Toyota A340e/f 00-Later, v6 & v8 zip Kit

PaRT NUMBER a340-late-ZIP Installation & TESTING BOOKLET

Valve Body Identification

This Zip Kit A340-late-ZIP is designed for 2000-Later, V6 & V8 applications using Type 3 (valve body casting identification #8935) or Type 4 (valve body casting identification #8938) style valve bodies.

Type 3 (Casting I.D. #8935) Valve Body

V8 applications, EPC style throttle control only. Valve Body Casting I.D.

Type 4 (Casting I.D. #8938) Valve Body

V6 or V8 applications, EPC (shown) or throttle cable style throttle control. Valve Body Casting I.D.

SLT Solenoid

Type 3 Contour I.D.

SLT Solenoid

Type 4 Contour I.D.

Figure 1 Type 3, Upper Valve Body

Figure 3 Type 4, Upper Valve Body

Separator Plate I.D.

Valve Body Casting I.D.

(visible here if used)

TC Control Valve

Separator Plate I.D.

Valve Body Casting I.D.

(visible here if used)

TC Control Valve

Pressure Regulator Valve (visible)

Pressure Regulator Valve (visible)

S1 Shift Solenoid Type 3 Contour I.D.

S2 Shift Solenoid Accumulator Piston Assembly

SL Shift Solenoid Pressure Relief Check Valve

S1 Shift Solenoid Type 4 Contour I.D.

S2 Shift Solenoid

SL Shift Solenoid

Accumulator Piston Assembly Pressure Relief Check Valve

Alternate Configuration: May have same lineup as Type 3, Figure 2

Figure 2 Type 3, Lower Valve Body

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Figure 4 Type 4, Lower Valve Body

A340-LATE-ZIP-Booklet04-10-13 Page 1

TIME TESTED INDUSTRY TRUSTED

Toyota A34OE/F, 00-later, V6 & V8 Zip Kit

Installation & Testing Booklet

Bolt Locations & Torque Specifications

Torque Specifications
Detent Spring Bolt 89 in-lbs (10 N.m) Oil Pan Bolt 65 in-lbs (7.3 N.m) Solenoid-to-Valve Body Bolt 89 in-lbs (10 N.m) Type 3 Valve Body to Case Bolts Bolt Color Code 1 2 3 Red Green Blue Bolt Length 23mm 28mm 36mm Type 4 Valve Body to Case Bolts Bolt Color Code 1 2 3 Purple White Yellow Bolt Length 23mm 28mm 36mm Type 3 & 4 Oil Pan Filter Bolts Bolt Color Code A B C Pink Black Orange Bolt Length 14mm 20mm 23mm Type 3 & 4 Valve Body Disassembly Bolts Bolt Color Code A B C Lt. Purple Teal Brown Bolt Length 20mm 28mm 40mm

Torque all to 8 ft-lbs

Torque all to 8 ft-lbs

Torque to 7 ft-lbs

Torque to 57 in-lbs

Type 3 (Casting I.D. #8935) Valve Body

V8 applications, EPC style throttle control only. Figure 5

Type 4 (Casting I.D. #8938) Valve Body

V6 or V8 applications, EPC (shown) or throttle cable style throttle control.

1 C

3 B

1 C

3 B

Figure 7

3 A 3 2 2 3 3 A 2 2 2 2 2 1 2 2 2

3 A 3 2 2 3 A 3

2 2 1

2 1 2 1 3

1 1

Type 3, Lower Valve Body, Case Removal - Bolt Locations

Type 4, Lower Valve Body, Case Removal - Bolt Locations

Figure 6
B C B B C A B A B A A A A A C C C B B B B B C B A A A B C C C C B C C A A A C B C C A C C B C B C B B C C B C

Figure 8

B C B

Type 3, Upper Valve Body, Valve Body Disassembly - Bolt Locations

Type 4, Upper Valve Body, Valve Body Disassembly - Bolt Locations

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Toyota A34OE/F, 00-later, V6 & V8 Zip Kit

Clutch & Band Application Chart
Selector Position - Gear Park Reverse Neutral D-1st Gear D-2nd Gear D-3rd Gear D-Overdrive 2-1st Gear 2-2nd Gear 2-2nd Gear Low-1st Gear Low-2nd Gear ON ON ON ON ON C0 ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON C1 C2 B0 B1 B2 B3 F0 F1 Figure 9 F2

Installation & Testing Booklet

TIME TESTED INDUSTRY TRUSTED

Shift Solenoid Chart

Selector Position - Gear D - 1st Gear D - 2nd Gear D - 3rd Gear D - Overdrive 2 - 1st Gear 2 - 2nd Gear 2 - 3rd Gear Low - 1st Gear Low - 2nd Gear Shift Solenoid S1 ON ON Off Off ON ON Off ON ON

