Toyota u151e-u250e

zip Kit
PaRT NUMBER u151e-u250e-ZIP Installation & TESTING BOOKLET

Torque Specifications Electronic Cautions

Pan Filter to Valve Body Oil Pan to Transaxle
8 ft-lb 69 in-lb
Resetting Shift Adapts
The ECM (engine control module) has memorized values which must be relearned
Component Pack Clearance after transmission repair. Use a scan tool (OE factory tool recommended) to reset
Forward (C1) Clutch Low & Reverse (B2) Brake the ECM.
U151E & U250E: U151E: .046–.053"
.039–.049" Post-Adapt Road Test
U250E: .029–.048"
After resetting the ECM, a road test is required. Start the engine and warm it to
2nd (B1) Brake Reverse (C2) Input
normal operating temperature. Perform a thorough road test with multiple accelera-
U151E: .024–.036" U151E & U250E:
.024–.032" tions from a stop until proper shifting is obtained.
U250E: .021–.036"
Direct (C0) Clutch Underdrive (B3) Brake Solenoids
U151E: .024–.033" U151E: .071–.087" Solenoids should be cleaned to remove debris that results in sticking and malfunction.
U250E: .020–.033" U250E: .065–.087"
Underdrive (C3) Clutch
U151E & U250E:
.059–.067"
End Play
Input Shaft Underdrive Unit
U151E & U250E: U151E: .020–.040"
.010–.049" U250E: .008–.027"
Direct Clutch Assembly Toyota/Lexus U151E/F, U250E Typical Solenoid Firing Order
U151E: .010–.036"
U250E: .008–.038" Gear SL1 SL2 SL3 S4 SR DSL/TCC SLT
1st ON ON Off Off Off ON/M1
Fluid 2nd Off ON Off Off Off Off
Modulates
Toyota Genuine ATF WS PN: JWS3324 or NWS9638 3rd ON Off Off Off ON ON based on
Fluid level should be between the 2 hot marks on the stick: engine load.
4th Off Off ON Off ON ON
• Dry Fill: 8.8 liters • Drain and Re-fill: 3.5 liters
5th Off Off ON ON ON ON

Toyota/Lexus U151E/F, U250E Component Application Chart

Reverse Low & No. 1 No. 2
Forward Input Direct Underdrive 2nd Brake Reverse Underdrive One Way One Way
Gear Range Clutch C1 Clutch C2 Clutch C0 Clutch C3 B1 Brake B2 Brake B3 Clutch F1 Clutch F2
Park ON
Reverse ON ON ON
Neutral ON
D-1st Gear ON ON ON ON
D-2nd Gear ON ON ON ON
D-3rd Gear
ON ON ON
High Ratio
D-3rd Gear
ON ON ON ON
Low Ratio
D-4th Gear ON ON ON ON
D-5th Gear ON ON ON

©2012 Sonnax Industries, Inc. U151E-U250E-ZIP-Booklet 02-17-12

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 U151E-U250E Zip Kit Installation & Testing Booklet
TIME TESTED • INDUSTRY TRUSTED

Figure 1
Zip Kit Instructions Bolt
Color Code
Bolt
Length

1. Valve Body Removal from Case Red 16.75mm

Green 21.50mm
Remove the 19 bolts indicated (Figure 1).
Yellow 25.00mm
2. Valve Body Disassembly: Step 1 Lt Purple 26.50mm
Note: See Figure 2 for bolt locations. Purple 35.50mm
Solenoids can be put into the wrong location in the White 41.00mm
valve body. Ensure each of them are put back in their Lt Blue 46.50mm
correct location. Solenoid designs have changed over the Blue 57.00mm
years, see Figure 3 for the most common configuration. Orange 62.50mm
a. Remove bolt #1 and locking plate. Remove shift
solenoid SL3 and the SLT solenoid.
b. Remove bolt #2 and shift solenoid S4, then SR solenoid.

Valve Body Removal from Case

c. Remove bolt #3 and shift solenoid DSL.
d. Remove bolt #4 and locking plate. Remove shift solenoid SL2.
e. Remove bolt #5 and locking plate. Remove shift solenoid SL1.
Figure 2
f. Remove the seven #6 bolts.
3 6 6 g. Remove the #7 bolt.

3. Valve Body Disassembly: Step 2

6
Note: See Figure 4 for bolt locations.
4
a. Remove the light blue #1 bolt, retaining bracket and checkball.
6 6
b. Remove the seven remaining light blue bolts.
2 6 c. Remove the purple bolt.
6 7
1

Valve Body Disassembly: Step 1

1 Figure 3 Figure 4

1. DSL (TCC) Solenoid,

2 11–15 Ohms
2. SL2 Solenoid,
4.5–6.0 Ohms
3. S4 Solenoid, 1
11–15 Ohms
3
4. SR Solenoid,
11–15 Ohms
5. SL3 Solenoid,
4 4.5–6.0 Ohms
7
6. SLT Solenoid,
5 6 4.5–6.0 Ohms
7. SL1 Solenoid,
Solenoid Locations and Resistance 4.5–6.0 Ohms Valve Body Disassembly: Step 2

02-17-12 U151E-U250E-ZIP-Booklet ©2012 Sonnax Industries, Inc.

