New OE Transfercase!

Only for 6T45/6T50 Automatic Transmission
(MHC)

Suitable for the following cars:
· Chevrolet Captiva 2.4L & 3.0L Gasoline
· Opel Antara 2.4L & 3.0L Gasoline
· Vauxhall Antara 2.4L & 3.0L Gasoline

Compatible with OE References:
· 23247709
· 24255142
· 24263580

Zip kit 6T40

• Pressure Switch Rebuild Kit 
• End Plugs (5)
• Compensator Feed Regulator Valve Kit 
• TCC Regulator Apply Valve, Shuttle Valve, End Plug, Spring & O-rings 2 O-Rings, 1 Extra
• AFL Valve, Sleeve, Spring & Retainer 
• Checkballs (6) .250" Dia.
• Drill Bit .062" Dia. 
• Aluminum Plugs (2) .062" Dia., 1 Extra
• O-Rings (7) 2 Extra

The Zip Kit quick guide provides clear and easy instructions on one sheet to get the unit sealed up and back on the road quickly. In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum testing information and locations at other key areas of the valve body.

• No reaming required
• Installs quickly with no separate special tools required
• Uniquely designed parts address root causes of valve body concerns by sealing critical pressure circuits
• Detailed technical booklet included with in-depth rebuild and inspection tips for comprehensive valve body repair
• Allows salvage of expensive TEHCM

Fits General Motors 6T40 2007-Up Generation 1 only                      

Includes Actuator Feed Limit valve assembly; New Pressure Regulator Valve for pump stability and Pressure Switch repair parts to save a TEHCM with pressure switch codes. 

Addresses Pressure Regulator valve, Actuator Feed Limit valve malfunctions which cause erratic high pressure condition that results in broken parts. Improves and restores correct drivability with added durability. Convenient drop in valves, No special tooling or machining necessary!

Symptoms:

• Burnt clutches

• Line pressure instability

• Loss of fuel economy

• No line rise

• Pressure loss

• Shift concerns

• TCC apply & release concerns

• TCC codes

Cause:

Loss of oil pressure due to worn components in critical circuits.

Correction:

Recover hydraulic control, restore normal shift operation and save the transmission control unit by installing Sonnax Zip Kit.

No tools needed.

Fits GEN2 Only. GEN2 units have no pressure switches in the TEHCM

Due to the new vent locations and the amount of bore wear, 6T40 GEN2 valve bodies have leakage issues that can only be corrected by reaming and installing new actuator feed limit (AFL) valves.

There are three FWD 6-speed GEN2 valve bodies that require reaming, so TransGo developed and engineered one universal tool kit for all three units. You will need to purchase separately the#AFL-G2-TL  toolkit to repair the actuator feed limit system.

Features:

• Drop-in components to address ratio and solenoid performance codes

Corrects/Prevents/Reduces:

• Erratic high pressure condition resulting in broken components

Includes:

• Drop-in pressure regulator valve
• Actuator feed limit valve assembly

Required:

#AFL-G2-TK toolkit to repair the actuator feed limit system

Zip kit 6F35

• O-Ringed End Plug Kit 
• Control Pressure Regulator Valve Kit 
• TCC Regulator Valve Kit, Spring, Shuttle Valve, End Plug & O-Rings 2 O-rings, 1 extra
• AFL Balance Plugs (2) Not Shown
• Solenoid Pressure Regulator Valve, Sleeve, Spring & Retainer Clip 
• SSA Damper Piston & Spring 
• Checkballs (3) .250" dia.
• Drill Bit Not Shown

Features and benefits:

This TransGo Shift Kit includes an oversized solenoid pressure regulator valve. The new valve is oversize, therefore you will need the TransGo tool-kit part # AFL-G2-TL to ream the bore. This universal tool-kit works for all generation 2 6F35, 6T30, 6T40, 6T45, 6T50, 6T70, 6T75 and 6T80 transmissions.

A new drop-in hardened steel TCC regulator valve that has re-positioned longer lands and incorporates a groove where a scarf cut seal is fitted so that it seals in the original worn bore. Also, a drop-in two-piece design PR valve reduces sticking and restores the function and reliability of the pressure regulator system. In addition, this valve will not delaminate and create future bore wear problems like the OE coated valves do. The two-piece design valve out performs the single piece valve in all operating environments. Lastly, the kit includes an improved replacement valve body separator plate and gaskets.

