TOYOTA/LEXUS U151E, U151F,

U250E ZIP KIT ®

PART NUMBER U151E-U250E-ZIP QUICK GUIDE
Parts are labeled here in order of installation. See other side of sheet for details on kit contents.

installation Diagram Install with open end out.

Upper Valve Body

Medium 6 5

Small 6 6 Small

Large 6 6 Large

7 NOTE: Before
removing OE boost
Plastic Checkball
sleeve, take note of
Shown in 11 places.
the adjustable step/
Lower Valve Body pin location and
ensure the Sonnax
sleeve is installed
at the same height/
location. Failure to
do so will result in
1 incorrect line pressure.
6 Small

6 Small

Cutaway shows a
side view of lower
valve body with
Sonnax boost valve
kit installed.

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.

©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U151E-U250E-ZIP-Guide_B 02-12-19

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 TOYOTA/LEXUS U151E, U151F, U250E ZIP KIT® Quick Guide

Kit Contents & Installation Steps

Step 1 Replace OE B2 Plunger Step 5 R

 eplace OE Accumulator
Valve & Sleeve Piston
NOTE: Use in the most worn location.
Packaging Pocket 1
• Plunger Valve Place O-ring in deep groove, lubricate with Sonnax Slippery Stick™
O-LUBE and roll on bench to size.
• Plunger Sleeve
Packaging Pocket 5
• Accumulator Piston
• O-Rings (2) 1 Extra

Step 2 Replace OE B1 Plunger

Valve & Sleeve
Packaging Pocket 2 Step 6 Replace OE End Plugs
• Plunger Valve Place O-ring in groove, lubricate with Sonnax Slippery Stick™ O-LUBE
• Plunger Sleeve and roll on bench to size. Install all end plugs with the O-ring outboard.

Packaging Pocket 6
• End Plugs, Large (5)
• O-Rings, Large (7)
Step 3 Replace OE Boost Valve, 2 Extra

Sleeve & Plug Packaging Pocket 7

NOTE: Ensure Sonnax sleeve is installed at the same • End Plug, Medium
height/location as OE boost sleeve. Failure to do so will • O-Rings, Medium (2) 1 Extra
result in incorrect line pressure.
Packaging Pocket 8
Packaging Pocket 3
• End Plugs, Small (4)
• Boost Valve • O-Rings, Small (6) 2 Extra
• Boost Sleeve
• Boost Valve Plug

Step 7 Replace OE Checkballs

Step 4 Replace OE Lockup Control Packaging Pocket 9

Plunger Valve & Sleeve Plastic Checkballs (11)

NOTE: Reuse OE spring if applicable.

Packaging Pocket 4
• Plunger Valve
• Plunger Sleeve

©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U151E-U250E-ZIP-Guide_B 02-12-19

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 TOYOTA/LEXUS U151E, U151F,
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

©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U151E-U250E-ZIP-Booklet_B 02-12-19

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
 TOYOTA/LEXUS U151E, U151F, Installation & Testing Booklet
U250E ZIP KIT®

Figure 1 Zip Kit Instructions Bolt

Color Code
Bolt
Length

1. Valve Body Removal from Case Black 12mm

Red 16.75mm
Remove the 19 bolts indicated (Figure 1).
Green 21.50mm
2. Valve Body Disassembly: Step 1 Yellow 25.00mm
NOTE: See Figure 2 for bolt locations. Lt Purple 26.50mm
Solenoids can be put into the wrong location in the Olive 30mm
valve body. Ensure each of them are put back in their Purple 35.50mm
correct location. Solenoid designs have changed over the White 41.00mm
years, see Figure 3 for the most common configuration. Lt Blue 46.50mm
a. Remove bolt #1 and locking plate. Remove shift Blue 57.00mm
solenoid SL3 and the SLT solenoid. Orange 62.50mm
b. Remove bolt #2 and shift solenoid S4, then SR
solenoid.
Valve Body Removal from Case
c. Remove bolt #3 and shift solenoid DSL.

Figure 2
d. Remove bolt #4 and locking plate. Remove shift solenoid SL2.
e. Remove bolt #5 and locking plate. Remove shift solenoid SL1.

3 6 6
f. Remove the seven #6 bolts.
g. Remove the #7 bolt.
6
3. Valve Body Disassembly: Step 2
4 NOTE: See Figure 4 for bolt locations.
6 6
a. Remove the light blue #1 bolt, retaining bracket and checkball.
b. Remove the seven remaining light blue bolts.
2 6 6 7
1 c. Remove the purple bolt.
5

Valve Body Disassembly: Step 1

Figure 3 Figure 4
1

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

02-12-19 U151E-U250E-ZIP-Booklet_B ©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company

Page 2 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
 TOYOTA/LEXUS U151E, U151F, Installation & Testing Booklet
U250E ZIP KIT®

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.
Figure 6
d. Torque all bolts to 90 in-lb.
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

©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U151E-U250E-ZIP-Booklet_B 02-12-19

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3
 TOYOTA/LEXUS U151E, U151F, Installation & Testing Booklet
U250E ZIP KIT®

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 • B2 Brake clutches burned
• UD/C3 Clutch burned • Delayed Reverse
• Delayed/No 5th • No engine braking in manual low
B2 (Low/Reverse) Apply
Control Plunger
• Delayed Reverse
• B2 Brake clutches burned
• No engine braking in manual low
• Erratic shift timing
Replace with Sonnax Part No.
27741-06K*

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

Boost Valve
• Soft shifts
• Low line rise in Drive
• High line pressure in Reverse
Replace with Sonnax Part No.
27741-01K*

Clutch Apply Control Valve

• Burnt Forward/C1 Clutch, Direct/C0 Clutch
and 2nd/B1 Brake
• Flare shifts • Bind-ups
Replace with Sonnax Part No.
27741-18K Requires F-27741-TL18 & VB-FIX
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.

