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ZIP KIT ®
PART NUMBER 6L45-6L90-ZIP IDENTIFICATION GUIDE
A. I f Early, 1st design 6L80 plate 24246916
is equipped, REPLACE with Early, 2nd
design plate 24245720 and install Sonnax
clutch select valve spring kit 104740-02K.
B. W
hen using Early, 2nd design plate
(2010-Earlier, OE part #24245720):
DO NOT install checkball #8. B. Early, 2nd Design Plate
ID Notches
(OE 24245720)
#8 Checkball Usage
Reference images C and D (Figure 4) for orifice
location and size in determining if #8 checkball
is used.
See location of #8 checkball on 6L80/90
models only, when necessary (Figure 5).
Figure 5
.175"
Orifice:
Do not
install #8
checkball
D. Requires #8 Checkball
#8 .054"
Checkball Orifice:
Location, Install #8
If Required Checkball
installation Diagram
Cup plug 1a 1b
bore 1
3
2
NOTE:
Pump must be
removed to install
Sonnax pressure
regulator valve.
4
9 Plastic Checkballs
6L80 Upper
CAUTION! Checkball #8 is only
Valve Body used with 24272467 (Late, 2nd
design) separator plates. See
figure four & five on page 2 of
5 separate Identification Guide for info.
6
6L80 Lower
Valve Body
8
6
7
In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum
testing and additional repair options for higher mileage units or for repairing specific complaints which are beyond the
scope of this kit.
bit on countersunk surface of cup plug bore works best. Clean bore Packaging Pocket 6
thoroughly, removing all debris and chips.
Packaging Pocket 1
• Springs (2) • End Plugs (2) • O-Rings (3) 1 extra
• Drill Bit, .039" dia. • Checkball, 1/8" (2) 1 Extra
Step 7 R
eplace Compensator
Step 2 Replace OE Pressure Feed Regulator Valve
Sleeve installs with end grooves inboard. Valve installs with spring
Regulator Valve pocket outboard.
Re-use OE springs. Packaging Pocket 7
Packaging Pocket 2 • Valve • Sleeve • Spring
Pressure Regulator Valve
Step 8 R
eplace TCC Regulator
Step 3 Replace OE Boost Valve Lineup
Assembly locking/Rotational alignment of components are critical. See
C
Packaging Pocket 3 page 2 of installation and testing booklet for details.
GM Tool DT-48285
Zip Kit Instructions Input/Output Speed
Sensor Assembly
Bolt Color Bolt Bolt
1. R
emove & Disassemble the Position Switch Connector
Code Length Head
Figure 5
Control Solenoid Valve Assembly Yellow 36mm 7mm
3. Installation
Install Zip Kit parts as shown on diagram of separate quick guide sheet included in
this Zip Kit. Sonnax recommends vacuum testing critical wear areas not covered by
this kit to determine whether additional Sonnax parts are required (see pages 5–6).
11 9 Retainer slot
7 3 5 holds plug boss
VERTICAL.
Figure 9 ard
e Upw
Fac
TS
FLA
5. R
eassemble Control Solenoid Valve Assembly Figure 17
It is important to follow the assembly and torque sequence as well as torque ratings indi-
cated in the bolt chart to ensure proper function of the control solenoid valve assembly.
a. Install the 12, 7mm head bolts and torque to 71 in-lbs. in sequence shown
(Fig. 8). TEHCM
b. Place the TEHCM on the valve body. Install the two 8mm head bolts and
hand-tighten only (Figure 6).
c. Install the four 10mm head and five 7mm head bolts and hand-tighten only
(Fig. 7).
Figure 18
d. Reconnect the position switch connector and align the switch activator slide
with the manual valve link as shown. Secure the assembly to the casting with
the 10mm head bolt and hand-tighten only (Figure 5 & 22).
e. Install the five 7mm head bolts and single 10mm head bolt and hand-tighten
only (Figure 23). ISS/OSS Connector
Figure 19
f. Tighten all 18 bolts in the sequence indicated to 71 in-lbs. Bolts 17 and 18 are
on the side of the TEHCM (Figure 24). 16-Way
Connector
g. Inspect the contact area between the aluminum portion of the TEHCM and
Check all
the valve body casting. There should be no visible gap. If a gap is found, loosen solenoid
all 18 bolts in step “f ” and re-torque until no gap exists (Figure 25). cavities.
h. Reconnect the input/output speed sensor connector and torque the two Check all
bolts to 106 in-lbs (Figure 4). supply
TFT & control
i. R
einstall the manual shaft detent assembly and torque the bolt to 106 in-lbs Sensor parts.
(Figure 5).
Figure 20 Figure 21
IMS
Solenoid Leads
Connector Sonnax pressure switch rebuild kits:
124740-28K, 124740-30K & 124740-TL30
Figure 22
Figure 23
Align
17 18 Figure 24
Figure 25
1 9
7
2 No Gap
14 8 4 3 6 13 15
12
10 5
11 16
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 VACUUM
TEST
to with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.
NOTE: The 104740-VTP vacuum test plate kit (VTP) can be used, but the plates do not check for wear in the pump body. Check these locations using
the small test plate and sealing pad included in the VACTEST-01K.
Pump Body
Remove Converter
Limit Valve 6L80 Shown
VTP* only.
3-5 Reverse Clutch
Regulator Valve
• Burnt 3-5 Reverse clutch
VTP* only. • Delayed/No Reverse
• 3rd & 5th Shift concerns
clarity only. Test with end plugs installed. • Harsh/Slide shifts • Slips & flares
Replace with Sonnax Part No.
104740-01
Requires F-104740-TL & VB-FIX
*Part numbers with an asterisk (*) are included in this Zip Kit.
02-11-19 6L45-6L90-Zip-Booklet_D ©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company
Page 6 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
GM 6L45, 6L50, 6L80, 6L90 ZIP KIT® Installation & Testing Booklet
OE Exploded View
Pump & Lower Valve Body • 6L80 Shown
NOTE: Depending upon vehicle application, the OE springs shown may not be present. 302
303
104
301
102
103
OE Exploded View
Upper Valve Body • 6L80 Shown
NOTE: Depending upon vehicle application, the OE springs shown may not be present.
201
208
CAUTION! Checkball #8 is only used
with 24272467 (Late, 2nd design)
separator plates. See separate
identification guide for info.
Notes:
For shift solenoids 1 and 2, “ON” = Solenoid Energized (Pressurized), “OFF” = Solenoid De-energized (No Pressure).
For pressure control (PC) solenoids, “ON” = Pressurized, “OFF” = No Pressure.
* = Applied with No Load.