Aisin AW 60-40LE Zip Kit® AW60-40LE-ZIP Available for this unit.

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 Here

2nd/4th Brake 1-2 Shift Valve

Modulator Valve 1-2 Shift complaints
Shift complaints in 2nd & 4th NOTE: Seal port on opposite side of casting.

Pressure Regulator Valve

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

2nd/4th Brake Modulator

Plunger Assembly
Shift complaints in 2nd & 4th
2-3 Shift Valve
2-3 Shift complaints
NOTE: Seal port on opposite side of
casting & solenoid port with thumb.

©2012 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 12-31-12

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
 Aisin AW 60-40LE Zip Kit® AW60-40LE-ZIP Available for this unit.
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 Here

3-4 Shift Valve

3-4 Shift complaints
NOTE: Seal solenoid port with thumb.

TCC Modulator Valve

• Converter slip/shudder/codes
2-3 Shift Valve • No converter apply
2-3 Shift complaints 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
Assembly
• Low reverse pressure
• Delayed reverse

1-2 Shift Valve Pressure Regulator Valve

1-2 Shift complaints • Low/High line pressure
NOTE: Seal port on opposite side of casting. • Soft/Harsh shifts
• Converter complaints
• Loss of lube

Shift Valve End Plugs

Shift complaints
3-4 Shift Valve
3-4 Shift complaints

©2012 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 12-31-12

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2
 Aisin AW 60-40LE Zip Kit® AW60-40LE-ZIP Available for this unit.
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 Here

Coast Clutch Solenoid Modulator Valve

Modulator Valve Shift complaints
Burned coast clutch Low Coast NOTE: Test using non-orificed 2nd/4th brake
NOTE: Test using non-orificed 2nd/4th modulator control valve
brake modulator control valve.
Modulator Valve
• Burned 1st & reverse clutch
• Delayed engagement reverse
or 1st in manual low
Reverse Clutch
NOTE: Test both at the same time.
Accumulator Piston
TCC Control Valve • Burned reverse clutch
Lockup complaints/codes • Delayed reverse
• Bump in reverse

Secondary Regulator Valve

• TCC complaints
• Loss of lube 2nd/4th Brake
& Foward Clutch
Accumulator Piston
2nd/4th Brake Modulator 2-3 Timing Valve • Burned forward clutch
Control Valve & Overdrive Clutch • Burned 2-4 brake
• Burned 2-4 brake Accumulator Piston • Delayed forward
• Shift complaints in 2nd & 4th • 2-3 Shift complaints • Bump 2nd & 4th gear
• Burned overdrive clutch
• Bump in 3rd gear
NOTE: Test one port while sealing the other.

©2012 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 12-31-12

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
104
I.D. No. Description
Reverse Boost Assembly
101 107
& Pressure Regulator Valve
Accumulator Control Valve
102
& Plunger Assembly
Check
2nd/4th Brake Modulator Valve Valve
103
& Plunger Assembly
104 1-2 Shift Valve
105 2-3 Shift Valve Front Valve Body
(Cover Side)
106 3-4 Shift Valve
107 TCC Modulator Valve

Check Valve

Filter

Filter

Front Control Valve Body

(Separator Side)

102

103

101 104
©2012 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 12-31-12
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
205 Check
Accumulator Piston Valve
2nd/4th Brake
206
Accumulator Piston
207 Manual Valve 202
Forward Clutch 203
208
Accumulator Piston
206
Overdrive Clutch 204
209
Accumulator Piston 205
207
210 2-3 Timing Valve
201
211 Coast Clutch Modulator Valve
TCC Control Valve
212
& Plunger Assembly

©2012 Sonnax Industries, Inc. AW60-40LE-Vac-Locations 12-31-12

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