Oversized Pressure Regulator & Boost Valve Kit Tool ... - cloudfront.net
T r a n s m is s ion Part s Instructions
GM 6L45, 6L50, 6L80, 6L90
Oversized Pressure Regulator & Boost Valve Kit
Tool Kit
Part No.
R
EQ
D
TOOL
UIRE
104520-07K
• Pressure Regulator Valve • Matching Outer Spring • Boost Valve • Boost Sleeve • Cup Plug • Self-Theading Screw • Drill Bit
6L80 Pump Cover Pressure Regulator Valve
Cup Plug
Self-Threading Screw
Matching Outer Spring
OE Boost Valve Spring
Drill Bit
Boost Valve Boost Sleeve OE Retaining Pin
Tool Kit Part No.
F-104520-TL7C
• 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.
Required
Oversized Pump Base Plate VB-06 Note: Use of the VB-06 is required with the VB-FIX reaming fixture for this installation unless the stator support shaft is removed from the pump body.
Note: In GM 6L45, 6L50, 6L80, 6L90 units the pressure regulator valve and boost assembly are in the pump body. The transmission must be removed from the vehicle to access the pump and repair the pressure regulator valve and boost assembly.
Figure 1
1. Disassembly a. Remove OE pressure regulator valve train from pump body bore.
Self-Threading Screw
b. Save the OE retaining pin and the boost valve spring for reuse and discard the remainder of the OE valve train. 2. R eroute Pressure Regulator Balance Feed Passage a. Locate the OE balance feed orificed cup plug and adjacent inboard balance port for the pressure regulator valve. b. Extract OE cup plug by twisting the Sonnax self-threading screw through the orifice in the OE cup plug far enough to grip the plug securely. Use a pair of channellocks to extract the screw and OE cup plug (Figure 1).
Figure 2 Drill Bit
c. Using the Sonnax drill bit, drill a new orifice from the (now empty) cup plug counter bore at an approximate 45° angle to the adjacent inboard balance port. Start the drilled hole high in the counter-bore opening (Figure 2). After drilling, clean the bore completely to remove all debris and aluminum chips.
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
104520-07K-IN 07-23-13 Page 1
T r a n s m is s ion Part s Oversized pressure regulator valve kit 104520-07K, f-104520-tl7C
3. 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
Instructions 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. • 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.
4. Bore Reaming Use the associated “F-Tool” F-104520-TL7C kit and VB-FIX reaming fixture as illustrated below to ream the bore.
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
104520-07K-IN 07-23-13 Page 2
T r a n s m is s ion Part s Instructions
Oversized pressure regulator valve kit 104520-07K, f-104520-tl7C
4. Installation & Assembly a. Block the counter bore by pressing the Sonnax (non-orificed) cup plug into casting until seated. Rim of cup plug MUST be below opening of newly drilled passage to ensure flow (Figure 3). b. Install Sonnax pressure regulator valve as shown and check that the valve moves freely in the bore. c. Install Sonnax matching outer spring. d. Reinstall OE boost valve spring. e. Install Sonnax boost valve and sleeve as shown. f. Reinstall OE retaining pin.
Cup Plug
Figure 3
Figure 4
5. Final Testing A vacuum test at the port indicated holds 16 in-Hg or more (Figure 4).
16"-Hg 20
15
10
25 0 30 VACUUM TEST
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
5
6L80 Pump Cover
104520-07K-IN 07-23-13 Page 3
GM 6L45, 6L50, 6L80, 6L90
Oversized Pressure Regulator & Boost Valve Kit
Tool Kit
Part No.
R
EQ
D
TOOL
UIRE
104520-07K
• Pressure Regulator Valve • Matching Outer Spring • Boost Valve • Boost Sleeve • Cup Plug • Self-Theading Screw • Drill Bit
6L80 Pump Cover Pressure Regulator Valve
Cup Plug
Self-Threading Screw
Matching Outer Spring
OE Boost Valve Spring
Drill Bit
Boost Valve Boost Sleeve OE Retaining Pin
Tool Kit Part No.
F-104520-TL7C
• 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.
Required
Oversized Pump Base Plate VB-06 Note: Use of the VB-06 is required with the VB-FIX reaming fixture for this installation unless the stator support shaft is removed from the pump body.
Note: In GM 6L45, 6L50, 6L80, 6L90 units the pressure regulator valve and boost assembly are in the pump body. The transmission must be removed from the vehicle to access the pump and repair the pressure regulator valve and boost assembly.
Figure 1
1. Disassembly a. Remove OE pressure regulator valve train from pump body bore.
Self-Threading Screw
b. Save the OE retaining pin and the boost valve spring for reuse and discard the remainder of the OE valve train. 2. R eroute Pressure Regulator Balance Feed Passage a. Locate the OE balance feed orificed cup plug and adjacent inboard balance port for the pressure regulator valve. b. Extract OE cup plug by twisting the Sonnax self-threading screw through the orifice in the OE cup plug far enough to grip the plug securely. Use a pair of channellocks to extract the screw and OE cup plug (Figure 1).
Figure 2 Drill Bit
c. Using the Sonnax drill bit, drill a new orifice from the (now empty) cup plug counter bore at an approximate 45° angle to the adjacent inboard balance port. Start the drilled hole high in the counter-bore opening (Figure 2). After drilling, clean the bore completely to remove all debris and aluminum chips.
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
104520-07K-IN 07-23-13 Page 1
T r a n s m is s ion Part s Oversized pressure regulator valve kit 104520-07K, f-104520-tl7C
3. 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
Instructions 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. • 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.
4. Bore Reaming Use the associated “F-Tool” F-104520-TL7C kit and VB-FIX reaming fixture as illustrated below to ream the bore.
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
104520-07K-IN 07-23-13 Page 2
T r a n s m is s ion Part s Instructions
Oversized pressure regulator valve kit 104520-07K, f-104520-tl7C
4. Installation & Assembly a. Block the counter bore by pressing the Sonnax (non-orificed) cup plug into casting until seated. Rim of cup plug MUST be below opening of newly drilled passage to ensure flow (Figure 3). b. Install Sonnax pressure regulator valve as shown and check that the valve moves freely in the bore. c. Install Sonnax matching outer spring. d. Reinstall OE boost valve spring. e. Install Sonnax boost valve and sleeve as shown. f. Reinstall OE retaining pin.
Cup Plug
Figure 3
Figure 4
5. Final Testing A vacuum test at the port indicated holds 16 in-Hg or more (Figure 4).
16"-Hg 20
15
10
25 0 30 VACUUM TEST
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
5
6L80 Pump Cover
104520-07K-IN 07-23-13 Page 3
