TOYOTALEXUS U140E, U140F,

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TOYOTA/LEXUS U140E, U140F,U240E, U241E ZIP KIT ® Quick GuideKit Contents & Installation StepsStep1Packaging Pocket 1• Plunger Valve• Plunger SleeveReplace OE ClutchApply Control Sleeve& Plunger ValveStep4Packaging Pocket 6• Boost Valve• Boost Sleeve• Boost PlugReplace OE Boost Sleeve& ValveStep2Replace OE LockupControl Sleeve& Plunger ValveNOTE: Reuse OE spring if applicable.Packaging Pocket 2• Plunger Valve• Plunger SleeveStep5Replace OEAccumulator PistonsNOTE: Place O-ring into deepest piston groove. Lubricatewith Sonnax Slippery Stick O-LUBE and roll on bench tosize. Install into casting bore with the O-Ring inboard.Packaging Pocket 7Accumulator PistonPackaging Pocket 8Accumulator PistonStep3Replace OE End PlugsPackaging Pocket 9O-Rings (3)1 ExtraNOTE: Install all end plugs with the O-ring outboard. PlaceO-ring into end plug groove. Lubricate with Sonnax SlipperyStick O-LUBE and roll on bench to size.Packaging Pocket 3• Small End Plugs (6)• Small O-Rings (9)3 ExtraStep6Packaging Pocket 10Plastic Checkballs (11)Replace OE CheckballsPackaging Pocket 4• Medium End Plug• Medium O-Rings (2)Packaging Pocket 5• Large End Plugs (2)• Large O-Rings (3)1 Extra1 Extra©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U140E-U241E-ZIP-Guide_B 02-12-19800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2
TOYOTA/LEXUS U140E, U140F,U240E, U241E ZIP KIT ®PART NUMBER U140E-U241E-ZIPINSTALLATION & TESTING BOOKLETTorque SpecificationsPan Filter to Valve Body Oil Pan to Transaxle96 in-lb72 in-lbComponent Pack ClearanceForward (C1) Clutch Low & Reverse (B2) BrakeU140E/F: 4-Cyl .069–.082" U140E/F: 4-Cyl .040–.048"U140E/F: V6 .082–.095" U140E/F: V6 .043–.051"U240/241E: .056–.069" U240/241E: .043–.049"2nd (B1) BrakeDirect (C2) InputU140E/F: .024–.036" U140E/F: .024–.033"U240E: .024–.029" U240/241E: .024–.029"U241E: .024–.036"Underdrive (C3) Clutch Underdrive (B3) BrakeU140E/F: .059–.075" U140E/F: .071–.087"U240E/241E: .058–.067" U240/241E: .074–.082"End PlayInput ShaftUnderdrive UnitU140E/F: .010–.049" U140E/F: .020–.039"U240E/241E: .011–.049" U240E/241E: .008–.027"Direct Clutch AssemblyU140E/F: .008–.037"U240E/241E: .008–.035"Electronic CautionsResetting Shift AdaptsThe ECM (engine control module) has memorized values which must be relearnedafter transmission repair. Use a scan tool (OE factory tool recommended) to resetthe ECM.Post-Adapt Road TestAfter resetting the ECM, a road test is required. Start the engine and warm it tonormal operating temperature. Perform a thorough road test with multiple accelerationsfrom a stop until proper shifting is obtained.TSB TC002-06Toyota published a Technical Service Bulletin regarding computer hardware problemsin 2001-2003 RAV4 vehicles. Resetting the ECM will not eliminate shiftingcomplaints for this unit. A new ECM will be required.SolenoidsSolenoids should be cleaned to remove debris that results in sticking and malfunction.FluidToyota Type T-IVToyota/Lexus U140E/F, U240E, U241EClutch Application ChartGear Range C1 C2 C3 B1 B2 B3 F1 F2ParkReverse ON ON ONNeutralD-1st Gear ON ON ON OND-2nd Gear ON ON ON OND-3rd Gear ON ON ON OND-Overdrive ON ON ON2-1st Gear ON ON ON ON2-2nd Gear ON ON ON ON ONLow-1st Gear ON ON ON ON ONONONToyota/Lexus U140E/F, U240E, U241ESolenoid Function & Apply ChartGearSL1 ControlsB1 BrakeSL2 ControlsC2 ClutchS4 Controls3-4 Shift1st ON ON Off2nd Off ON Off3rd Off Off4th Off ONSLT: Controls line pressure.DSL: Controls lockup clutch.N-D ENGAGEMENT: 3rd gear is commanded during theengagement, then 1st after the engagement is complete.©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U140E-U241E-ZIP-Booklet_B 02-12-19800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
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