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T R A N S M IS S ION PART S Instructions
Oversized Primary Pressure Regulator & Reverse Boost Valve Kit
Toyota/Lexus U660E, U660F, U760E, U760F U660E Middle Valve Body
Pressure Regulator Valve
Part No.
R
47740-02K
• Pressure Regulator Valve • Boost Valve • Boost Sleeve • Cup Plugs (2) • Spring
EQ
D
TOOL
UIRE
Spring
Cup Plug
Tool Kit 1 Extra
Boost Valve Boost Sleeve
Patent Pending
Tool Kit
1. Disassembly a. Remove OE retaining clip and save for reuse. b. Remove OE reverse boost sleeve and valve, note if the sleeve has an identification groove (Figure 1) and then discard. c. Remove and discard OE spring and pressure regulator valve.
Part No.
F-47740-TL2
• Reamer • Reamer Jig • Guide Pin NOTE: Sonnax “F-Tool” kits designed to service a specific bore require the VB-FIX, a self-aligning valve body reaming fixture. More information and instructions can be found online at www.sonnax.com. Figure 1 Note if sleeve has a ID groove or not.
2. Bore Preparation a. Clean the bore thoroughly in a solvent tank. b. Generously lubricate the bore and reamer with cutting fluid (i.e. Mobilmet S-122, Lubegard® Bio-Tap, Tap Magic™, etc.). For best results, provide a continuous flow of water-soluble cutting fluid (i.e. Mobilmet S-122) during the reaming process. c. The reamers should be turned using a low RPM, high-torque air drill regulated to a maximum of 200 RPM. d. Examine the bore after cleaning for surface finish, debris and burrs. Flashing and burrs on the exit side of land and in bores must be carefully removed. A small piece of Scotch-Brite™ material attached to a wire and powered with a drill motor is ideal for the task. Scotch-Brite™ is a very abrasive material and all residual debris must be cleaned to ensure particles do not migrate or remain imbedded into the surface. Post cleaning involves several progressive steps with solvent on a lint-free rag. CAUTIONS AND SUGGESTIONS: • Turning the reamer backward will dull it prematurely. • Pushing on the reamer will result in poor surface finish and inadequate and sporadic material removal.
No Groove: U660E/U660F
With Groove: U760E
OE Reverse Boost Sleeve Identification
• Never use a crescent wrench, ratchet or pliers to turn the reamer. • A dull reamer will cut a smaller hole. Reamers can be sharpened, but should only be done by a professional tool sharpener. Actual life of a Sonnax reamer before resharpening or replacing averages 50-70 bores.
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
47740-02K-IN 03-27-14 Page 1
T R A N S M IS S ION PART S Instructions
OVERSIZED PRIMARY PRESSURE REGULATOR & REVERSE BOOST VALVE KIT 47740-02K, F-47740-TL2
3. Bore Reaming Use the associated “F-Tool” F-47740-TL2 kit and VB-FIX reaming fixture as illustrated below to ream the bore.
4. Installation & Assembly a. Be sure all debris has been removed from the valve bore and body. b. Install Sonnax primary pressure regulator valve with the spring guide facing out. c. Install Sonnax spring over the spring guide on the PR valve. d. Determine which side of the Sonnax reverse boost valve needs to be plugged (Figure 2):
Figure 2 No Groove: U660E/U660F
With Groove: U760E
1. If OE reverse boost sleeve does not have an ID groove...
1. If OE reverse boost sleeve has an ID groove...
• U660E/U660F & No groove on OE sleeve = Plug large diameter end • U760E & Groove on OE sleeve = Plug small diameter end e. Apply a drop of red Loctite® 262 (or equvalent) to the Sonnax cup plug prior to installation. Place the Sonnax reverse boost valve on a piece of wood or other soft material. Using a flat punch that fits inside the Sonnax cup plug, press one cup plug into the appropriate end of the reverse boost valve until seated (Figure 2). NOTE: A spare cup plug is provided. ©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
Large Dia.
2. Install the Sonnax cup plug in the large diameter end of Sonnax boost valve.
Small Dia.
2. Install the Sonnax cup plug in the small diameter end of Sonnax boost valve. 47740-02K-IN 03-27-14 Page 2
T R A N S M IS S ION PART S OVERSIZED PRIMARY PRESSURE REGULATOR & REVERSE BOOST VALVE KIT 47740-02K, F-47740-TL2
Instructions
4. Installation & Assembly (continued) f. Install the Sonnax reverse boost valve into the Sonnax boost sleeve, small diameter first. Then install this assembly into the bore.
Figure 3
g. Reinstall the OE retaining clip.
16"-Hg
5. Final Testing Vacuum tests at the ports indicated hold the recommended minimum 18 in-Hg (Figures 3 & 4).
20
15
10
25
5
0 30 VACUUM TEST
Top Side of U660E Middle Valve Body Figure 4 18"-Hg 20
15
10
25
5
0 30 VACUUM TEST
Bottom Side of U660E Middle Valve Body
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
47740-02K-IN 03-27-14 Page 3
Oversized Primary Pressure Regulator & Reverse Boost Valve Kit
Toyota/Lexus U660E, U660F, U760E, U760F U660E Middle Valve Body
Pressure Regulator Valve
Part No.
