ZIP-kit ZF6HP19, ZF6HP26, 6R60

Sonnax Zip Kit ZF6-6R60-ZIP targets the root cause of multiple complaints by sealing the critical circuit pressure losses in the ZF6HP19/26/32 (Generation 1) and Ford 6R60/6R80 valve bodies. The kit contains uniquely designed parts to prevent the loss of pressures within the main line, solenoid regulator, reverse, clutch control and solenoid apply circuits with no special tools required.

The Zip Kit quick guide provides clear and easy instructions on one sheet to get the unit sealed up and back on the road fast. In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum testing and additional repair options for higher mileage units or for repairing specific complaints which are beyond the scope of this kit.

NOTE: This Zip Kit ZF6-6R60-ZIP is designed for ZF6HP19/26/32 (Generation 1) and Ford 6R60/6R80 applications only. A separate Zip Kit ZF6-GEN2-ZIP is available for ZF6HP21/28/34 (Generation 2) applications. To verify valve bodies, see this identification guide for further details.

ZIP-kit ZF6HP21, ZF6HP28

Sonnax Zip Kit ZF6-GEN2-ZIP targets the root cause of multiple complaints by sealing the critical circuit pressure losses in listed valve bodies.

The kit contains uniquely designed parts to prevent the loss of pressures within the main line, solenoid regulator, reverse, clutch control and solenoid apply circuits with no special tools required.

The Zip Kit quick guide provides clear and easy instructions on one sheet to get the unit sealed up and back on the road fast.

In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum testing and additional repair options for higher mileage units or for repairing specific complaints which are beyond the scope of this kit.

NOTE: This Zip Kit ZF6-GEN2-ZIP is designed for ZF6HP21/28/34 (Generation 2) applications only. A separate Zip Kit ZF6-6R60-ZIP is available for ZF6HP19/26/32 (Generation 1) and Ford 6R60/6R80 applications. To verify valve bodies, see this identification guide for further details.

PERFORMANCE

ZF S671 Lifeguard 6
BMW 83220142516
BMW 83220144137
BMW M1375.4
Hyundai 040000c90sg
Jaguar Fluid 8432
Landrover TYK500050
VW/Audi G 055 005 A1/A2/A6

Special transmissionfluid for the ZF 8-speed automatic transmission used by several manufacturers.

Performance level

Aisin Warner AW-1

Bentley Oil PY112995PA

CHRYSLER 68157995AA

DSI H 6-SPEED TRANSMISSION (AT 3292)

Fiat 9.55550-AV2

Fiat 9.55550-AV5

Ford WSS-M2C924-A

GM Dexron VI

Honda ATF DW-1

HYUNDAI NWS-9638

Hyundai SP IV, SPH-IV

JAGUAR 02JDE26444

Jaguar Fluid 8432

JWS 3324 (ATF WS)

LAND ROVER LR023288

Land Rover TYK 500050

M-1375.4

Maserati 231603

Mazda FZ

MB 236.12

MB 236.41

Mercon LV

Mercon SP

Mitsubishi SP-IV & ATF J-2

Nissan Matic S

SAAB 93 165 147

Toyota Type WS (JWS 3324)

VW G 055 005

VW G 055 162

VW G 055 540

VW G 060 162

ZF Lifeguardfluid8

8HP45, 8HP45X, 8HP55A 8HP70, 8HP70X, 8HP90, en 9HP48.

PERFORMANCE

ZF S671 Lifeguard 6
BMW 83220142516
BMW 83220144137
BMW M1375.4
Hyundai 040000c90sg
Jaguar Fluid 8432
Landrover TYK500050
VW/Audi G 055 005 A1/A2/A6

PERFORMANCE

ZF S671 Lifeguard 6
BMW 83220142516
BMW 83220144137
BMW M1375.4
Hyundai 040000c90sg
Jaguar Fluid 8432
Landrover TYK500050
VW/Audi G 055 005 A1/A2/A6

"Y" Shaped Valve Retainer

Part No. 95740-04K

Package Quantity: 10

For:

6R100, 6R60, 6R75, 6R80 (2009-2014), 6R80 (2015-Later), 845RE, 

ZF6HP19, ZF6HP21, ZF6HP26, ZF6HP28, ZF6HP32, ZF6HP34, ZF8HP45, ZF8HP50, ZF8HP55, ZF8HP70, ZF8HP75

Sol.reg. valve OS ZF6HP26, ZF6HP19

ZF valve name: DR.REO-V

In ZF6HP19/26/32 (Gen. 1) and Ford 6R60, 6R80 units, the variable force solenoids control clutch apply/release, torque converter clutch apply/release and line pressure. The solenoid pressure regulator valve ensures proper flow and pressure to the solenoids during hot conditions and low pressure.

