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Aisin AW 60-40LE

TIME TESTED • INDUSTRY TRUSTED

Critical Wear Areas & Vacuum Test Locations 20


25
30
15

0
10
5

NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to VACUUM
TEST

with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.

Front Control Valve Body - Separator Plate Side Shown

B1 Modulator Valve 1-2 Shift Valve


• Shift concerns 2nd & 4th • 1-2 Shift concerns
NOTE: Seal port on opposite side of casting.

Pressure Regulator Valve


• Low/High line pressure
• Soft/Harsh shifts
• Converter concerns
• Loss of lube oil

B1 Modulator
Plunger Valve
• 2-3 Bind-up • 4-3 Bind-up
2-3 Shift Valve
• B1 brake clutches burned
• 2-3 Shift concerns
Replace with Sonnax Part No.
NOTE: Seal port on opposite side of
19741-03K casting & solenoid port with thumb.

Click on Sonnax part numbers to see more information.

©2018 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 04-25-18


800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
Aisin AW 60-40LE
TIME TESTED • INDUSTRY TRUSTED

Critical Wear Areas & Vacuum Test Locations 20


25
30
15

0
10
5

NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to VACUUM
TEST

with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.

Front Control Valve Body - Cover Side Shown

Click on Sonnax part


numbers to see more 3-4 Shift Valve
information. • 3-4 Shift concerns
NOTE: Seal solenoid port with thumb.

TCC Modulator Valve


• Converter shudder & TCC slip
2-3 Shift Valve • TCC codes • No lockup
• 2-3 Shift concerns NOTE: Test using non-orificed 2nd/4th
NOTE: Seal port on opposite side of casting and modulator brake control valve.
seal solenoid port with thumb.

Seal

Seal Reverse Boost Valve


• Burnt Reverse clutch
• Delayed Reverse • No Reverse
• Low line rise in Reverse
• Low Reverse Boost • Reverse slip
Replace with Sonnax Part No.
19741-07K

 Pressure Regulator Valve


 • Low/High line pressure
• Soft/Harsh shifts
End Plugs
• Converter concerns
• Burnt brake clutches
• Loss of lube oil
• Various shift concerns
Replace with Sonnax Part No.
19741-13K
NOTE: Several Locations = 1-2 Shift Valve
• 1-2 Shift concerns
NOTE: Seal port on
3-4 Shift Valve
opposite side of casting. • 3-4 Shift concerns

©2018 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 04-25-18


800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2
Aisin AW 60-40LE
TIME TESTED • INDUSTRY TRUSTED

Critical Wear Areas & Vacuum Test Locations 25


30
20
15

0
10
5

NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to VACUUM
TEST

with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.

Rear Control Valve Body - Separator Plate Shown


Solenoid Modulator Valve
Coast Clutch • Shift concerns
Modulator Valve Low Coast NOTE: Test using non-orificed 2nd/4th brake
modulator control valve
• Coast clutch burned Modulator Valve
NOTE: Test using non-orificed 2nd/4th • Burnt 1st & Reverse clutch
brake modulator control valve.
• Delayed Reverse
NOTE: Test both at the same time. Reverse Clutch
Accumulator Piston
Lockup • Burnt Reverse clutch
Control Valve • Delayed Reverse
• Lockup concerns • Bump in Reverse
• TCC codes

Secondary
Regulator
Valve
• TCC concerns
• Loss of lube oil

End Plugs
• Various shift concerns
• Pressure loss • Burnt clutches
2nd/4th Brake & Foward
• TCC apply concerns
2nd/4th Brake Clutch Accumulator Piston
Replace with Sonnax Part No.
19741-13K Modulator • Burned Forward clutch • Delayed Forward
Control Valve • Burnt 2-4 brake • Bump 2nd & 4th

NOTE: Several Locations =
• Burnt 2-4 brake
• Shift concerns 2nd & 4th
Lockup Control Plunger Valve Kit 2-3 Timing Valve & Overdrive
• TCC codes • TCC apply & release concerns Clutch Accumulator Piston
• Overheating • Burnt converter • Poor fuel economy • 2-3 Shift concerns • Bump in 3rd gear
Replace with Sonnax Part No. • Burned Overdrive clutch
Click on Sonnax part • NOTE: Test one port while sealing the other.
59954-01K
numbers to see more
information.

©2018 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 04-25-18


800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3
Aisin AW 60-40LE
TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Front Control Valve Body - Cover Side (Separator Side Inset) Shown Here

106
Front Control Valve Body Descriptions
105
I.D. No. Description 104
Reverse Boost Assembly
101
& Pressure Regulator Valve
107
Accumulator Control Valve
102
& Plunger Assembly
B1 Modulator Valve Check
103
& Plunger Assembly Valve

104 1-2 Shift Valve


105 2-3 Shift Valve
Front Valve Body
106 3-4 Shift Valve (Cover Side)
107 TCC Modulator Valve

Check Valve

Filter

Filter

Front Control Valve Body


(Separator Side)

102

103

101 104
©2018 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 04-25-18
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 4
Aisin AW 60-40LE
TIME TESTED • INDUSTRY TRUSTED

OE Exploded View
Rear Control Valve Body

212

208 209

211

210

Check
Filter
Checkball, Large .250" dia. Valve
(All 10 others, Small .218" dia.)

Rear Control Valve Body Descriptions Check


Valve
I.D. No. Description
201 Secondary Regulator Valve
2nd/4th Brake Modulator
202
Control Valve
203 Low Coast Modulator Valve
204 Solenoid Modulator Valve
Reverse Clutch Check
205
Accumulator Piston Valve
2nd/4th Brake
206
Accumulator Piston
207 Manual Valve 202
203
Forward Clutch
208
Accumulator Piston 206
204
Overdrive Clutch
209
Accumulator Piston 207 205
210 2-3 Timing Valve 201
211 Coast Clutch Modulator Valve
Lockup Control Valve
212
& Plunger Assembly

©2018 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 04-25-18


800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5

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