lockupclutchcontrolkit.pdf

I n s t r u c t i o nD a t a S h e e t TF-80/81SC, TF-60SN

PART NUMBERS 15741-29K, F-15741-TL29

Lockup Clutch Control Valve Kit

15741-29K1 Lockup Clutch Control Valve1 Lockup Clutch Control Sleeve1 Spring1 Spacer1 Plunger Valve1 Plunger Sleeve

F-15741-TL291 Reamer Jig1 Guide Pin1 Reamer

Also available for use with VB-FIX

F-15741-TL29PLRequired for

1 Adapter Plate TF-80SC & TF-60SN

3 Assorted Screws

Note: Fits Volvo (AM6); Opel (AF40);Peugeot (TF80); Saab (AF40/6); Land Rover (TF80); Ford (AF21); Mazda (AW6A-EL); BMW (6F21WA) & VW/Audi (09G, 09K, 09M).

©2009 Sonnax Industries, Inc. 15741-29K Rev:-, 15741-29K 06-25-09

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com • info@sonnax.com 1

REQUIRED

TOOL

REQUIRED

TOOL

CautionAdapter plate F-15741-TL29PL is required to hold VW 09G (TF-60SN) and Volvo/Opal (TF-80SC)valve body sections while reaming. Adapter plate is not required for Ford/Mazda (TF-81SC).

Note: Mounting instructions are included with the Adapter plate F-15741-TL29PL.

Disassembly StepsRemove the retainer, plunger sleeve with plunger valve, spring and lock-up valve. Keep the retainer forre-use and discard all other OE pieces.

Important Notes:1. Clean the bore thoroughly in a solvent tank.2. 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.

3. The reamers should be turned using a low rpm, high torque air drill regulated to a maximum of 200 rpm.4. Examine the bore after cleaning for surface finish, debris, and burrs. Flashing and burrs on the exit

side of lands and bores must be carefully removed. A small piece of Scotchbrite™ material attachedto a wire and powered with a drill motor is ideal for the task.

Tool Kit F-39741-TL29

TF-80SC Rear Casting

TF-60SNUpper Valve Body #2

Spacer

Spring

Lockup Clutch Control Valve

PlungerSleeve

Lockup Clutch Control Sleeve

TF-81SC Rear Cover

Plunger Valve

Adapter PlateF-15741-TL29PL

TF-80/81SC, TF-60SNPART NUMBERS 15741-29K, F-15741-TL29

Lockup Clutch Control Valve Kit

©2009 Sonnax Industries, Inc. 15741-29K Rev:-, 15741-29K 06-25-09

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com • info@sonnax.com 2

Installation & Assembly Steps For TF-60SN only:1. Insert the Sonnax TC lock-up valve and sleeve assembly into the

reamed bore with the smaller OD in-board.2. Insert the Sonnax spring.3. Shorten the plunger valve by

cutting the extended end off at thev-notch. The overall length of themodified plunger valve shouldbe .670" [17.02mm] +/- .015"[0.38mm] (see illustration).

4. Insert the modified plungervalve into the plunger sleeve cutend first. Do NOT use spacer.

5. Insert the Sonnax plungervalve/sleeve assembly into thereamed bore with the opensleeve end in-board.

6. Install the OE plunger sleeveretainer*.

For TF-80/81SC:1. Insert the Sonnax TC lock-up valve and sleeve assembly into

the reamed bore with the smaller sleeve OD in-board.

2. Insert the Sonnax spring.

3. Insert the Sonnax sleeve spacer into the reamed bore.

4. Insert the Sonnax plunger valve/sleeve assembly into thereamed bore with the open sleeve end in-board.

5. Install the OE plunger sleeve retainer*.

* If the stack-up of components does not allow the installation of the

retainer, carefully remove the minimum necessary material from:

TF-60SN: The open or inboard end of the plunger sleeve. Besure to remove any burrs that may interfere withplunger valve movement.

TF-80/81SC: Either face of the sleeve spacer. Remove burrs.

YESNO

Use a loose fitting reamer socket, a wobble adapter and a regulated air drill.Insert the Reamer.

Use a continuous supply of cuttingfluid and little or no inward force.

Remove guide pin.Do not loosen Clamp or wing nuts.

Tighten wing nuts.Guide pin must move freely.Do not clamp over bore. Leave gap.

Insert the reamer jig. Align the guide pin and valve body.Tighten the clamp.

Guide pin must move freely.

NO DRAG

NO DRAG

1. 3.2.

6.5.4.

7. 9.8.

Ream

ing Inst

ruct

ions

Sonnax Plunger Valve

Cut at V-notch

Use original full length for

TF-80/81SC

Use shortenedlength for TF-60SN