Pressure regulator valve ZF5HP24 Oversize

Wear is commonly found at different areas in the ZF5HP24 pressure regulator valve bore. Wear at the inner portion of the bore causes high pressure spikes leading to broken drums, pistons or other parts, as well as restricting converter/lubrication flow. Wear at the spring end of the bore allows line pressure to exhaust resulting in low line pressure, soft shifts and burnt clutches. The Sonnax oversized pressure regulator valve kit 139740-01K restores valve-to-bore clearances so the pressure regulator valve can maintain correct pressures.

Required tool:

F-139740-TL

Neutral Ctrl valve JF506E oversize

• Valve 
• End Plug 

 Found in Jaguar, Land Rover, Mazda, and VW.

 The Jatco JF506E, VW 09A neutral control valve controls the low clutch operating pressure in gears 1, 2 and 3. Because the valve is constantly oscillating from solenoid pressure, it commonly wears the valve bore. Wear in this bore can result in loss of control in the low clutch circuit, causing delayed forward and slipping in any of these low gears. Sonnax oversized neutral control valve kit 122892-13K allows you to restore the proper hydraulic control to the low clutch circuit.

Boost reg.valve 01M Oversize

• Valve 
• Ratcheting Plug 

If regulated line leaks to exhaust at the pressure regulator, it creates a low pressure condition. Wear at the inner balance spools prevent the valves from stroking, which can cause high line pressure. Wear at the inboard bore also affects the K1 clutch circuit, which can result in 1-2 or 2-3 shift complaints. Wear at the inboard end of the boost regulator bore can reduce the ability of EPC/TV pressure to stroke this valve open. Full boost exiting this valve combines forces with the main regulator spring, increasing line pressure. Sonnax offers oversized valve kits for both the main regulator valve, 119940-03K, and the boost regulator valve, 119940-05K. These kits allow the valve bores to be refurbished.

• Oversized hard-coat anodized aluminum valves restore hydraulic integrity of the circuits andprevent wear.
• The main regulator valve kit contains an o-ringed end plug to positively seal the bore and prevent regulated boost line pressure from exhausting.
• A new spring is included to work with the oversized valve and re-establish OEM regulated pressure specifications.
• A replacement ratcheting end plug is included in the boost regulator kit, as the OEM one often breaks.
• An adjustment tool is provided in the boost regulator tool kit for repeated assembly, disassembly and adjustment of the ratcheting end plug.

Required tool:

F-119940-TL5

End plug 01M Ratcheting

The boost regulator valve, which regulates EPC pressure feed to the main regulator valve, is secured in the valve body with a ratcheting end plug. Attempting to turn the end plug in order to tune line pressure will cause the end plug to break. Additionally, the boost regulator valve can cause significant wear to the bore, allowing EPC leakage, which can result in low line pressure, soft shifts and burned clutches. This bore should be inspected for wear on every rebuild. The worn bore may be salvaged using the Sonnax Oversized Boost Regulator Valve 119940-05K for 01M, 01N, 01P units, or 119940-07K for 096, 097 and 098 units. Sonnax offers a replacement ratcheting end plug and an adjustment tool to allow line pressure to be fine-tuned.

• High-quality plastic ratcheting end plug is designed to replace broken or missing OE end plugs.
• Adjustment tool allows line pressure to be tuned without breaking the end plug by compressing the ratcheting arms of the OE or Sonnax end plug.

Required tool:

119940-TL9

Bushing DP0,AL4 inputshaft E1

E1/E2 Clutch Drum

OE replacement bushings can allow critical line pressure to exhaust because of poor fit. This line pressure feeds the E2 clutch and provides critical lube.

When the bushing is worn or incorrectly toleranced, it will result in poor or erratic 2nd gear shifts, burned clutches and loss of lube. The Sonnax replacement bushing 120002 is designed to provide the proper clearance for this application.

The Sonnax bushing is designed to maintain minimal clearance between the bore and the mating shaft to greatly enhance the life of the bushing. As a result, there may be situations where the mating shaft and bushing don't fit due to some small interference.

In this instance you may carefully polish the bushing bore with fine emery cloth or a fine abrasive hand pad until the shaft fits in the bushing.