Figure 10 Shift Solenoid S2 Off ON ON Off Off ON ON Off ON

Shift Strategies
The computer (ECM) controls the ON/Off combination of the shift solenoids S1 (A) and S2 (B) to shift between 1st gear and overdrive (O/D). If an electrical failure occurs in one of these two solenoids, the computer continues to control the other solenoid to allow the vehicle to operate as smoothly as possible while in Fail Safe mode. The ECM also turns off the SL (E) solenoid during Fail Safe. Should both solenoids S1 (A) and S2 (B) fail, shifting must be done manually. Figures 11 and 12 give typical solenoid codes and solenoid malfunctioning shift strategies.
Figure 14

Solenoid Diagnostic Trouble Chart

DTC P0750 P0753 P0755 P0758 P0770 P0773 Description Shift Solenoid S1 (A)/S2 (B) Malfunction Shift Solenoid S1 (A)/S2 (B) Electrical Malfunction Shift Solenoid S1 (A)/S2 (B) Malfunction Shift Solenoid S1 (A)/S2 (B) Electrical Malfunction Shift Solenoid SL (E) Malfunction Shift Solenoid SL (E) Electrical Malfunction

Figure 11

Solenoid Malfunctioning Shift Strategies

Shift Solenoid S1 (A) Malfunctioning Selector Position Normal Gear D-1st Gear D-2nd Gear D-3rd Gear S1 (A) X X X X X X X X X S2 (B) ON ON ON Off ON ON ON Off ON Gear 3rd 3rd 3rd O/D 3rd 3rd 3rd 1st 2nd Shift Solenoid S2 (B) Malfunctioning S1 (A) ON Off Off Off ON Off Off ON ON S2 (B) X X X X X X X X X Gear 1st O/D O/D O/D 1st 3rd 3rd 1st 1st

Figure 12 Both Solenoids Malfunctioning

When selector position in manually operated

Gear

Figure 13

Overdrive Overdrive Overdrive Overdrive 3rd 3rd 3rd 1st 1st

D-Overdrive
2-1st Gear 2-2nd Gear 2-2nd Gear Low-1st Gear Low-2nd Gear

To test shift solenoids S1 (A), S2 (B) or SL (E) for sticking, force 71 psi of compressed air into the snout (Figure 13, arrow); it should not leak. Energizing the solenoids should cause them to open and allow air flow. Resistance on these three shift solenoids should be 1115 ohm at 68F, and resistance on the SLT solenoid should be 5.05.6 ohm at 68F. Some valve bodies have an accumulator piston assembly (Figure 14) that can be mistaken for a solenoid. This is actually an accumulator for lockup and should be checked to ensure the piston can move freely.

2013 Sonnax Industries, Inc. 800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

A340-LATE-ZIP-Booklet04-10-13 Page 3

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Toyota A34OE/F, 00-later, V6 & V8 Zip Kit

Installation & Testing Booklet

Critical Wear Areas & Vacuum Test Locations

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 for visual clarity. Low vacuum reading indicates wear and Sonnax parts noted for replacement.

Upper Valve Body  Type 3, EPC Style Shown Here

12
9

1. Primary Regulator Valve

Delayed Shifts Poor Shift Quality Burnt clutches & brakes Delayed engagements Replace with Sonnax Part No. 97741-06K 97741-10K 2-Dot Ratio 3-Dot Ratio

2. Boost Assembly
Delayed forward/reverse engagement Soft shifts No kickdown Burnt clutches & brakes Replace with Sonnax Part No. 97741-01K*

10

11
5

3.  TCC Control Valve & Plunger Assembly

Loss of lockup Converter slips/shudder/codes Replace with Sonnax Part No. 19741-01K

Lower Valve Body  Type 3, EPC Style Shown Here

1

13

4. Secondary Regulator Valve

TCC complaints Lockup codes Loss of lube Burnt clutches & brakes Replace with Sonnax Part No. 97741-18K

5.  Lockup Relay Valve & Plunger Assembly

Lockup complaints/codes Replace with Sonnax Part No. 77741-02K*

6. Secondary Modulator Valve

2 8 6 7
*Part numbers with an asterisk (*) are included in this Zip Kit.
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Shift complaints Solenoid codes