R
47740-02K
• Pressure Regulator Valve • Boost Valve • Boost Sleeve • Cup Plugs (2) • Spring
EQ
D
TOOL
UIRE
Spring
Cup Plug
Tool Kit 1 Extra
Boost Valve Boost Sleeve
Patent Pending
Tool Kit
1. Disassembly a. Remove OE retaining clip and save for reuse. b. Remove OE reverse boost sleeve and valve, note if the sleeve has an identification groove (Figure 1) and then discard. c. Remove and discard OE spring and pressure regulator valve.
Part No.
F-47740-TL2
• Reamer • Reamer Jig • Guide Pin NOTE: Sonnax “F-Tool” kits designed to service a specific bore require the VB-FIX, a self-aligning valve body reaming fixture. More information and instructions can be found online at www.sonnax.com. Figure 1 Note if sleeve has a ID groove or not.
2. Bore Preparation a. Clean the bore thoroughly in a solvent tank. b. Generously lubricate the bore and reamer with cutting fluid (i.e. Mobilmet S-122, Lubegard® Bio-Tap, Tap Magic™, etc.). For best results, provide a continuous flow of water-soluble cutting fluid (i.e. Mobilmet S-122) during the reaming process. c. The reamers should be turned using a low RPM, high-torque air drill regulated to a maximum of 200 RPM. d. Examine the bore after cleaning for surface finish, debris and burrs. Flashing and burrs on the exit side of land and in bores must be carefully removed. A small piece of Scotch-Brite™ material attached to a wire and powered with a drill motor is ideal for the task. Scotch-Brite™ is a very abrasive material and all residual debris must be cleaned to ensure particles do not migrate or remain imbedded into the surface. Post cleaning involves several progressive steps with solvent on a lint-free rag. CAUTIONS AND SUGGESTIONS: • Turning the reamer backward will dull it prematurely. • Pushing on the reamer will result in poor surface finish and inadequate and sporadic material removal.
No Groove: U660E/U660F
With Groove: U760E
OE Reverse Boost Sleeve Identification
• Never use a crescent wrench, ratchet or pliers to turn the reamer. • A dull reamer will cut a smaller hole. Reamers can be sharpened, but should only be done by a professional tool sharpener. Actual life of a Sonnax reamer before resharpening or replacing averages 50-70 bores.
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
47740-02K-IN 03-27-14 Page 1
T R A N S M IS S ION PART S Instructions
OVERSIZED PRIMARY PRESSURE REGULATOR & REVERSE BOOST VALVE KIT 47740-02K, F-47740-TL2
3. Bore Reaming Use the associated “F-Tool” F-47740-TL2 kit and VB-FIX reaming fixture as illustrated below to ream the bore.
4. Installation & Assembly a. Be sure all debris has been removed from the valve bore and body. b. Install Sonnax primary pressure regulator valve with the spring guide facing out. c. Install Sonnax spring over the spring guide on the PR valve. d. Determine which side of the Sonnax reverse boost valve needs to be plugged (Figure 2):
Figure 2 No Groove: U660E/U660F
With Groove: U760E
1. If OE reverse boost sleeve does not have an ID groove...
1. If OE reverse boost sleeve has an ID groove...
• U660E/U660F & No groove on OE sleeve = Plug large diameter end • U760E & Groove on OE sleeve = Plug small diameter end e. Apply a drop of red Loctite® 262 (or equvalent) to the Sonnax cup plug prior to installation. Place the Sonnax reverse boost valve on a piece of wood or other soft material. Using a flat punch that fits inside the Sonnax cup plug, press one cup plug into the appropriate end of the reverse boost valve until seated (Figure 2). NOTE: A spare cup plug is provided. ©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
Large Dia.
2. Install the Sonnax cup plug in the large diameter end of Sonnax boost valve.
Small Dia.
2. Install the Sonnax cup plug in the small diameter end of Sonnax boost valve. 47740-02K-IN 03-27-14 Page 2
T R A N S M IS S ION PART S OVERSIZED PRIMARY PRESSURE REGULATOR & REVERSE BOOST VALVE KIT 47740-02K, F-47740-TL2
Instructions
4. Installation & Assembly (continued) f. Install the Sonnax reverse boost valve into the Sonnax boost sleeve, small diameter first. Then install this assembly into the bore.
Figure 3
g. Reinstall the OE retaining clip.
16"-Hg
5. Final Testing Vacuum tests at the ports indicated hold the recommended minimum 18 in-Hg (Figures 3 & 4).
20
15
10
25
5
0 30 VACUUM TEST
Top Side of U660E Middle Valve Body Figure 4 18"-Hg 20
15
10
25
5
0 30 VACUUM TEST
Bottom Side of U660E Middle Valve Body
©2014 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
47740-02K-IN 03-27-14 Page 3