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 U151E-U250E Zip Kit Installation & Testing Booklet
TIME TESTED • INDUSTRY TRUSTED

4. Installation
Figure 5
Install Zip Kit parts as shown on diagram of separate quick guide sheet included in
this Zip Kit.
• When installing the lockup control plunger valve and sleeve kit in Step 4,
reuse the OE spring between the new valve and sleeve.
8
• The Sonnax O-ringed end plugs in Step 6 must be installed with the O-ring
outboard.
5. Valve Body Assembly: Step 1
Note: See Figure 5 for bolt locations.

a. Loosely install the purple bolt.

b. Loosely install the seven, unnumbered light blue bolts. Valve Body Assembly: Step 1

c. Loosely install the light blue #8 bolt, retaining bracket and checkball.
d. Torque all bolts to 90 in-lb. Figure 6
5 2 2
6. Valve Body Assembly: Step 2
Note: See Figure 6 for bolt locations and torque specifications.
2
a. Loosely install bolt #1. 4
b. Loosely install the seven #2 bolts. 2 2

c. Install shift solenoid SL1 and locking plate. Loosely install bolt #3.
6 2
d. Install shift solenoid SL2 and locking plate. Loosely install bolt #4. 7
2 1

e. Install shift solenoid DSL. Loosely install bolt #5. 3

f. Install the SR solenoid, then shift solenoid S4. Loosely install bolt #6.
g. Install shift solenoid SL3 and the SLT solenoid. Install the locking plate and
Valve Body Assembly: Step 2
loosely install bolt #7.
h. Torque all bolts as indicated in chart (Figure 6). Bolt ID & Color Code Installation Torque Specs
Bolt #1 90 in-lb
7. Valve Body Reinstallation to Case Bolt #2 90 in-lb
Note: See Figure 7 for bolt locations. Bolt #3 58 in-lb
a. Loosely install all 19 bolts. Reference the color chart on previous page for bolt Bolt #4 8 ft-lb
lengths. Bolt #5 8 ft-lb
b. First tighten the two #1 positioning bolts to 8 ft-lb. Torque the remaining Bolt #6 8 ft-lb
bolts to the same 8 ft-lb. Bolt #7 58 in-lb

Figure 7

Valve Body Reinstallation to Case

©2012 Sonnax Industries, Inc. U151E-U250E-ZIP-Booklet 02-17-12

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3
 U151E-U250E Zip Kit Installation & Testing Booklet
TIME TESTED • INDUSTRY TRUSTED

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.

Lower Valve Body – Bottom Side • U

 250E Shown Here

4-5 Shift Valve B2 (Low/Reverse) Switch Valve

• Delayed 3rd gear • Burned B2 brake
• Burned UD/C3 clutch • Delayed reverse
• Delayed or no 5th gear • Loss of engine braking in manual low

B2 (Low/Reverse) Apply
Control Plunger
• Burned B2 brake
• Delayed reverse
• Loss of engine braking in manual low
Replace with Sonnax Part No.
27741-06K*

B1 (2nd) Apply
Control Plunger
• Burned B1 brake
• 2-3 or 4-3 Bind-up
• Harsh 1-4 shifts
Replace with Sonnax Part No.
27741-04K*
NOTE: Seal port on opposite side when testing.

Boost Valve
• Insufficient line rise in drive ranges
• Soft shifts
• Higher than normal reverse pressure
Replace with Sonnax Part No.
27741-01K*

Clutch Apply Control Valve

• Shift flares and bind-ups
• Burned forward/C1 clutch, direct/C0 clutch
and 2nd/B1 brake
Replace with Sonnax Part No.
27741-18K
NOTE: Stroke valve to ensure it is not stuck.

*Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately.

02-17-12 U151E-U250E-ZIP-Booklet ©2012 Sonnax Industries, Inc.

Page 4 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
 U151E-U250E Zip Kit Installation & Testing Booklet
TIME TESTED • INDUSTRY TRUSTED

15
20 10
25 5
30 0
VACUUM
TEST For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

Lower Valve Body – Top Side • U

 250E Shown Here

End Plugs, Multiple Locations B2 (Low/Reverse) Switch Valve

• Oil pressure loss • Burned B2 brake
• Shift, engagement and converter complaints • Delayed reverse
Replace with Sonnax Part No. • Loss of engine braking in manual low
27741-20K*
NOTE: Two Locations = 

Pressure Regulator Valve

• Low/High line pressure
• Soft/Harsh shifts
• Clutch and brake failures
• Higher than normal reverse pressure
• Low converter pressure
Replace with Sonnax Part No.
27741-08K


Clutch Apply Control Valve

• Shift flares and bind-ups
• Burned forward/C1 clutch, direct/C0 clutch
and 2nd/B1 brake
Replace with Sonnax Part No.
27741-18K
NOTE: Stroke valve to ensure it is not stuck.


