in the loss of 4th servo feed and 4th accumulator pressure. Scoring is caused by repeated oscillation of the accumulator piston within the bore during normal operation. Once this bore is damaged the case must be scrapped. Install the Sonnax Accumulator Sleeve Kit 77998-01K.

• Helps cure poor line rise

• Helps cure delayed reverse

• Helps cure low line pressure

• Helps cure excessive endplay

# 77917-TLC. Tool Kit, required for 700R4 Sure Cure Kit above. Carbide Reamer & Drill Jig. Cost $299.00

77917-TLC Sonnax Part Summary

A worn OEM pressure regulator valve can be detected in two ways. The first is a dynamometer test that reveals low line pressure during boost conditions (look for 50-100 PSI less than specified in Reverse). The second is vehicle symptoms such as clutch slippage, reverse chatter, and 3-4 clutch failure. Any of the above problems indicate a worn pressure regulator valve that should be replaced. Sonnax now offers an oversized pressure regulator valve for the 700R4 / 200-4R, 77917-06, and the 4L60E, 77917-07. The Sonnax valve permits pump covers to be restored to OEM specifications despite wear and leakage at the pressure regulator valve.

# 77917-06. Sonnax now offers an Oversized Pressure Regulator Valve for the 700R4, 200R4. #77917-06 Kit can be installed with unit still in vehicle. Requires tool # 77917-TLC above. Cost $25.00

77917-06 Sonnax Part Summary

A worn OEM pressure regulator valve can be detected in two ways. The first is a dynamometer test that reveals low line pressure during boost conditions (look for 50-100 PSI less than specified in Reverse). The second is vehicle symptoms such as clutch slippage, reverse chatter, and 3-4 clutch failure. Any of the above problems indicate a worn pressure regulator valve that should be replaced. Sonnax now offers an oversized pressure regulator valve for the 700R4 / 200-4R, 77917-06. The Sonnax valve permits pump covers to be restored to OEM specifications despite wear and leakage at the pressure regulator valve.

# 77917-07. Sonnax now offers an Oversized Pressure Regulator Valve for the 4L60E, #77917-07. Kit can be installed with unit still in vehicle. Requires tool # 77917-TLC above. Cost $25.00

77917-07 Sonnax Part Summary

A worn OEM pressure regulator valve can be detected in two ways. The first is a dynamometer test that reveals low line pressure during boost conditions (look for 50-100 PSI less than specified in Reverse). The second is vehicle symptoms such as clutch slippage, reverse chatter, and 3-4 clutch failure. Any of the above problems indicate a worn pressure regulator valve that should be replaced. Sonnax now offers an oversized pressure regulator valve for the 4L60E, 77917-07. The Sonnax valve permits pump covers to be restored to OEM specifications despite wear and leakage at the pressure regulator valve.

Sonnax Part Number: SC-4L60E

# SC-4L60E. Sonnax 4L60E Sure Cure Transmission Reconditioning Kit. Sure Cure Kits combine “the best” Sonnax products into one box. Cost $223.00

Requires 77754-R2, 77754-TL, 77917-TL Tool Kits.

# 34200-16K. 4L80E Actuator Feed Limit Valve Kit. Cost $47.00

Sonnax Part Summary

The OEM 4L80E actuator feed limit (AFL) valve has a large reaction area and is greatly affected by side loading, which wears the valve body bore. The EPC solenoid oscillates the torque signal and AFL oil, which increases valve action. As bore wear increases, oil pressure is reduced to the shift solenoids, which causes solenoid and ratio codes. The same AFL oil loss results in lower line pressure.

• Kit includes wear-resistant sleeve and anodized valve with annular grooves to prevent side loading. • Valve operates in full-contact sleeve, providing 54% more support. • Boosts oil pressure to the shift solenoids. • Eliminates AFL oil loss, corrects low line pressure. • Kit can now be installed using bench style reamer kit 77754-TL and the valve body fixture VB-FIX.

