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GM 6T40 (GEN. 1), 6T45 (GEN. 1),
6T50 (GEN. 1) ZIP KIT
PART NUMBER 6T40-ZIP QUICK GUIDE
Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents.

installation Diagram NOTE: All components of this kit

install into the mechatronic unit,
and not the pump. Removal of
the pump is not required for
Control this kit, unless vacuum testing is to
Valve Body be performed.

6
1 Plastic Checkballs

1
CAUTION

Block AFL Balance

WARNING: Spacers should 4 Port by drilling and
not be used on TEHCMs that plugging separator plate
WARNING have plastic fluid conduits. where indicated using drill
bit and aluminum plug
NOTE: Reference pages 3 and 4 in the provided (not shown). Solenoid
technical booklet for installation details.
Valve Body

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.

2014 Sonnax Industries, Inc. 6T40-ZIP_Guide12-23-14

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GM 6T40 ZIP KIT
Quick
Guide

Zip Kit Contents & Installation Steps

Step 1 Replace 5 OE End Plugs Step 5 Replace OE Actuator Feed

Place O-ring in groove, lubricate with Sonnax Slippery Stick O-LUBE Limit (AFL) Valve Lineup
and roll on bench to size.
Remove and discard OE valve and spring. Keep outboard retainer clip
Packaging Pocket 1 for reuse. Install Sonnax sleeve and valve as illustrated. Secure sleeve
into bore by installing included clip into sleeve groove at inboard port.
End Plugs (5) Install included spring and secure all into bore with OE retainer.
O-Rings (7) 2 extra
Packaging Pocket 5
Sleeve
Valve
Step 2 R
 eplace OE Compensator Spring
Feed Regulator Valve Retainer Clip
Packaging Pocket 2
Valve
Sleeve Step 6 Replace OE Checkballs
Spring Packaging Pocket 6
Retainer
Checkballs, .250" dia. (6)

Step 3 R
 eplace TCC Regulator
Step 7 Replace 4 Pressure
Apply Valve Bore Lineup
Switch Laminate Discs &
Remove and discard all OE components except the retainer clip. Keep
retainer clip for reuse. D-Rings (& O-Rings when
CAUTION: The small shuttle valve should be positioned with the applicable)
CAUTION rounded end face outboard, and the blind bore inboard.
Reference pages 3 and 4 in the technical booklet for installation details.
Packaging Pocket 3
Packaging Pocket 7 and 8
Spring
Laminated Discs (4)
Valve
D-Rings (4)
Shuttle Valve
O-Rings (4)
End Plug
Spacers (4)
O-Rings (2) 1 extra
WARNING: Spacers should not be used on TEHCMs that
WARNING
have plastic fluid conduits.

Step 4 Block AFL Balance Port

Drill indicated separator plate orifice with included .062" dia. drill bit.
Remove any burrs. Insert .062" dia. aluminum plug into drilled hole and
peen in place on both sides of plate. Ensure plate will still fit flush on
both castings.
Packaging Pocket 4
Drill Bit, .062" dia.
Aluminum Plugs, .062" dia. (2) 1 extra
CAUTION: Use care when modifying the balance orifice.
CAUTION Gaskets are bonded to the plates and damage could occur.

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GM 6T40 (GEN. 1), 6T45 (GEN. 1),
6T50 (GEN. 1) ZIP KIT
PART NUMBER 6T40-ZIP INSTALLATION & TESTING BOOKLET

6T40 Generation 1 Figure 1 Valve Body Identification

Valve Body
Confirm Generation
This Zip Kit works in Generation 1 6T40 series valve bodies. To confirm core is a
Generation 1 versus a Generation 2, check for 4-5-6 clutch boost valve in control
valve body (Figures 1 & 2).

TCM
Also check the Transmission
6T40 Generation 2 Figure 2 Control Module (TCM) identi-
Control Valve Body Section
fications as shown in (Figures 3
& 4). The valve body and TCM
must have the same Generation.

Adaptive Learning
The 6T40, 6T45 and 6T50 are
Generation 1 - No 4-5-6 clutch boost valve equipped with several adaptive
Generation 2 - Has 4-5-6 clutch boost valve learning strategies. After valve
Figure 3
body service the existing adap-
TCM Identifier Figure 4
TCM tive values will need to be erased. Then, a Fast Learn
Generation 1 1 or 2 or 3 process should be performed. Reference GM material
Generation 2 B or C or D for proper Fast Learn process.