Low feed pressure at idle can create delayed engagement or wrong gear starts. This valve also limits the maximum pressure to all the solenoids. Excessive solenoid feed pressure can flood the solenoids, causing gear ratio codes, harsh up/downshifts and excessive line pressure.

Clutch A & E Control Boost Valve Kit

Sevices 2 bores

ZF6HP21/28/34 (Gen. 2) transmissions are equipped with an aluminum sleeve for the clutch A and E control boost valve. This material is prone to wear from valve plunger reciprocation. Failure of this sleeve results in a variety of shift problems and solenoid codes. The Sonnax clutch A and E control boost valve kit 95740-28K will restore the correct hydraulic clearance and proper function of the assembly.

Contents

Sol. press.reg valve kit OS 6HP21/28/34

ZF valve name: DR.REO-V

Pressure reg.valve kit OS 6HP21/28/34

 ZF valve name: SYS.DR-V

In ZF6HP21/28/34 (Gen. 2) valve bodies, wear is commonly found at different areas in the pressure regulator bore.

Wear at the balance end causes high pressure spikes leading to broken drums, pistons or other parts and wear at the spring end of the bore allows low line pressure and lube/TC fluid to exhaust, leading to burnt converter clutches and premature bushing failure.

The Sonnax oversized pressure regulator valve kit 95740-69K restores valve-to-bore clearances to maintain correct pressures.

Overs.Lubrctn Cntr v.kit 6HP21/28/34

ZF valve name: SCHM-V 

In ZF6HP21/28/34 (Gen. 2) valve bodies, severe wear of the lubrication control valve bore results in loss of converter pressure, cooler flow and critical lube feed resulting in overheating as well as bushing, bearing and planet failures.

The Sonnax oversized lubrication control valve kit 95740-71K restores the function of the lube control valve and limits oil loss due to a worn bore.

A & E cntl Valve kit OS 6HP21/28

This kit fits either clutch A or E control bore locations in E-shift versions of ZF6HP21/28/34 (Generation 2) valve bodies only. For M-shift versions use 95740-66K.

Flare upshifts or downshift bind-ups are common problems in vehicles equipped with ZF6HP21/28/34 (Generation 2) transmissions. These problems can be accompanied by a coastdown neutral condition or pressure control out-of-range codes.

The clutch control valves control clutch apply and release timing, and problems occur when the clutch control valves wear. Sonnax offers the oversized clutch A and clutch E control valve kit 95740-72K (E-shift version) to restore shift timing and vehicle drivability.

Shift valve 3 kit OS 6HP21/28

This kit fits M-shift versions of ZF6HP21/28/34 (Generation 2) valve bodies only.

Harsh reverse engagement, slippage in reverse or a burned D1 brake can indicate a worn shift valve 3 in vehicles equipped with ZF6HP21/28/34 (Gen. 2) units. In Reverse, the valve uses reverse pressure to regulate line pressure into the D1 brake control circuit. The valve moves under the combined influence of the spring and orificed reverse pressure inboard, which are opposed by reverse pressure outboard.

Wear at the inboard spool can reduce apply pressure, causing the D1 brake to slip and burn. Outboard wear lessens the valve's ability to regulate line pressure leading to a harsh D1 apply. Sonnax oversized shift valve 3 kit 95740-74K allows the worn bore to be refurbished, restoring proper hydraulic clearances and eliminating loss of valuable line, reverse and D1 brake control circuit fluid pressures.

Bypass Cl Cntrl V.kit OS, 6HP21/28/34

This kit fits E-shift versions only of the ZF6HP21/28/34 (Generation 2) and ZF6HP19/26/32 (Generation 1) valve bodies with an 053 separator plate.

In the noted units, the position valve, a two-valve train controlled by the MV2 solenoid, directs line pressure to the driving clutches (A, B, E) through their related clutch regulator valves. Wear of either valve’s spools or in the bore (depending on the wear location) can result in loss of command fluid pressure from the MV2 solenoid or reduced line pressure to the clutch regulator valves.