# 34200-14K. 4L80E Line-to-Lube Pressure Regulator Valve Kit. The Sonnax replacement pressure regulator valve allows regulated flow to the converter charge/lube circuit at vehicle idle, while preventing converter or pump drain-back. Cost $80.00

Sonnax Part Summary

The OEM pressure regulator valve design prevents adequate cooler flow at low RPM and high pressure/demand conditions, which can create overheat complaints. Additionally, in '99-up vehicles, the factory EPC pressure was set high at idle, resulting in engine surge conditions. The Sonnax line-to-lube pressure regulator valve provides a significant increase in cooler flow under low RPM and high pressure conditions that benefits all vehicles, and eliminates the need for reprogramming '99-up vehicles with high EPC pressure at idle.

# 34006-05. Sonnax now offers two solutions for excessive endplay in your GM TH400 / 4L80-E units. The Sonnax rear unit endplay shim 34006-05 can be stacked under the four-tab metal thrust washer on the rear of the output shaft flange to set unit endplay in the same manner as the OEM selective three-tab spacers. These shims eliminate the need to stock expensive or hard-to-find OEM three-tab spacers. 10 Shims, .005” Thick. Cost $6.00

• Shims allow for setting of rear unit endplay by shimming components at the same location as OE selective spacers 

• Can also be used between the two carriers to optimize reaction carrier endplay

Sonnax Part Number: SC-4L80E

# SC-4L80E. Sonnax 4L80E Sure Cure Transmission Reconditioning Kit. Sure Cure Kits combine “the best” Sonnax products into one box. Cost $127.00

Requires 77754-TL Tool Kit.

77754-TL Tool kit for AFL valve. Cost $186.00

# 34910-03K. TH400 Pressure Regulator Valve Kit. High-mileage vehicles with a TH400 often experience poor line pressure control due to a worn pressure regulator bore. This will result in high cooler pressure and converter, crankshaft, and/or friction element failure. This bore wear can be verified by testing line pressure and Wet Air Testing the pump. This hardened steel valve continuously oscillates within the cast-iron pump bore, resulting in wear. Balance line pressure is then allowed to leak past the valve and exhaust to the sump. This prevents the pressure regulator valve from moving completely to the lower line pressure position. Sonnax now offers a pressure regulator valve kit 34910-03K that eliminates these problems. Cost $21.00

• The pressure regulator valve has been modified to incorporate a solid Teflon® seal ring that properly separates the balance line circuit from the pump suction, preventing cross leakage.

• Kit also includes an o-ringed end plug to ensure proper back pressure to the pressure regulator valve.

• This kit eliminates the need to replace the pump casting to ensure pressure control.

# 34006-05. Sonnax now offers two solutions for excessive endplay in your GM TH400 / 4L80-E units. The Sonnax rear unit endplay shim 34006-05 can be stacked under the four-tab metal thrust washer on the rear of the output shaft flange to set unit endplay in the same manner as the OEM selective three-tab spacers. These shims eliminate the need to stock expensive or hard-to-find OEM three-tab spacers. 10 Shims, .005” Thick. Cost $6.00

• Shims allow for setting of rear unit endplay by shimming components at the same location as OE selective spacers 

• Can also be used between the two carriers to optimize reaction carrier endplay

Rear Unit Endplay Shim

# 77406-10. 10 Rear Unit Sonnax Endplay Shims, .0107" Sold 10 per bag. Fits 700R4, 4L60E, TH350, Powerglide. Cost $7.00

Sonnax 77406-10 Part Summary

Sonnax has designed shim 77406-10 for use in 350, 350C, 700-R4 and 4L60E applications. This selective shim installs between the rear reaction carrier support and the case bearing. This shim allows for adjustment to the total and top unit endplay. The total unit endplay (tested by dial indicator on the input shaft) should not exceed .036"(.005" to .036").