02-12-19 U151E-U250E-ZIP-Booklet_B ©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company

Page 4 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
 TOYOTA/LEXUS U151E, U151F, Installation & Testing Booklet
U250E ZIP KIT®
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 • U250E Shown Here

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

• Inconsistent shift quality • Flare shifts • B2 Brake clutches burned
• Clutch failure • Bump shifts • Bang shifts • Delayed Reverse
• Shift codes • No engine braking in manual low
Replace with Sonnax Part No.
27741-20K*
NOTE: Two Locations = 

Pressure Regulator Valve

• Soft shifts • Low line pressure • Harsh shifts
• High line pressure in Reverse
• Clutch & band failures
• Low converter pressure • High line pressure
Replace with Sonnax Part No.
27741-08K Requires 57917E-TL8


Clutch Apply Control Valve

• Burnt Forward/C1 Clutch, Direct/C0 Clutch
& 2nd/B1 Brake
• Flare shifts • Bind-ups
Replace with Sonnax Part No. 
27741-18K Requires F-27741-TL18 & VB-FIX
NOTE: Stroke valve to ensure it is not stuck.

B1 (2nd) Apply
Control Plunger
• 2-3 or 4-3 Bind-up
• B1 brake clutches burned
• Harsh 1 through 4 maneuver shifts
• Erratic shift timing
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.

©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U151E-U250E-ZIP-Booklet_B 02-12-19

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5
 TOYOTA/LEXUS U151E, U151F, Installation & Testing Booklet
U250E ZIP KIT®

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 End Plugs, Multiple Locations
• Shift concerns
Solenoid Modulator Valve • Clutch failure
• Slips & flares • Erratic shift feel & engagements Replace with Sonnax Part No.
27741-20K*
• Harsh upshifts • Bind-up • Low cooler flow
• Excess Reverse pressure & distorted housings 
NOTE: Eight locations =

• TCC cycling/slip • Overheating

Replace with Sonnax Part No.
27741-13K Requires F-27741-TL13 & VB-FIX

B2 (Low/Reverse)
Control Valve 
• B2 Brake clutches burned
• Delayed Reverse
• Delayed engagement in manual 1st

B3 Orifice Control Valve 
• Shift concerns
• UD/B3 Brake clutches burned
Replace with Sonnax Part No.
27741-16K Requires F-15741-TL18 & VB-FIX
NOTE: Stroke valve to ensure it is not stuck.


Accumulator Control Valve

• Shift concerns
• Burnt clutches & brakes 
C0 (Direct) Control Valve
• C0 Clutch burned

• Slipping/Flares in 3rd, 4th & 5th

C0 (Direct)
Accumulator Piston
• Delayed engagement • Flare shifts
• Forward slip • Burnt clutches
Replace with Sonnax Part No.
57917E-19K*†

B1 (2nd) Accumulator Piston

• Delayed engagement • Flare shifts Solenoid Relay Valve
• Forward slip • Burnt clutches
• Shift concerns
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.

02-12-19 U151E-U250E-ZIP-Booklet_B ©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company

Page 6 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
 TOYOTA/LEXUS U151E, U151F, Installation & Testing Booklet
U250E ZIP KIT®
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 • U250E Shown Here Lockup Control Valve
• TCC apply & release concerns
Lockup Relay Valve • TCC codes
• TCC apply & release concerns • Burnt converter
• TCC codes Replace with Sonnax Part No.
• Burnt converter/overheating 27741-25K Requires F-27741-TL25 & VB-FIX

Lockup Control
Plunger Assembly
• TCC apply & release concerns NOTE: Place
• TCC codes • Burnt converter clay here to
isolate circuit.
Replace with Sonnax Part No.
57917E-03K
NOTE: Vacuum testing of lockup control plunger assembly not possible
while in casting. Perform visual inspection to identify wear.

B1 (2nd) Control Valve

• B1 Brake clutches burned
• Slipping/Flares in 2nd, 4th & 5th

Secondary Pressure
Regulator Valve
• TCC apply & release concerns • TCC codes
• Burnt converter • Lube failures
Replace with Sonnax Part No.
57917E-16K Requires F-57917E-TL16 & VB-FIX

C1 (Forward) Control Valve

• C1 Clutch burned
• Delayed engagement
• Slipping/Flares in 1st, 2nd & 3rd
NOTE: Seal these ports and test on opposite side.

C1 (Forward)
C1 (Forward) Control Valve
Accumulator Piston
• C1 Clutch burned
• Delayed engagement • Flare shifts
• Delayed engagement
• Forward slip • Burnt clutches
• Slipping/Flares in 1st, 2nd & 3rd
Replace with Sonnax Part No. NOTE: Seal ports on opposite side when testing.
57917E-19K*†

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.

©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U151E-U250E-ZIP-Booklet_B 02-12-19

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 7
 TOYOTA/LEXUS U151E, U151F, Installation & Testing Booklet
U250E ZIP KIT®

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

02-12-19 U151E-U250E-ZIP-Booklet_B ©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company

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