2013 Sonnax Industries, Inc. 800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

Toyota A34OE/F, 00-later, V6 & V8 Zip Kit

Installation & Testing Booklet

TIME TESTED INDUSTRY TRUSTED

20 25

15

10

0 30 VACUUM TEST

For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

7. Accumulator Control Valve

Shift complaints Solenoid codes Loss of throttle/line pressure

Upper Valve Body  Type 4, EPC Style Shown Here

14

12

8. Cutback Valve
No kickdown Loss of throttle pressure

9. L  ow Coast Modulator Valve

Burned 1st/reverse brake (B3) Loss of manual low

10. 2  nd Coast Modulator Valve

Burned 2nd brake (B2) Loss of manual second

10

11 5

11. 34 Shift Valve

34 Shift complaints

Lower Valve Body  Type 4, EPC Style Shown Here

1

12. 23 Shift Valve

23 Shift complaints

13

13. 12 Shift Valve

12 Shift complaints

14. Reverse Control Valve

Delayed reverse No reverse

15. End Plugs

Slips & flared shifts Soft shifts Low line pressure Replace with Sonnax Part No. 97741-19K*  NOTE: Several Locations =

2013 Sonnax Industries, Inc. 800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

A340-LATE-ZIP-Booklet04-10-13 Page 5

TIME TESTED INDUSTRY TRUSTED

Toyota A34OE/F, 00-later, V6 & V8 Zip Kit

Installation & Testing Booklet

OE Exploded View
Upper & Lower Valve Body Type 3, EPC Style Shown Here
Note: Depending upon vehicle application, the OE springs shown may not be present. Upper Valve Body - Type 3

Checkball Cautions & Notes Care should be taken during disassembly. Note location of checkballs as usage varies greatly!  When determining when a checkball is required, the circuit orifice in the separator plate over that location will be about .090" dia. When no ball is required, the orifice will be about .150" dia.  All checkballs are .218" dia. except where noted (.250" dia.).
CAUTION

101

106

.250" dia. 105

102

103 Upper Valve Body Descriptions

.090" dia. Orifice

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

Description
Lockup Relay Valve & Plunger Assembly 34 Shift Valve 2nd Coast Modulator Valve Low Coast Modulator Valve 23 Shift Valve Secondary Regulator Valve

104

Lower Valve Body - Type 3

Separator Plate .150" dia. Orifice

207

Lower Valve Body Descriptions

201 202 203

I.D. No.
201 202 203 204 205 206 207

Description
Accumulator Control Valve Secondary Modulator Valve Cutback Valve Primary Regulator Valve & Boost Assembly Converter Limit Valve Manual Valve 12 Shift Valve 206 205
NOTE: Filters should be installed into the separator plate during assembly. The open end of the filter snaps into the plate opening.

204

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Toyota A34OE/F, 00-later, V6 & V8 Zip Kit

Installation & Testing Booklet

TIME TESTED INDUSTRY TRUSTED

Upper & Lower Valve Body Type 4, EPC Style Shown Here
NoteS: Depending upon vehicle application, the OE springs shown may not be present. Slight wormtrack difference and valve components will vary in throttle cable style valve bodies. Upper Valve Body - Type 4

101

108

Upper Valve Body Descriptions

I.D. No.
101 .250" dia. 102 102 103 104* 103 105* 106 105* 104* 107 108

Description
Lockup Relay Valve & Plunger Assembly 34 Shift Valve 2nd Coast Modulator Valve Check Valve Check Valve Reverse Control Valve 23 Shift Valve Secondary Regulator Valve

107

106

*Not in throttle cable style. .090" dia. Orifice

Please review Checkball Cautions & Notes as well as Filter Note on page 6 as they apply to both Type 3 & Type 4 valve bodies.
CAUTION

Separator Plate Lower Valve Body - Type 4

.150" dia. Orifice

Lower Valve Body Descriptions Large Filter

I.D. No.
201 202 203 204** 201 205 206 203 207 208 209 204**

Description
Accumulator Control Valve Secondary Modulator Valve Cutback Valve TCC Control Valve & Plunger Assembly Primary Regulator Valve & Boost Assembly Converter Limit Valve Manual Valve 12 Shift Valve Low Coast Modulator Valve

209 208

Teardrop Filter

202

**Not in all applications

207 206
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Small Filter

205

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Toyota A34OE/F, 00-later, V6 & V8 Zip Kit

Installation & Testing Booklet

Detailed Instructions for Steps 6 to

from Quick Guide

Figure 15

For Replacing a NoDot OE Boost Valve Assembly

Add 2 Sonnax Shims Under OE Washer

Choose Sonnax EPC Boost Valve with Flat on Large Diameter

Primary Regulator Valve & Boost Assembly Bore

For Replacing a 2Dot OE Boost Valve Assembly

Do NOT add Sonnax Shims Here Choose Sonnax EPC Boost Valve with Flat on Small Diameter

Figure 16

Primary Regulator Valve & Boost Assembly Bore

For Replacing a 3Dot OE Boost Valve Assembly

Do NOT add Sonnax Shims Here

Figure 17

Choose Sonnax EPC Boost Valve with Flat on Large Diameter

Primary Regulator Valve & Boost Assembly Bore

04-10-13A340-LATE-ZIP-Booklet Page 8

2013 Sonnax Industries, Inc. 800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com