# SC-4T65E. 4T65E. The Sure Cure Transmission Reconditioning Kit. Kit. Sure Cure Kits combine “the best” Sonnax products into one box. Cost $178.00

Requires 84754-TL3 Tool Kit & VB-FIX Valve Body Reaming Fixture

84754-TL3. Cost $188.00

# SC-4T60E-1. 1997 Up 4T60E. The Sure Cure Transmission Reconditioning Kit. Kit. Sure Cure Kits combine “the best” Sonnax products into one box. Cost $190.00

Requires 84754-TL5 Tool Kit

# SC-4T60E. 1993-1996 4T60E Sure Cure Transmission Reconditioning Kit. Sure Cure Kits combine “the best” Sonnax products into one box. Helps cure: •CODES 1870, 740, 36. •Falls out of lock-up when hot •torque converter shudder •torque converter overheats •soft shifts •poor line rise •excessive end play. Cost $188.00

Requires 84754-TL5 Tool Kit

84754-TL5 Tool Kit. Cost $114.00

# 22771-04K. Oversized Throttle Valve Kit. Common complaints with Chrysler RWD units are shift timing concerns, throttle buzz, poor kick-down and/or early up-shifts caused by throttle valve and bore wear. When only the valves are worn, Sonnax’s drop-in replacement valve kit 22771-03K addresses these issues. However, when these complaints are caused by bore wear, the valve body typically has to be scrapped. Sonnax offers an oversized TV repair kit, 22771-04K, to salvage the valve body and restore throttle valve control by over-sizing the bore and replacing the valve with an oversized version that restores proper clearances. Both Sonnax kits have been revised to work in all year models, including the 2005-up OEM units with a “motorized” style linkage.

Fits 42RE, 42RH, 46RE, 46RH, 47RE, 47RH, 48RE, A727, A904 Transmissions.

Requires F-22771-TL Tool and VB-FIX Valve Body Reaming Fixture.

# 22556-BRG. Case Repair Bearing. The inner race or hub of the one-way roller clutch may come into contact with and cause wear to the back of the transmission case. This rearward movement of the hub is primarily a result of excessive endplay. To protect the case from further wear and eliminate excessive endplay, install a Sonnax case repair bearing, 22556-BRG. This repair bearing requires that the case be machined using a milling machine with a rotary table. Late cases will require machining of the reverse drum. Cost $30.00

Fits 46RE, 46RH, 47RE, 47RH, 48RE, A727 Transmissions. Requires machining. Case Repair Bearing, 3 per bag.

• Salvages hard-to-find expensive cases.

• Eliminates excessive endplay.

• Prevents further wear.

# 22912-01K. Reverse Servo Piston Plug. There are two styles of the OEM reverse servo piston plug in Chrysler RWD units: the extended tip version for the 47RH/RE (A618) and 48RE, and the flat tip version for the 40RH, 42RH/RE, 44RE (A500), 46RH/RE (A518), 36RH, 37RH (A727) and 30RH (A904). Both versions of these OEM aluminum plugs are subject to wear, galling, and breaking at the spring seat area due to high stresses in reverse. The Sonnax replacement plug 22912-01K can be configured to work in both OE applications, and has been manufactured from hardened steel to more than double the tensile strength of the part. Cost $20.00

• Plug is machined from wear-resistant hardened steel with more than double the tensile strength of the OEM part.

• A larger radius is provided at the spring seat area to minimize the primary stress riser and prevent breakage.

• 2-for-1 design works in all applications, with minimal modification.

• O-Ring added to seal between the plug and the piston eliminates leakage of servo apply oil.

• Replacement heavy-duty retaining ring included in kit.