In either case, the result is loss of apply fluid pressure to the driving clutches. Initial signs of this problem are shift issues leading to slipping in gear as the clutches burn and eventually disintegrate. Sonnax oversized position valve 95740-75K allows the worn bore to be refurbished, restoring proper hydraulic clearances and eliminating loss of necessary MV2 command fluid at the position valve or line pressure to the clutches.

Press.reg.v. OS ZF6HP26, ZF6HP19

Cannot be used in units that have a 053 separator plate.

OE valve name: SYS.DR-V

Wear is commonly found at different areas in ZF6HP19/26/32 (Gen. 1) and Ford 6R60/6R80 pressure regulator bores. Wear at the sleeve end causes high line pressure leading to broken drums, pistons or other parts, as well as restricted converter/lubrication flow.

Wear at the spring end of the bore allows low line pressure and lube/TC fluid to exhaust leading to a burned converter clutch and premature bushing failure. The Sonnax oversized pressure regulator valve kit 95740-01K restores valve-to-bore or sleeve clearances so the pressure regulator valve can maintain correct pressures.

Press.reg.sleeve ZF6HP26, ZF6HP19

Does not fit units with a 053 separator plate. Verify OE valve & sleeve measurements before use.

Wear is commonly found at different areas in the ZF6HP19/26/32 (Gen. 1) and Ford 6R60, 6R80 pressure regulator bores. When the sleeve is worn, line pressure balance fluid will leak to exhaust, causing high or inconsistent pressure.

When wear is limited to the sleeve, the Sonnax direct replacement pressure regulator sleeve 95740-03 will restore valve-to-sleeve clearances so the pressure regulator valve can maintain correct pressures.

If the remainder of the pressure regulator bore is worn, consider Sonnax oversized pressure regulator valve kit 95740-01K.

Conv.reg.v. OS ZF6HP26, ZF6HP19/21/28

OE valve name: WK-V

In ZF6 & Ford 6R applications listed above, the oversized converter release regulator valve provides lube pressure regulation and contributes to the timing of the converter clutch apply/release action. Significant bore wear can allow release or apply pressures to leak to sump, which results in converter clutch slippage and related codes.

This can affect lockup clutch apply and release timing and feel. Installation of the Sonnax oversized converter release regulator valve kit 95740-05K restores circuit pressure regulation and control timing of the converter clutch apply/release action.

Required tool:

F-95740-TL5

Clutch D1/E cntrl.v. OS ZF6HP26, ZF6HP19

Flare upshifts or downshift bind-ups are common problems in vehicles equipped with ZF6HP19/26/32 (Gen. 1) and Ford 6R60, 6R80 transmissions. These problems can be accompanied by a coastdown neutral condition or pressure control out of range codes.

The clutch control valve controls clutch apply and release timing, and problems occur when the clutch control valve or bore wears.

To fix these issues, Sonnax offers the oversized clutch D1/E control valve kit 95740-08K. Installing this kit will restore shift timing and vehicle drivability.

Kit is NOT compatible with ZF6HP21/28/34 (Gen.2) units. To differentiate between Gen. 1 and Gen. 2 valve bodies, see ZF Identification Guide.

Required tool:

F-95740-TL8

Oversized Clutch A Control Valve Kit

Partnr. 95740-09K

Tooling: F95740-TL8

Flare upshifts or downshift bind-ups are common problems in vehicles equipped with ZF6HP19/26/32 (Gen. 1) and Ford 6R60, 6R80 transmissions.

These problems can be accompanied by a coastdown neutral condition, or pressure control out-of-range codes.

The clutch control valve controls clutch apply and release timing, and problems occur when the clutch control valve wears. To fix these issues, Sonnax offers the oversized clutch A control valve kit 95740-09K to restore shift timing and vehicle drivability.

Lubrication cntrl v OS ZF6HP26, ZF6HP19

OE valve name: SCHM-V

Severe wear of lubrication control valve bores in ZF6HP19/26/32 (Gen. 1) and Ford 6R60, 6R80 units can allow loss of converter pressure, cooler flow and critical lube feed resulting in overheating and failure of bushings, bearings and planets.

The lube control valve also supplies balance pistons with oil, so bore wear can also cause shift timing issues such as bumps and flares. Reconditioning the bore and installing Sonnax oversized lubrication control valve kit 95740-11K renews the functions of the lube control valve and restores normal circuit operation.

