Ford AXODE Sure Cure Kit - Amazon S3

1 ford AXODESure Cure KitPart No. SC-AXODENOTE: This kit is fully compatible with '91-Later AXODE and AX4S Body PartsBoost Valve Kit96201-01 KBypass TCC Control Plunger Valve Kit96206-01 KForward Control Valve Kit96201-16K3-2 Timing Valve Saver Cap Kit96201-15K3-2 Timing Valve Retainer96201-091-2 Capacity Modulator Valve Retainer96201-10 Backout Valve Clip96201-11 Reassembly PartsRelief Valves (2) Low Radius 10000-01 Retaining Ring Rear Ring Gear 96730-RRRetainer, Split 1-2 Servo 96945 RServo Tube Bracket 96806 The following tool kit is not required but is highly recommended for proper installation:Part No. 96201-BSTBore Sizing Tool NOTE: Instructions are provided with the bore-sizing tool. Not using this tool could result in valve hangups or TubeBracketRetaining Ring,Rear Ring GearBypass TCC Control Plunger Valve KitBoost Valve KitForward Control Valve KitRetainer, Split,1-2 Servo3-2 Timing ValveSave Cap KitReliefValvesOil PumpShaft PlugRetainer,3-2 Timing Valve 2014 Sonnax Industries, Inc.

2 SC- AXODE -IN pg1 09-09-14800-843-2600 802-463-9722 F: 802-463-4059 Page 1 TRANSMISSION PARTSI nstructionsSTEP 1 INSTALL REVERSE BOOST VALVE AND SLEEVEV alve BodyBoost ValveO-Ringsensures boost oilTV test hereassembledBoost Sleevehighest qualityaluminum1. Remove worn boost valve and boost sleeve from valve body and discard. 2. Set aside the springs and retainer clip Place o-rings in two grooves on boostsleeve Boost valve assembly includes boost valveproperly oriented in the boost Return the springs to the valve bodywith the smallest spring on the Push boost valve assembly into the valvebody, open end toward springs, andreplace retainer SPECIFICATIONSVB to channel plate, pump to valvebody, stiffener plate7 - 9 ft. lbsSeparator plate bolts7 - 9 ft. lbsOil pan & side cover7 - 9 ft. lbs (rubber gasket)8 - 11 ft. lbs (cork gasket)Reverse clutch anchor bolt & nut7 - 9 ft. lbs (bolt) & 25 - 35 ft. lbs (lock-nut)CLEARANCE AND ENDPLAYMain unit " to.

3 015" (selective #8 thrust wash-er) Check with the final drive pushed upand the overdrive drum removed. Overdrive drum " to .015" (selective #5 thrust wash-er) Check with the final drive pushed down on sprocket support andreach through case check overdrive drummovement. Differential unit end " to .015" selective washer betweengovernor gear and CLEARANCEPump clearance, rotor slide and " to .002"Super Important:Too loose = low pres-sure, while too tight = no line rise (slidestuck)CLUTCH CLEARANCEF orward & (.060" to .075"), selectivesnap SHO (.040" to .060"), selectivesnap ringsIntermediate & (.045" to .067"), selectivesnap SHO (.050" to .070"), selectivesnap ringsReverse " to .064" & (.041" to .061"), selectivesnap SHO (.050" to .070"), selectivesnap ringsBAND ADJUSTMENTLow & intermediate " to .120" (recommended) Checkpiston travel by drilling off-center hole inspare cover (selective ser vo pins).

4 OD " to .149" (selective ser vo pins)TECH TIP* Cooler return line = lower line* Always clean Mass Air Flow sensorwire. Fuzz/dirt on wire = low line pres-sure.* Be careful when hooking up harness; itis possible to cross wires. All 3 shiftsolenoids should have 1 red wire. ( EPC= green & blue) ( TCC = green & brown)Clicking noise and high line pressureoccur if wires are crossed.* Check converter hub seal sur face tobushing inner diameter concentricity witha pair of vernier calipers. Measure in sev-eral spots. All should be within .002" * Always use pump centering and valvebody alignment pins during assembly. 04-09-10 SC- AXODE -IN 2010 Sonnax Industries, 2800/843-2600 802/463-9722 fax: 802/463-4059 TESTED INDUSTRY TRUSTED1. Remove the worn bypass clutch controlsleeve and plunger valve assembly from thevalve body and Lubricate the replacement sleeve andplunger Place the OEM compression spring into thehole in the replacement plunger Insert this spring and valve assembly intothe Sonnax sleeve, spring end Return this assembly to the valve bodybore, with the nubbed end of the Press this assembly into the bore just farenough to return the retaining : In AX4S and AXODE units, the size of the feed ori-fices in the Sonnax sleeve has been decreased toimprove TCC control.

5 If the TCC apply is too firm,the speed of the TCC apply can be slowed byenlarging the feed ports. Using a 3 32" to 1 8" bit, drillthrough the existing hole, exiting out the other side. Do not drill larger than 1 8" diameter. Inspect TCC bypass valve bore at the location of largest diameter spool. The valve can be flipped end-to-end and installed with largest diam-eter spool into same location it lives during use. If there is excessive wiggle, clearance or sag, the bore is worn and body needs replacementor repair. STEP 2 INSTALL BYPASS CLUTCH CONTROL SLEEVE AND PLUNGER VALVEV alve BodySpringRetaining ClipBypass Plunger ValveBypass ClutchControl SleeveSmaller feed ports result inresponsive TCC OilRetaining clipRegulated converter andlube oil feedExtended sleeve preventsoil loss & provides bettervalve for wear here:oil loss is cooler circuit oil thatwill bleed to CHECKT hese feed ports havebeen reduced toimprove TCC AIR TESTP lace a small amount of lube/converter oil into the indicated regu-lated converter feed circuit.