#76989K. Throttle Valve Plug & Sleeve Kit. Uncontrollable throttle pressure due to oil loss is a common complaint in vehicles with an AOD transmission. This results in low line pressure and poor throttle and shift timing adjustments. The hardened steel throttle valve plug continuously reciprocates within the aluminum throttle valve sleeve, wearing the inside diameter of the sleeve. This wear allows throttle valve feed oil to leak past the plug and exhaust, resulting in poor line rise. This excessive leakage can be eliminated by installing Sonnax throttle valve plug and o-ringed sleeve kit 76989K. Cost $30.00

"This part always wears out 99% of the time and should be replaced on every rebuild."

• The throttle valve sleeve is manufactured from high-quality aluminum to prevent wear.

• O-rings added to the outside diameter of the sleeve prevent feed oil from escaping past the valve body bore.

• Steel plug has been tightly toleranced to allow minimum clearance with the inside diameter of the sleeve, thus restoring the hydraulic integrity of the assembly.

# 76999-05K. Governor Circuit End Plug Kit, Mid'83-later. Vehicles with an AOD transmission often have shift timing complaints due to governor or accumulator oil circuit leakage caused by leaking valve end plugs in the valve body. Most AOD valve assemblies are designed with an end plug to help retain the line-up and seal the circuitry. As these end plugs wear, circuit oil is lost and affects shift timing. Installing Sonnax o-ringed valve end plugs can eliminate this excessive leakage. Cost $56.00

• Replacement plugs are included for the following valve applications: 1-2 accumulator, 1-2 shift, 2-3 shift, 1-2 capacity modulator, orifice control, O.D. servo regulator, 3-4 shift (plug or sleeve), and either the 3-4 shuttle or 2-3 back-out.

• Plugs have been manufactured from of high-quality aluminum designed to resist wear.

• O-ring on the outside diameter prevents leakage between the plug and the valve body.

• Plugs have a standard 8-32 UNC threaded hole for assistance in installation and removal.

• O-ringed plugs are more durable than knurling the O.D. of the original plug.

# 76811-01K. Direct Drum Shaft Retaining Ring, sold in bag of 5. In vehicles with an AOD transmission, the direct drum splines can wear, causing the direct drum shaft to contact the output shaft and shut off lube flow. The late shaft design allows the Sonnax retaining ring 76811-01K to fit into the OEM groove. The early shaft design requires a groove to be machined to accept the retaining ring. The shaft has been depth hardened sufficiently from OEM to ensure strength after machining. Cost $9.00

Features & Benefits:

• Late-model shaft requires no modifications. Early-style shafts will require machining a ring groove.

• Prevents lube flow shut-off.

• Salvages drums with worn splines.

# 76948-16K. AODE / 4R70E Oversized Pressure Regulator Valve Kit, '91-'95. # 76948-17K Oversized Pressure Regulator Valve Kit, '96-Up. A common complaint in vehicles with AODE and 4R70W transmissions is low line pressure or throttle-sensitive buzz, especially when hot. This wear allows EPC (electronic pressure control) oil to leak to exhaust, resulting in poor line rise. When the oil temperature increases, the oil becomes less viscous and more leakage occurs. Sonnax offers standard size valves 76948-01 ('91-'95) and 76948-09 ('96 & up). However, when valve bodies are severely worn, a standard size replacement valve will still allow leakage. Sonnax also offers 76948-16K and -17K, two oversized pressure regulator valves that allow the valve body to be salvaged. See tools below.

Features & Benefits:

• Improved PR/EPC reaction area ratio provides higher line rise response to EPC pressure, which results in noticeably firmer shifts.

• Oversized pressure regulator valves are manufactured from hard-anodized aluminum to prevent wear.

• PR valves have annular grooves to prevent side loading that results in wear.

• The spring seat on the PR valves has been lengthened to compensate for the increased diameter.

• Anodized aluminum boost valve is slightly larger than OEM, to provide to correct ratio with the oversized pressure regulator valve.

• Either tool kit works for all model years.

# 76948-TL4. 2 Reamers. Note: This tool kit allows the bore to be oversized at the bench to fit both 76948-16K and 76948-17K.