Required tool:

F-95740-TL11

OS Bypass Clutch Control Valve Kit

OE valve name: WD-V

Common problems in vehicles equipped with ZF6HP19/26/32 (Gen. 1) and Ford 6R60, 6R80 transmissions include torque converter clutch slip, firm shifts and an overheating torque converter.

One cause of these problems is a worn bypass clutch control valve resulting in slow applyand release of the torque converter clutch. Installing the Sonnax oversized bypass clutch control valve kit 95740-13K restores factory torque converter clutch apply and release rates. This will resolve the converter slip, harsh shift and overheating problems.

Required tool:

F-95740-TL13

Accumulator.pist.kit 6HP19, 6HP26, 8HP

Overly firm up/downshift feel or harsh engagement can be a sign of deformed accumulator piston bumpers in ZF6HP19/26/32 (Generation 1), ZF6HP21/28/34 (Generation 2), ZF8HP45/55/70, and Ford 6R60, 6R80 units.

The OE elastomeric (rubber) bumpers tend to take a set, resulting in loss of hydraulic damping. The Sonnax accumulator piston kit 95740-15K restores hydraulic damping with improved service life.

Boost sleeve A-clutch  6HP gen1

ZF6HP19/26/32 (Gen. 1) and Ford 6R60, 6R80 transmissions are equipped with a plastic sleeve for the clutch A control boost valve. This material is prone to damage, especially during removal. Failure of this sleeve results in delayed or harsh forward engagement, flare 5-4 downshifts and no 4-5 upshift.

The Sonnax clutch A control boost valve and sleeve kit 95740-21K will restore the 4-5 downshift function, correct the missing 4-5 upshift as well as correct forward engagement problems.

The Sonnax boost valve and sleeve kit can also be used to replace an OE boost assembly that was damaged during disassembly and must be used with the OE clutch A control valve.

End plug kit internal ZF6HP26, ZF6HP19

Valves, springs and pressurized fluid repeatedly push on end plugs causing them to deform and wear. As a result critical pressure is lost due to excessive clearance between the plug and bore.

The Sonnax double O-ring sealed end plug kit for ZF6HP19/26/32 (Gen. 1) and Ford 6R60, 6R80 units replace the damaged OE end plugs and restore pressure containment to the valve bore. Sonnax internal end plug kit 95740-25K services the four individual bores in the valve body which use internal end plugs to isolate valves from solenoids.

End Plug Kit, O ringed 6HP21/28

Valves, springs and pressurized fluid repeatedly push on end plugs causing them to deform and wear. As a result, critical pressure is lost due to excessive clearance betweeen the plug and bore.

Sonnax O-ringed end plug kit 95740-27K services the eight individual bores in the ZF6HP21/28/34 (Gen. 2) valve body which use internal end plugs to isolate valves from solenoids. The O-ringed end plugs replace damaged OE end plugs and restore pressure containment to the valve bore.

Also available for this unit is the double O-ringed end plug kit 95740-30K that services all seven of the 12mm dia. bores.

NOTE: Kit is NOT compatible with ZF6HP19/26/32 (Gen.1) units. To differentiate between Gen. 1 and Gen. 2 valve bodies, see ZF Identification Guide.

End Plug Kit, O ringed internal 6HP21/28

Valves, springs and pressurized fluid repeatedly push on end plugs causing them to deform and wear. As a result, critical pressure is lost due to excessive clearance between the plug and bore.

Sonnax O-ringed internal end plug kit 95740-30K services the seven individual bores in the ZF6HP19/26/32 (Gen. 1) with 053 separator plate code, and ZF6HP21/28/34 (Gen. 2) valve bodies which use internal end plugs to isolate valves from solenoids. The double O-ringed end plugs replace damaged OE end plugs and restore pressure containment to the valve bore.

Press.reg.v. OS ZF6HP26, ZF6HP19

Fits units with 053 separator plate only. Verify OE valve & sleeve measurements before use.

OE valve name: SYS.DR-V

Vehicles equipped with ZF6HP19, ZF6HP26 and ZF6HP32 transmissions often develop erratic or high line pressure due to excessive wear in the OE pressure regulator bore and/or sleeve. This wear allows critical oil loss, preventing proper line pressure regulation.

Without correct oil pressure, the PR valve will be out of its desired position, resulting in line pressure instability and possibly restricting cooler and lube flow. Reconditioning the bore and installing Sonnax oversized pressure regulator valve kit 95740-78K renews pressure regulator action for revived line pressure control in all ranges.