Solenoids
The Generation 1 6T40, 6T45 and 6T50 solenoids are Variable Bleed Type (VBS)
and cannot be interchanged with Generation 2 solenoids. These are calibrated at
TCM Identifier is 8th the factory and switching locations in the valve body should be avoided. Different
digit from left. suppliers were used, resulting in different solenoid plastic snout colors. Colors are
black, blue, yellow and natural.
Solenoid & Clutch Apply Chart Figure 5
Figure 6
Low Rev. 4-5-6
CL PC Sol 3 N.H.

1-2-3-4 Clutch
3-5 Rev. CL PC
1-2-3-4 CL PC

Low & Rev. CL

Shift Solenoid

4-5-6 Clutch

3-5 Reverse

Low & Rev.

2-6 Clutch
2-6 CL PC

Sol 2 N.H.
Sol 5 N.L.

Sol 4 N.L.

Clutch
Clutch

(OWC)

Range/Gear

Park On Off Off Off On Applied*

Reverse On Off Off On On Applied Applied

1
Neutral On Off Off Off On Applied* 2
3
1st
On On Off Off On Holding Applied Applied 4
Breaking 1. Line PCS 5
1st Off On Off Off Off Holding Applied 2. 2-6 PCS
6
2nd Off On On Off Off Applied Applied 3. 1-2-3-4 PCS 7
Drive

3rd Off On Off On Off Applied Applied 4. Shift Solenoid

5. TCC PCS 6T40 Generation 1
4th Off On Off Off On Applied Applied
6. 3-5 Reverse PCS Solenoid Locations
5th Off Off Off On On Applied Applied
7. L/R 4-5-6 PCS
6th Off Off On Off On Applied Applied
Pressure Control Solenoid (PCS) 3-5 ohms at 70oF
NOTE: For shift soleoinds, "ON" = solenoid energized (pressurized), "OFF" = solenoid de-energized
(no pressure). For pressure control (PC) solenoids, "ON" = pressurized, "OFF" = no pressure. *Applied Shift Solenoid 16-20 ohms at 70oF
with no load. Holding but ineffective.

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1st GEN. 6T40, 6T45, 6T50 ZIP KIT 
Installation & Testing Booklet

Figure 7 OSS
Connection
Zip Kit Instructions
1. Valve Body Removal from Case
a. Disconnect the input speed sensor, output speed sensor and shift position
B
B B B switch connectors from valve body.
B B
b. Remove the three control valve body bolts, 40.5mm long (Figure 7).
B
B B B B B c. Remove the 12 control valve body bolts, 105mm long (Figure 7).
Shift
A
A Position d. Remove the control solenoid valve assembly with TCM from valve body.
Switch
Connection e. Remove the nine control valve body bolts, 60mm long (Figure 8).
ISS A
Connection
f. Remove the two control valve body bolts, 53mm long (Figure 8).
g. Remove the valve body from the case.
Figure 8
D D 2. Installation
Install Zip Kit parts as shown on diagram of separate quick guide sheet included in
this Zip Kit. Sonnax recommends vacuum testing critical wear areas not covered
by this kit to determine whether additional Sonnax parts are required (see page 3).
C 3. Filter Plate & Pressure Switches (Figure 12)
C NOTE: Keep the filter plate clear from any solvents, as distortion to the seals could occur.
C C C
C C C a. Remove and replace the filter plate. The seals take a set and will leak if reused.
C
b. Examine the pressure switches and seals for damage or contamination. Fracture
or delamination of the pressure switch laminate disc can occur, requiring seal
Removal Bolts Figure 9
and laminate discreplacement.
Bolt Color Bolt Torque
Quantity
Code Length Specification 4. Valve Body Reinstall into Case
A Red 40.5mm 3 71 in-lb a. Install valve body into case and secure with (2x) 53mm and (9x) 60mm bolts
B Green 105mm 12 106 in-lb until finger-tight (Figure 8).
C Blue 60mm 9 106 in-lb b. Tighten to 106 in-lbs of torque in the indicated sequence (Figure 10).
D Yellow 53mm 2 106 in-lb
c. Install control solenoid body to valve body with (12x) 105mm and (3x)
40.5mm bolts until finger-tight (Figure 7).
Figure 10 d. Tighten (12x) 105mm bolts to 106 in-lb of torque in the indicated sequence
4 5 (Figure 11).
e. Tighten the (3x) 40.5mm bolts to 71 in-lb torque in the indicated sequence.
f. Reconnect the input speed sensor, output speed sensor and shift position
switch connectors (Figure 7).
9
Four Pressure Switches Figure 12
3
8 2 11
10 6 7 NOTE: Valve body
1 shown is a Gen. 1
late (TCM Identifier
#3, Figure 4), which
Figure 11 contains the neutral
or white colored
11 pressure switch
8 4 6 plastic conduits.
2 10
Early Gen. 1 valve
12 9 1 7 bodies (TCM
5 3
Identifier #1 or #2,
13 Figure 4) do not
14 have these
conduits.
15 Filter Plate