Cost $239.00

# 76948-BST. 1 Bore Sizing Tool. Note: This bore sizing tool is highly recommended to provide exact sizing and better bore surface finish after the reaming with 76948-TL4.

Cost $37.00

# F-76948-TL. 1 Reamer Jig, 1 Guide Pin, 1 Reamer. This valve body fixture is required.

Cost $305.00

# 76507F-01K. The valve body stiffener plate in the 2-3 accumulator area was eliminated on 2001-up 4R70W & 4R75W transmissions. Oil pressure builds up in unused cavities under the separator plate causing the plate to flex upwards as much as .010", allowing forward and direct oil passages to cross leak. The Sonnax retainer plate 76507F-01K bolts in place and provides the clamping force to compress the lower valve body gasket. This prevents cross leaks, separator plate flexing and cracking, so that cracked separator plates can be reused. Cost $22.00

Features & Benefits:

• Allows previously cracked separator plates to be reused.

• Prevents cross leaking.

• No special tools required.

• Installs in just minutes.

Sonnax E40D Transmission High efficiency internal filter #36423-BPF

Sonnax Part Summary

The circuit design of the Sonnax filter ensures adequate oil pressure and flow to force fluid through the densely wound radial filter element. Sump filters and cooler line filters must balance flow and restriction, thus limiting their effectiveness. Sonnax has solved this problem by feeding the filter directly from internal transmission pressure in a “kidney loop bypass” configuration. By installing the filter inside the transmission at time of rebuild, all problems associated with external filters are eliminated. No more hassles, leaks, comebacks or filters “left off” by the installing shop.

Features & Benefits

• This 5-micron filter removes post-rebuild contamination 10 to 100 times more effectively than currently available cooler line filters.
• The filter continuously and efficiently removes residual contamination from prior failure
• Fluid is pushed through the filter.
• Filter is in the pan.

Sonnax C6 Transmission 1-2 accumulator spring #36946-05K

Cures • Long slide 1-2 shift • Burned clutch band • Broken springs

Sonnax Part Summary 

Package of 5 Sonnax 36946-05K Ford vehicles with the C6 transmission can experience a harsh 1-2 shift or a long slide 1-2 shift with an accompanying burned clutch band. The cause of the harsh 1-2 shift is often broken 1-2 accumulator springs, which break due to fatigue. Without one or both of the springs, the accumulator cannot adequately dampen the 1-2 shift. A long slide 1-2 shift with burned clutch band is caused by weakened 1-2 accumulator springs that have been subjected to excessive stress. Sonnax now offers a replacement spring set for the C6 1-2 accumulator, #36946-05K. $9.00

Features & Benefits 

• Springs have a larger spring wire diameter capable of withstanding higher stresses.
• Spring is pre-stressed for resistance to load relaxation.
• Spring surface is shot peened for fatigue resistance

Sonnax C6 Transmission finish in place pump bushing #36002-01

Cures • Excessive converter hub-to-bushing clearance • Pump noise 

Sonnax Part Summary

#36002-01. It can be difficult to establish the proper clearance between the converter hub and bushing in E4OD, AOD & E, C6 units because aftermarket drop-in replacement bushings are not thick enough. We have the perfect solution for you. PATC and Sonnax now offers #36002-01, a finish-in-place front pump bushing. $6.00

Features & Benefits 

• Bushing is steel-backed bronze for better wear resistance.
• When installed, bushing allows .008" to .010" material removal for maintaining correct bushing to hub clearance.