Corrects/Prevents/Reduces:

• 2-3 cut-loose
• No reverse
• Erratic or hunting TCC
• Codes: P0729, P0731, P0732, P0733, P0734, P0735, P0741 and P1744

Includes:

• Drop-in USA-made hardened steel two-piece pressure regulator valve
• Oversized USA-made hardened steel solenoid regulator valve
• Drop-in USA-made hardened steel TCC regulator valve, scarf cut sealing ring, spring and O-ring (for sizing only)
• Improved valve body separator plate and gaskets

Case Saver Kit
Part No. 144281-01K

Oversized pressure regulator valve

• Valve 
• Spring 
• End Plug 

GM 6T40, 6T45 and 6T50 first generation transmissions may exhibit multiple line pressure and converter-related problems due to high wear in the main pressure regulator bore. Wear at the balance spool end allows critical fluid loss, resulting in excess line pressure, harsh shifts, and reduced cooler/converter flow. Wear at the outboard spool robs converter feed pressure and lowers line pressure, resulting in soft shifts and burnt clutches. Reconditioning the bore and installing Sonnax oversized pressure regulator valve kit 144510-01K restores hydraulic integrity for proper line pressure control in all ranges.

• Oversized pressure regulator valve and matched spring restore OE function
• Hardcoat anodized aluminum valve combats premature wear
• Annular grooves help center valve in bore to reduce future side-load wear

TCC Control Valve 6T40E OS

• Valve 
• Spring 

• Hardcoat anodized aluminum valve combats premature wear

Pressure Switch Rebuild Kit
Part No. 144510-09K

Contents

• Allows salvage of TEHCM
• No special tools necessary

Lube On Demand Valve Kit

In 2014, GM moved to Generation 3 on the 6T40 family, featuring a vastly different pump than previous generations. The pump moved to an off-axis, binary vane style design that reduces pump flow demands and torque requirements, aiding in better fuel economy. A lube on demand regulating valve has been added to the pump, allowing cooler/lube flow to double when converter feed is above 87psi. This highly active valve is a huge source of pump wear, opening a path for converter feed pressure to exhaust, resulting in converter apply issues, reduced line pressure and overheating.

Sonnax has developed a unique, patent-pending, drop-in solution that maintains the integrity of the OE design of double-flow at increased pressure, while mitigating any existing bore wear and preventing future pump casting degradation. Sonnax drop-in lube on demand valve kit 144510-19K reroutes fluid to a sleeved limit valve for proper cooler/lube flow and includes an O-ring to seal the path that previously allowed valuable converter feed pressure to exhaust.

Sol.reg.v. OS 6T40 GM

The function of the actuator feed limit (AFL) valve is to provide regulated pressure to shift solenoids. Wear in the AFL bore causes low clutch pressure and results in transmission slips/harsh shifts. This eventually leads to a loss of 4th through 6th gears, and finally the loss of transmission function. Reconditioning the bore and installing Sonnax oversized AFL valve 144740-01 restores hydraulic control for revived shift operation in all ranges for first generation GM 6T40/6T45/6T50 units.

• Hardcoat anodized aluminum valve combats premature wear
• Annular grooves help center valve in bore to reduce future side-load wear

End plug kit 6T40/45/50 (gen 1)

• End Plugs (6)
• O-Rings (9) 3 extra

TCC reg.v. OS 6T40 GM

• Regulator Valve 
• Shuttle Valve 
• End Plug 
• Spring 
• O-ring 

• Lengthened spools for additional bore contact and support
• Hardcoat anodized aluminum valves combat premature wear
• Annular grooves help center valves in bore to reduce future side-load wear

Symptoms:

• 1-2-3-4 Clutch burned

• Delayed engagement

• Harsh shifts

• Shift quality is not load sensitive

• Slide shifts

• Slip codes

• Slips & flares

Cause:

Wear in 1-2-3-4 clutch boost valve bore causes feedback pressure instability, preventing normal shift operation.

Correction:

Recover hydraulic control and renew shift performance by reconditioning the bore and installing Sonnax oversized clutch boost valve kit.

Tooling:

F-144740-TL22 • VB-FIX

Sol.reg.v. OS 6F35 Ford

The function of the solenoid pressure regulator is to provide regulated pressure to shift solenoids. Wear in the solenoid pressure regulator bore causes low clutch pressure and results in transmission slips/harsh shifts. This eventually leads to a loss of 4th through 6th gears, and finally the loss of transmission function. Reconditioning the bore and installing Sonnax oversized solenoid pressure regulator valve 144740A-01 will restore hydraulic control and prevent wear in the Ford 6F35 unit.