B1 (2nd) Apply
Control Plunger
• Burned B1 brake
• 2-3 or 4-3 Bind-up
• Harsh 1-4 shifts
Replace with Sonnax Part No.
27741-04K*
NOTE: Seal this port and test on opposite side.

Items without part numbers are valid vacuum test locations for indicated drivability complaints, but do not have corresponding Sonnax parts due to low
percentage of bore wear.

©2012 Sonnax Industries, Inc. U151E-U250E-ZIP-Booklet 02-17-12

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5
 U151E-U250E Zip Kit Installation & Testing Booklet
TIME TESTED • INDUSTRY TRUSTED

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 – Bottom Side • U

 250E Shown Here

Solenoid Modulator Valve

• Harsh/Flare upshifts
• TCC slip or RPM cycling
• Loss of cooler flow/overheating
Replace with Sonnax Part No.
27741-13K

B2 (Low/Reverse)
Control Valve
• Burned B2 brake

• Delayed reverse
• Delayed engagement in manual 1st


B3 Orifice Control Valve 
• Burned UD/B3 brake
• Shift complaints
Replace with Sonnax Part No.
27741-16K
NOTE: Stroke valve to ensure it is not stuck.


Accumulator Control Valve 
• Shift complaints
• Burned clutches/brakes

C0 (Direct) Control Valve

• Burned C0 clutch
• Slipping/Flares in 3rd, 4th and 5th 
C0 (Direct)
Accumulator Piston
• Burned C0 clutch
• Slipping/Flares in 3rd, 4th and 5th
Replace with Sonnax Part No.
57917E-19K*†

B1 (2nd) Accumulator Piston

• Burned B1 brake Solenoid Relay Valve
• Slipping/Flares in 2nd, 4th and 5th • Shift complaints
Replace with Sonnax Part No.
57917E-19K*†

*Part numbers with an asterisk (*) are included in this Zip Kit. Other part numbers are available separately.
†
One accumulator piston kit included in Zip Kit, choose most worn location.

02-17-12 U151E-U250E-ZIP-Booklet ©2012 Sonnax Industries, Inc.

Page 6 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
 U151E-U250E Zip Kit Installation & Testing Booklet
TIME TESTED • INDUSTRY TRUSTED

15
20 10
25 5
30 0
VACUUM
TEST For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

Upper Valve Body – Top Side • U

 250E Shown Here

End Plugs, Multiple Locations

• Oil pressure loss
• Shift, engagement and converter complaints
Replace with Sonnax Part No.
27741-20K*
NOTE: Eight locations = 

Lockup Relay Valve

• TCC apply/release problems
• Converter codes
• Burnt converters/overheating

B1 (2nd) Control Valve

• Burned B1 brake
• Slipping/Flares in 2nd, 4th and 5th

Secondary Pressure
Regulator Valve
• Harsh lockup
• Converter apply/release complaints
• Burnt converters
Replace with Sonnax Part No.
57917E-16K

C1 (Forward) Control Valve

• Burned C1 clutch
• Delayed engagements
• Slipping/Flares in 1st, 2nd and 3rd
NOTE: Seal these ports and test on opposite side.

C1 (Forward)
Accumulator Piston
• Burned C1 clutch C1 (Forward) Control Valve
• Delayed engagements • Burned C1 clutch
• Slipping/Flares in 1st, 2nd and 3rd • Delayed engagements
Replace with Sonnax Part No. • Slipping/Flares in 1st, 2nd and 3rd
57917E-19K*† NOTE: Seal ports on opposite side when testing.

Items without part numbers are valid vacuum test locations for indicated drivability complaints, but do not have corresponding Sonnax parts due to low
percentage of bore wear.

©2012 Sonnax Industries, Inc. U151E-U250E-ZIP-Booklet 02-17-12

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 7
 U151E-U250E Zip Kit Installation & Testing Booklet
TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Upper & Lower Valve Body • U250E Shown Here

Installed on Top Side

Upper Valve Body Descriptions
Upper Valve Body
I.D No. Description Bottom Side Shown
201 Lockup Relay Valve 211
Lockup Control Valve & Plunger 201
202 210
Valve Assembly
203 B1 Control Valve 202
204 Secondary Regulator Valve 209 203
205 C1 Control Valve 208
206 Solenoid Relay Valve 204
207
207 C0 Control Valve
205
208 Accumulator Control Valve
209 B3 Orifice Control Valve 206
210 B2 Control Valve
Accumulator Pistons
211 Solenoid Modulator Valve Installed on Top Side
212 C0 Accumulator Piston
213 B1 Accumulator Piston
214 C1 Accumulator Piston

213

212
214

Lower Valve Body

Installed on Top Side Shown
Lower Valve Body Descriptions Bottom Side 101

I.D. No. Description 102

101 Manual Valve
103
102 B2 Switch Valve & Plunger Valve
104
103 4-5 Shift Valve
B1 Switch Valve & Plunger
104 105
Valve Assembly
Main Pressure Regulator Valve 106
105
& Boost Valve Assembly
106 Clutch Apply Control Valve

02-17-12 U151E-U250E-ZIP-Booklet ©2012 Sonnax Industries, Inc.

Page 8 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com