6 Follow with low air pressure. Thereshould be no oil leakage past the plunger valve through either of theindicated exhaust ports. 2010 Sonnax Industries, 04-09-10800/843-2600 802/463-9722 fax: 802/463-4059 3 TIME TESTED INDUSTRY TRUSTEDF orward ClutchControl ValveRetainerSpringSTEP 3 INSTALL FORWARD CONTROL VALVE AND BORE SIZING TOOL SPECIAL TESTSS troke the originalforward clutchcontrol valve the full length of thebore (see photo of Sonnax and OEMvalves below). Rotate the valve 90 ,and then stroke the valve again, sever-al times. Check the valve for stickingin several positions. If it ever sticks,replace the valve. If the Sonnaxreplacement valve sticks, resize thebore. Follow the instructions ValveOEM ValveBORE SIZING INSTRUCTIONS1. Lubricate the bore-sizing tool with Carefully push the tool into the bore until it bottoms Stroke the tool in the bore several times, until it strokes the Clean the bore and install the new Sonnax valve.

7 Make sure to lubri-cate it with ATF. If the new valve sticks in the bore, repeat the resizingprocess. Bore Sizing ToolTip: While the resizing tool is bottomed out, try tap-ping lightly on the tool with a screwdriver and ham-mer. Place the screwdriver through several valve bodypassages and tap on the tool in several places, andfrom different spool design prevents future valve or retainer damage04-09-10 SC- AXODE -IN 2010 Sonnax Industries, 4800/843-2600 802/463-9722 fax: 802/463-4059 TESTED INDUSTRY TRUSTEDSTEP 4 INSTALL VALVE SAVER CAP1. Remove the pull-in assembly and clip to get to the 3-2 control Remove the 3-2 timing valve to verify it is not bent and ensure stroke action is complete. 3. Verify that the Sonnax valve saver cap 96201-15K*will be able to move freely over the end of the :Assemble with Trans-Gel to keep the cap from coming off the valve during OVERVIEW1. OEM 3-2 shift valve, Sonnax valve saver cap2.

8 OEM spring, Sonnax retainer clip3. OEM spring4. OEM pull-in valve5. OEM end plug6. Sonnax retainer clip 96201-10 STEP 5 INSTALL RETAINER CLIPSV alve Saver Patent ,722,385 SpringSpringPull-in valveplugRetainer96201-10 Retainer3-2 shift timing valve* Patent No. 6,722,38596201-09(for 3-2 timing valve in step 4)96201-10(for pull-invalve in step 4)96201-11(Multiple locations,reuse as needed) 2010 Sonnax Industries, 04-09-10800/843-2600 802/463-9722 fax: 802/463-4059 5 TIME TESTED INDUSTRY TRUSTEDSTEP 6 INSTALL RELIEF VALVESA4LD4R44 AODAXODEREPLACESS onnax now offers replacements 10000-01 Kand 10000-02 Kfor thevarious relief valves and drainback valves that are found in valve bod-ies. The design of the OEM valves causes the separator plate andvalve bore to wear. The result is leakage or valve sticking. The Sonnaxvalve is rounded so it seals against an unworn part of the separatorplate and eliminates sticking Sonnax valve is ideally suited for replacing the drainback valve onAXOD, AXODE , ax4n and AX4S units.

9 The OEM drainback valvefrequently sticks in the bore. A common shop practice is to replacethe OEM drainback valve with a checkball. However, this practicerequires shortening the spring. The Sonnax valve solves the stickingproblem and is designed to work with the existing spring. No springmodifications are either part number can be used in multiple locations, it issuggested to use a relief with a radius close to original, maintainingthe spring rate. On a severely worn plate or bore, the higher radiuswill allow for better plate contact and less bore 7 CLEAN OIL PUMP SHAFTThe oil pump shaft s inner tube may have moved or may be restricted due to debrisbuild-up. This can result in delayed engagements, no movement and/or reduced coolerflow. It is highly recommended that the pump shaft be thoroughly cleaned prior toreassembly. Included in the kit is a replacement end plug for the pump Press out the inner tube and end plug by using a 17 64" (.)

10 265" diameter) transfer punchor blunted drill bit (Figure 1). 2. Remove all debris from the pump shaft and inner Reinstall the inner tube by pressing in place using a 19 64" (.297" diameter) transferpunch or blunted drill bit. Take care to fully seat the inner tube in the pump installed height should be approximately " from the end of the pump shaft(Figure 2).4. The Sonnax pump shaft 96855-02 Khas a unique design to increase cooler flow andminimize debris-related restrictions. The inner tube is not round in cross section, butoval. When reinstalling a Sonnax oval inner tube, 96855-03(patent pending), it iscritical to have the flat sides of the inner tube facing the pump shaft cross holes(Figure 3).5. Install the enclosed end plug by pressing in place using a 19 64" (.297" diameter) trans-fer punch or blunted drill bit. The end plug should be installed until about .07"below flush with the end of the pump shaft (Figure 4).