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 AKPPHELP.RU
1st GEN. 6T40, 6T45, 6T50 ZIP KIT Booklet
Installation & Testing
TIME TESTED INDUSTRY TRUSTED

Installing Sonnax Pressure Cover Plate Figure 13

Switch Rebuild Kit

GM first generation 6T40, 6T45, and 6T50 transmissions often set
various trouble codes related to failures of fluid pressure switches
that are internal to the transmission control module (TCM). These
codes may be accompanied by shift irregularities such as slipping,
flares, harsh application, and bindups.
As time goes by, the laminated portions of the pressure switches
can breach, preventing normal switch operation. If more than one
switch breaks down, failsafe mode can be triggered. Solenoid
Body & TCM assembly
1. Disassembly
a. Remove retaining screws and detach
Figure 14 Figure 15
solenoid body cover plate (Figure 13). TCM


NOTE: Before installing Sonnax
pressure switch rebuild kit,
test switches to verify proper
electrical operation.
Place ohmmeter leads on each side of pres-
sure switch, outside of the rivet (Figure 14).
Switches are normally closed and should
read from about 2.2 to 2.8 ohms in their non-
operated state. Pressing on the switch opens
the contacts and should result in O.L. reading.
If these tests fail, test resistance again at the Solenoid
switch side, before the rivet; loose rivets can Body
cause circuit interruption. If testing is success-
ful, proceed with installation of Sonnax kit.
Figure 16
b. Separate solenoid body from TCM (Figure 15). Four pressure
switch laminate discs are now exposed on underside of TCM
(Figure 16).
c. Remove D-rings from switches and discard (Figure 17).
d. Using a pencil eraser dabbed with assembly gel, remove OE
laminate discs from switches and discard (Figure 18).

Figure 17 Figure 18

2014 Sonnax Industries, Inc. 6T40-ZIP_Booklet12-23-14

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1st GEN. 6T40, 6T45, 6T50 ZIP KIT 

Installation & Testing Booklet

2. Installation & Assembly Figure 19

a. Ensure any dirt or debris is cleaned from switches before
proceeding.
b. Place Sonnax laminate discs on switches.
c. Install Sonnax D-rings over laminate discs, flat side facing
down. D-rings have slight interference fit; ensure they fit snugly
into switch (Figure 19).
NOTE: Some solenoid bodies are equipped with plastic fluid
conduits (Figure 20). If so equipped, remove conduits to expose
O-rings (Figure 21). Replace O-rings with Sonnax O-rings and
reinstall conduits.
Place Sonnax laminate discs, then install D-rings flat side down.
d. Reinstall solenoid body to TCM (Figure 22).
WARNING: Steps "e" and "f" apply only to units that DO NOT Figure 20
have plastic fluid conduits.
WARNING

e. Turn assembly to expose back side of switches (Figure 23).

f. Place Sonnax spacers over switches. A dab of assembly lube will
help keep them in place during reassembly (Figure 24). These
spacers assist in keeping appropriate support on switches to
provide a good seal and prevent over-flexing, which is vital to
maintaining proper switch function.
Plastic fluid conduits equipped on some solenoid bodies.
WARNING: Do NOT install Sonnax spacers into units equipped
with plastic fluid conduits! WARNING: Do NOT install Sonnax spacers into units equipped
WARNING with plastic fluid conduits!

g. Reinstall solenoid body cover plate and secure with retaining

screws (Figure 13). Figure 22

Figure 21
TCM

Solenoid
Body

Lift plastic fluid conduits to expose O-rings.

Figure 23 Figure 24

Dab with assembly lube and place Sonnax spacers over switches,
then reassemble TEHCM.
WARNING: Do NOT install Sonnax spacers into units equipped with
plastic fluid conduits!

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 AKPPHELP.RU
1st GEN. 6T40, 6T45, 6T50 ZIP KIT Booklet
Installation & Testing 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.