Sonnax C6 Transmission Sunshell saver shim #36414-01K

Cures Driveline slack and Engagement Noise

Sonnax Part Summary

Vehicles with a C6 transmission often have severely worn sunshells at the sun gear contact area. This wear allows the forward planet to make contact with the inside of the sunshell and results in increased driveline slack/noise. Quality used sunshells are virtually non-existent and new sunshells are expensive. Sonnax has developed a shim #36414-01K to allow the sunshell to be reused. Sold as set of 5.  $25.00

Features & Benefits

• Shims allow the sunshell to be brought back to its original height at the sun gear        
• Shims prevent unwanted contact between the forward planet and sunshell

Sonnax C6 Transmission end play Shim #36428-Z

Cures • Clunk • Reduced seal ring life

It can be difficult to reduce C6 unit endplay with spline or sunshell wear. When driveline wear is excessive, sealing ring and thrust wear increases. As the lower unit wear increases, OEM selective thrust washers are not thick enough to compensate. Rebuilders often try to correct excessive endplay by adding thicker shims to the pump surface, but adding too much shim material to the pump area will push the sealing rings toward a minimal drum contact. Sonnax now offers shims to compensate for driveline wear. Sold as set of 10 #36428-Z $14.00

Features & Benefits:

• 36428-Z is a 6-slotted, .010" thick shim to be used between the 6-tanged thrust washer and 3-pinion rear planetary assembly. 
• 36428A-Z is a 4-slotted, .010" thick shim to be used between the 4-tanged thrust washer and 4-pinion rear planetary. 
• These shims, together with OEM thrust washer material, will allow precise endplay adjustment.

Sonnax C6 Transmission Line Pressure Coasting Regulator Valve #36941-03

Cures • No cutback line rise • Fixed high line pressure

An incorrect length-to-diameter ratio of the 2nd spool valve causes the valve to stick or hang up in the valve bore. This replacement line pressure coasting regulator valve #36941-03 will restore smooth valve actuation and properly regulate coas-tdown line pressure.

• Replacement valve has increased spool length with exhaust flats that will eliminate the 2nd valve spool from sticking or hanging up in the valve bore. 
• Annular grooves have been provided on the long spool diameter to improve valve oil distribution, and reduce valve sideloading.
• Bore-sizing tool removes bore ridges created by sticking or hung up valve.

Note: For this replacement valve to work properly, the valve bore must be resized for smooth valve
actuation. Use Sonnax valve bore-sizing tool 36941-BST to refurbish the OEM valve bore.

# SC-AX4N. AX4N Sure Cure Transmission Reconditioning Kit. Sure Cure Kits combine “the best” Sonnax products into one box. Cost $170.00

Requires 96206-TL, 96201-TL2, 96201-TL3, 96206-BST Tool Kits

96206-TL. Cost $221.00

96201-TL2. Cost $219.00

96201-TL3. Cost $250.00

96206-BST. Cost $37.00

# SC-AXODE. AXODE Sure Cure Transmission Reconditioning Kit. Sure Cure Kits combine “the best” Sonnax products into one box. Also fits AX4S transmissions. Cost $94.00

96201-BST Bore Sizing Tool recommended

96201-BST Bore Sizing Tool.

Cost $65.00

# S29509450

HT-700. 7" Deep, with magnet; OEM style gray paint, exterior only. Allison Part #29509450. Cost $239.00

HT700

29509450 Pan

# S29503772. Shallow MT-600 Pan features larger, strong magnet to reduce contamination. Zinc plated to resist corrosion. Allison Part #29503772. MT (B) 644, 647 / 654CR MT 640 / 643 / 650 / 653. Cost $130.00

MT600

29503772 Pan

# S23018884. New Deep Allison MT-600 Pan. Allison part number 23018884. Fits MT 644 / 647 / 654 / 643 / 653. Cost $97.00

MT600

Sonnax offers the first aftermarket replacement pan for the 600 series Allison transmissions. This pan features a larger, stronger anti-contamination magnet as well as dual fill locations. The pan is zinc plated to resist corrosion.

# S23045906. New Deep Sonnax Allison MT-500 Pan. Allison Part #23045906. Cost $67.00

MT500

Deep Ribbed with heater hole

# S29501358. New Deep Sonnax Allison MT-500 Pan. Allison Part #29501358. Cost $99.00

MT500

Deep Oil Pan, Dual Fill Tube Locations