Sonnax Industries, Inc. Ford 4R44E ZIP KIT Installation & Testing Booklet

Torque Specifications

Band Adjuster Lock Nut
35 to 45 ft-lb
Converter Housing-to-Case
27 to 39 ft-lb
Extension Housing-to-Case
27 to 39 ft-lb
Manual Lever Inner Nut
30 to 40 ft-lb
Oil Cooler Line-to-
Connector Nut
18 to 23 ft-lb
Transmission-to-Engine
28 to 38 ft-lb
(Except 3.0L)
33 to 44 ft-lb
(3.0L)
Center Support-to-Case Bolt
80 to 115 in-lb
TR Sensor
71 to 98 in-lb
Recommended Fluid & Capacities
Mercon V (XT-5-QM) ATF
4R44E 2WD, 2.3L
9.9 Qts (9.4L)
4R44E 4WD
10.4 Qts (9.8L)
5R55E 2WD
10.0 Qts (9.5L)
©2012 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
FORd 4R44E, 4R55E, 5R44E, 5R55E
ziP KiT
PaRT NUMBER 4R44E-5R55E-ziP
Transmission Oil Pan Bolt
115 to 133 in-lb
Converter-to-Flywheel
22 to 30 ft-lb
Oil Pump-to-Cnvtr Housing
16 to 21 ft-lb
Manual Lever Outer Nut
30 to 40 ft-lb
Oil Cooler Line-to-
Connector 5/16" Tube Nut
26 to 32 ft-lb
Low-Reverse Servo
Cover Bolt
106 to 124 in-lb
Separator Plate Bolt
53 to 71 in-lb
Valve Body-to-Case Bolt
71 to 98 in-lb
4R44E 2WD, 3.0L
10.0 Qts (9.5L)
5R55E 4WD
10.3 Qts (9.8L)
Valve Body Rebuild Tips
& Techniques
Bore-by-bore tips for removal, installation, options and checks of valve body
components. The detailed steps below correlate to the quick guide steps.

1. Replace OE Boost Assembly

This kit includes an increased ratio boost assembly and strong pressure regulator
valve spring. These provide for firmer forward and reverse engagement and slightly
firmer upshifts. These elevated versions should not be used if testing determines that
the Sonnax EPC and engagement control kit 37947-11K (not included in this Zip
Kit) is necessary and installed.

2. Replace OE Forward Modulator Valve

By positioning the manual valve furthest into the bore, air pressure can be used to blow
the modulator valve out. If there is any visible wear or ridge in the bore, buff this area
with Scotch-Brite™ placed on a twisted wire and inserted into drill. Install the Teflon®
seal onto the Sonnax valve. Invert the valve and push into the bore just far enough to
size the Teflon seal. After sizing the seal, install the OE forward modulator spring into
the end of the Sonnax valve and install into the bore (illustrated in Quick Guide).

3. Replace OE Solid Plug

If the OE end plug has a relief valve in it, do NOT install the Sonnax end plug or the
spring. If the OE end plug was solid, replace with the Sonnax end plug and spring.
Optional Step: Seal the "L" pin circuits at the forward and reverse modulator valve
bores (inboard at bores in steps 3 and 4). These locate and hold plugs which separate
and seal oil circuits. As the valves toggle, the plugs become loose and allow fluid to
pass around them. It is suggested to vacuum test the area for severe wear first (reference
page 7) to determine if refurbishing the bore is a better option. The following sealant
process requires cure time, so time must be allowed. Using Permatex® Surface Prep
Activator #24163 or a similar product, clean the middle plug and "L" pin area from
both sides and through the open bore. Air dry, then drip a small amount of Loctite®
609 or 3M #04732 sealant into the "L" pin opening. This must have a cure time to
hold properly. Epoxy is not suggested, as it is permanent. Loctite can be heated to
allow removal. To remove plugs once sealed, heat the area until the sealant melts, then
air dry. Flat stone the valve body surface and clean well to remove surface imprints.

4. Replace OE End Plugs

a. Most plugs require two O-rings and have a tapped hole to allow for easy
removal in the future. To install, lube the plug, slip on the O-rings and roll
the plug on a clean surface to seat the O-rings. Verify that the valves and
springs are in their original positions and install the end plugs with the tapped
hole facing out. Extra O-rings are supplied in case an O-ring is torn during
installation.
b. The OE "U"-shaped retainer is used to hold the plug into the casting, and
should be inserted into the plug groove between the two O-rings. The outer
plug groove will protrude from the bore and is used to help retain the OE
solenoid bracket.
iNsTallaTioN & TEsTiNG BooKlET
4R44E-5R55E-ZIP-Booklet 01-26-12
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