Control Valve Body Front Gen. 1 6T40 Shown *Plug port Compensator Feed
on back.
Regulator Valve
*Plug port
3-5 Reverse Clutch on back.
Harsh shifts; CPC codes
Regulator Valve Bump up/down shifts
Burnt 3-5 reverse clutch Erratic shift quality
Delayed Reverse Replace with Sonnax Part No.
104740-09K*
3rd & 5th Shift complaints

2-3 & 4-5 Shift flare

2-6 Clutch
1-2-3-4 Clutch Regulator Valve
Burnt 2-6 clutch
Regulator Valve
*Plug port 2nd & 6th Shift complaints
Burnt 1-2-3-4 clutch on back. 1-2 & 5-6 Shift flare
Delayed Forward
1-2-3-4 Shift complaints

TCC Regulator
Apply Valve
1-2-3-4 Clutch No TCC/slip, soft apply
Boost Valve Harsh TCC apply
Burnt 1-2-3-4 clutch

Replace with Sonnax Part No.
Delayed Forward 144740-16K
1-2-3-4 Shift complaints Requires F-144740-TL16 & VB-FIX
Replace with Sonnax Part
No. 144740-22 Requires
F-144740-TL21 & VB-FIX
Clutch Select Valve
Various shift complaints
*Plug port
Shift related trouble codes
on back.
Low Reverse
4-5-6 Clutch
Regulator Valve
*Note: Plug casting valley with foam, putty
Burnt L/R & 4-5-6 clutch or appropriately sized O-ring coated in
Delayed Reverse *Plug port assembly lube to isolate circuit.
4-5-6 Shift complaints on back.
3-4 Shift flare
Actuator Feed
Limit Valve
Harsh shifts
No/Slipping shifts
Low clutch pressure
Control Valve Body Back Replace with Sonnax Part No.
144740-01 Requires 144740-TL
Gen. 1 6T40 Shown

O-Ringed End Plugs

*Plug these ports (as
noted above) while Burnt clutches/brakes
vacuum testing. Various shift complaints
NOTE: : Vacuum test end plugs at
outboard port while sealing bore
opening with thumb.
Replace with Sonnax Part No.
*Part numbers with an asterisk (*) 144740-02K*
are included in this Zip Kit. NOTE: Several Locations =
2014 Sonnax Industries, Inc. 6T40-ZIP_Booklet12-23-14
800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com Page 5
 AKPPHELP.RU
TIME TESTED INDUSTRY TRUSTED

1st GEN. 6T40, 6T45, 6T50 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.

Pump Body Gen. 1 6T40 Shown

Pressure
Regulator Valve
Harsh/Soft shifts
High/Low line pressure
Burnt clutches
Replace with Sonnax Part No.
144510-01K
Requires F-144510-TLC & VB-FIX

Plug casting valley with foam, putty

or appropriately sized O-ring coated
in assembly lube to isolate circuit.

TCC Control Valve

Incorrect TCC apply/release
Inadequate lube & cooling
Transmission overheat
Converter codes
Replace with Sonnax Part No.
144510-05K
Requires F-144510-TL5C & VB-FIX

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1st GEN. 6T40, 6T45, 6T50 ZIP KIT Booklet
Installation & Testing
TIME TESTED INDUSTRY TRUSTED

OE Exploded View
Control Valve Body Gen. 1 6T40 Shown
NOTE: Depending upon vehicle application, the OE springs shown may not be present.

101
110

109

108 102

107

103

106 104

105

Control Valve Body Descriptions

I.D. No. Description

101 Compensator Feed Limit Valve
102 TCC Regulator Apply Valve
Clutch Select Valve (inboard)
103
Shuttle Valve (outboard)
104 Actuator Feed Limit Valve
105 Manual Valve
Reverse & 4-5-6 Clutch
106
Regulator Valve
107 1-2-3-4 Clutch Boost Valve
108 1-2-3-4 Clutch Regulator Valve
109 2-6 Clutch Regulator Valve
3-5 Reverse Clutch Regulator
110
Valve

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TIME TESTED INDUSTRY TRUSTED

1st GEN. 6T40, 6T45, 6T50 ZIP KIT 

Installation & Testing Booklet

OE Exploded View
Pump Body Gen. 1 6T40 Shown
NOTE: Depending upon vehicle application, the OE springs shown may not be present.

201

202

Pump Body Descriptions

I.D. No. Description

201 Line Pressure Relief Ball
202 Pressure Regulator Valve
203 TCC Control Valve
204 TCC Relief Ball
204

203

12-23-146T40-ZIP_Booklet 2014 Sonnax Industries, Inc.

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