• Hardcoat anodized aluminum valve combats premature wear
• Annular grooves help center valve in bore to reduce future side-load wear

The 3-5-R waved plate in GM Gen. 1 and 2 6T40, 6T45, 6T50 units commonly fails and breaks into pieces, resulting in code P0776, harsh and flare shifts or complete loss of 3-5-R.

Additionally, the broken pieces damage the housing splines, requiring a new housing. Even though the OEM attempted to prevent this issue with an updated waved plate, there are still units with the updated plates failing in the field. Sonnax 3-5-R drum saver kit 144555K is specially designed to allow salvage of the damaged housing by preventing the damaged spline portion from interfering with proper clutch pack travel.

Precision-machined, billet cupped steel plate restores stack height and centers waved plate Better than OE-quality, shot-peened, stress-relieved waved plate designed to operate without interference from damaged housing splines Sonnax kit can be used to restore normal operation or on an undamaged housing to prevent failure

Contents

• Cupped Steel

• Plate Waved Plate

1. Disassembly

a. Remove OE 3-5-R clutch pack.

b. Locate, remove and discard all pieces of broken OE waved plate.

c. Discard OE steel plate located next to waved plate.

2. Installation & Assembly

a. Install Sonnax waved plate on top of piston.

b. Install Sonnax cupped steel plate on top of waved plate, lip facing downward.

c. Continue assembling clutch pack.

3. Verify Correct Clearance

After snap ring installation, verify clutch pack clearance is within specification (.020-.060") using a dial indicator.

Note: If there is too much clearance, the piston had been distorted. In these cases, piston replacement is required to enable proper clearance.

Bushing
Part No. GM-B-8

For use with bushing style impeller hubs only.

Part # K0199 thick wall bushing;

fits all 2014-up 6F35 Ford units.

These can be used during overhaul as an upgraded seal & bushing fix or added to the K0100 for a late 2014–up 6F35 case.

6F35 / 6T40 Axle Tool Kit (Superior K0100) Problem Solver

Complaint:

ATF leak from axle area on the driverâ??s side. This is usually due to a worn axle/case bushing and can result in seal failure, causing shifting complaints or slippage as is common with low fluid-level condition.

Root Cause:

Original bushing fails due to inadequate surface area, Babbitt material fatigues due mainly from stress and lack of lubrication to bushing surface and CV axle stub shaft.

The Superior Correction:

The durable SuperTuff Teflon coated bushing from Superior Transmission Parts Inc. virtually eliminates premature wear and the resulting leak at the axle seal.

The new SuperTuff bushing is 23% wider than original to offer more support, Teflon coated for durability and engineered with a lube window that allows more oil in to provide better lubrication. Our New K0100 includes a high-quality, 3-piece tool set designed for quick removal of the worn bushing and an indexed re-installation of the SuperTuff bushing. The two-sided driver head allows the user to install an included seal made of better-than-OEM materials.

Kit includes:

(5) axle seals and (5) SuperTuff Teflon bushings.

Re-order Kit K099 for bushing and seal reloads ( one seal / one bushing per K099 ).

**Needs to be programmed after installation**

Suitable for:
Opel, Vauxhall & Chevrolet

Compatible with OE References:
· 24041955
· 24287419

**Needs to be programmed after installation**
2012-2017
TEHCM; Confirm OEM Part Number Before Purchasing; OE:24252577, 24260642, 24262069, 24264425, 24265367, 24265789, 24275863

**Needs to be programmed after installation**

Suitable for:
Opel, Vauxhall & Chevrolet

Compatible with OE References:
· 24041958
·24257276
· 24258582
·24260030
·24264683
·24275861
·24287422

**Needs to be programmed after installation**

Suitable for:
Opel, Vauxhall & Chevrolet

Compatible with OE References:
· 24252871
· 24253557
· 24256524
· 24258587
· 24260028
· 24275859
· 24264420
· 24287420

**Needs to be programmed after installation**

Suitable for:
Opel, Vauxhall & Chevrolet

**Needs to be programmed after installation**

Suitable for:
Opel, Vauxhall & Chevrolet

Compatible with OE References:
·24265367
·24275863
·24287424

**Needs to be programmed after installation**

Suitable for:
Opel, Vauxhall & Chevrolet

Compatible with OE References:
· 24267724
· 24275865
· 24277473
· 24287426
· 24291306