4R44E-5R55E ziP KiT
installation & Testing Booklet
01-26-12 4R44E-5R55E-ZIP-Booklet
©2012 Sonnax Industries, Inc.
Page 2
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
TIME TESTED • INDUSTRY TRUSTED
4. Replace OE End Plugs (continued)
c. Remove the plug between the EPC solenoid and the 1-2/2-3 shift valve. The
plug may not come out easily after removing the “U”-shaped retainer. A rod
(.125" dia.) can be inserted into the opposite bore (113, page 7) to drive out
the plug. After the plug is removed, push the shift valve to the bottom of
the bore and retain it with a screwdriver. Install the small OE plunger valve
into the Sonnax O-ringed plug before installing into the bore. The large OE
“U”-shaped retainer should be installed with the longer leg closest to the
manual valve.
d. Pull out the “L” pin near the solenoid. The OE plug can be difficult to remove.
With a strong needle-nose pliers, turn the plug and hit it with the tip of your
pliers. Continue this until the spring drives out the plug. If the OE plug
will not come out, you must also remove the inner “L” pin retainer. You will
then have to drill an access hole to drive out the valves (
Figure 1
). A new
spring is supplied for the inner coast clutch valve in case the OE is damaged
during this process. Use the needle nose pliers to install the Sonnax end plug
(O-ring only) by holding the small nub. Twist while inserting the plug until
the O-ring is inboard of the “L” pin retainer port.
e. These three plugs seal shift solenoid oil. The two smaller end plugs use four
small O-rings. The larger end plug is .630" in diameter, 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 originals
are lost or damaged.
6. drill Separator Plates
a. Drill the pressure regulator balance orifice to .055" dia. with included drill. To
prevent flashing, start the drill on one side and then finish from the opposite. It’s
always best to taper the orifice holes when done with a larger drill.
b. Drill the overdrive servo apply orifice to .072" dia. with included drill. This
will supply firmer 4th in 4R units and firmer 5th and 2nd in 5R units. Later
5R55E units are already this size.
c. Drill line pressure circuit to converter feed orifice in the plate to .062" dia.
with included drill. Late-model 5R55E units are already this size. Drill the
indicated converter clutch orifice to .062" dia., then insert the included .062"
aluminum plug and peen in place to close off the hole.
d. Drill the TCC exhaust hole to .110" dia. with included drill.
7. TCC Modification
Remove the smallest spring from the cooler bypass valve bore. This spring can be
pulled out from the lower side of the casting, through the slot next to the filter inlet
(
Figure 2
).
8. Replace OE Solenoid O-Rings
Replace small and large O-rings from the four indicated solenoids (see Quick Guide).
Lube the O-ringed solenoid snout prior to bore installation.
Figure 1
For bore 109 valve removal, drill .110" hole, entering
at bolt and exiting into spring pocket of bore 109.
This allows rod to drive out the valve.
Figure 2