Oversized "E" Latch Valve Kit
Part No. 95740-80K

O-Ringed End Plug Kit

Part No. 95740-81K

Fits ZF6HP19/26/32 (Gen. 1) units with 053 separator plate code only.

• Valves, springs and pressurized fluid repeatedly push on end plugs causing them to deform and wear.

• As a result, critical pressure is lost due to excessive clearance between the plug and bore.

Sonnax O-ringed end plug kit 95740-81K for ZF6HP19/26/32 (Gen. 1) units with a 053 separator plate code replaces the damaged OE end plugs, and restores pressure containment to the valve bore.

Prevents loss of critical pressure Single O-ring sealed end plugs replace all 11 of the 13mm and 17mm dia. end plugs

ZF6HP/6R60 Sure Seal End Plug Kit (Superior K095) Problem Solvers

With our new ZF6HP19,24,26,30,32 and Ford 6R60 thur 6R75/80 End Plug Kits and Pressure Regulator Support Sleeve, you won't have to worry about cutting the seals on the sharp bore clip retainer slots either.

Simple and Precise, The New K095 End Plug Kit seals and prevents fluid loss of the often loose and worn sides of the stock end plugs and the worn O.E. P.R. Valve Sleeve.

CAUSE:

Due to the constant oscillations and cycling of the valve, the head of the valve contacts the butt of the O.E. designed end plug causing the O.E. aluminum shoulder of the Plug to prematurely wear against the bore wall.

COMPLAINT:

This wear creates circuit leakage and allows fluid to bypass the end plug. The complaint is usually low pressures to the circuit, slips, flairs, downshift clunks, bangs and eventually burnt frictions. Technicians have reported that even if they use a tube cutter to "knurl" the sides, it is only a short term band-aid. Eventually it wears off the "knurl" and leakage returns.

CORRECTION:

The New Proprietary Design of the Superior Transmission Parts Inc. K095 Product incorporates a "Self Sealing" feature.

As pressure pushes against the rear of the New End Plug, the plug compresses the seal to the bore wall and the unique design creates a "Sure-Seal" between the plug shoulder and bore wall.

End plug kit ZF6HP26, ZF6HP19

Valves, springs and pressurized fluid repeatedly push on end plugs causing them to deform and wear. As a result critical pressure is lost due to excessive clearance between the plug and bore.

The Sonnax O-ring sealed end plug kits for ZF6HP19/26/32 (Gen. 1) and Ford 6R60, 6R80 units replace the damaged OE end plugs and restore pressure containment to the valve bore. Sonnax O-ringed end plug kit 95740-19K has single O-ring sealed end plugs that service all 12 of the 13mm and 17mm diameter bores.

OE-quality valve body separator plate for ZF6HP19/26/32 (Generation 1) applications.

These plates incorporate a black silicon sealant bead to bond upper and lower valve body sections together once rebuild is complete.

This plate is a direct replacement part for:

• OE Valve Body Codes: A035 and B035

• Number Stamped on Original Plate: 1068-327-141

OE-quality valve body separator plate for ZF6HP19/26/32 (Generation 1) applications.

These plates incorporate a black silicon sealant bead to bond upper and lower valve body sections together once rebuild is complete. This plate is a direct replacement part for:

• OE Valve Body Codes: A047 and B047

• Number Stamped on Original Plate: 1068-327-163

OE-quality valve body separator plate for ZF6HP19/26/32 (Generation 1) applications.

These plates incorporate a black silicon sealant bead to bond upper and lower valve body sections together once rebuild is complete. This plate is a direct replacement part for:

• OE Valve Body Codes: A036 and B036 Number Stamped on Original Plate: 1068-327-145

• OE Valve Body Codes: A051 and B051 Number Stamped on Original Plate: 1068-327-179

OE-quality valve body separator plate for ZF6HP19/26/32 (Generation 1) applications.

These plates incorporate a black silicon sealant bead to bond upper and lower valve body sections together once rebuild is complete.

This plate is a direct replacement part for:

• OE Valve Body Codes: A052 and B052

• Number Stamped on Original Plate: 1068-327-180

OE quality valve body separator plate for ZF6HP19/26/32 (Generation 1) applications.

These plates incorporate a black silicon sealant bead to bond upper and lower valve body sections together once rebuild is complete.

This plate is a direct replacement part for OE valve body codes A046 and B046.