Toyota/Lexus U66OE, U660F

ZIP KIT ®
PART NUMBER U660E-ZIP IDENTIFICATION GUIDE

Valve Body Identification Guide

U660E, U660F use U660E-ZIP U760E, U760F use U760E-ZIP
Upper Valve Body Casting Upper Valve Body Casting

Extended Exhaust Small Exhaust Groove

Groove

U660 Casting Number No Transmission

(may be seen here) Designation

Solenoid Casting Solenoid Casting

Larger Solenoid Smaller Solenoid
Casting Boss Casting Boss

U660 Casting Number

No Casting Number

No Pressure
Pressure Switch Plate
Switch Plate
Flat Casting
Casting Cutouts

NOTE: Large canister solenoid connectors NOTE: Large canister solenoid connectors
are brown and black. are brown and white.

©2022 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U660E-ZIP-Identify_B 07-28-22

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 Toyota/Lexus U66OE, U660F
ZIP KIT ®
PART NUMBER U660E-ZIP QUICK GUIDE
Parts are labeled here in order of installation. See other side of sheet for details on kit contents.

installation Diagram
Middle Valve Body

Solenoid modulator
balance port.

11 Drill to .062" diameter.

Insert aluminum plug
& peen in place or insert
optional rivet, snip stem and
peen in place.

1
2
9 10 4
8

Upper Valve Body

6
3 8
5

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.

©2022 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U660E-ZIP-Guide_B 07-28-22

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 Toyota/Lexus U66OE, U660F ZIP KIT® Quick Guide

Kit Contents & Installation Steps

Step 1 Replace OE B1 Apply Step 7 R

 eplace OE (Short)
Boost Assembly C1 Accumulator Piston
Packaging Pocket 1 Packaging Pocket 7
• Sleeve • Valve • Accumulator Piston • O-Rings (2) 1 Extra

Step 2 Replace OE Reverse Step 8 Replace OE (Long) B1, B2,

Boost Assembly B3 & C2 Accumulator Pistons
Packaging Pocket 2 Packaging Pocket 8
• Sleeve • Valve • Accumulator Pistons (4) • O-Rings (6) 2 Extra

Step 3 Replace OE Small End Plugs Step 9 Replace OE Checkballs

CAUTION!: O-rings go on Inboard spool! Inboard retaining port NOTE: See pages 6 & 7 in installation and testing booklet for locations.
edge on casting should be chamfered prior to installation to
prevent O-ring shear. See page 8 of installation and testing Packaging Pocket 9
booklet for details. • Checkballs (3)
Packaging Pocket 3
• End Plugs, Small (6) • O-Rings, Small (9) 3 Extra
Step 10 R
 eplace OE O-Rings on
Case Connector & Fluid
Step 4 Replace OE Solenoid Temperature Sensor
Modulator Valve Lineup NOTE: See page 8 in installation and testing booklet for locations.

CAUTION! Many units use tri-lobed end plug. Note location of Packaging Pocket 10
OE retainer on tri-lobed OE end plug. See page 8 of installation • Fluid Temperature Sensor O-Ring, Small
and testing booklet for assembly details.
• Case Connector O-Ring, Large
Packaging Pocket 4
• Valve • Sleeve • Spring • End Plug • Shims (2)
Step 11 D
 rill & Plug Separator
Plate Balance Orifice at
Step 5 Replace OE Lockup Solenoid Modulator Valve
Control Boost Assembly To prevent solenoid modulator leakage, drill indicated separator plate
Packaging Pocket 5 orifice with included .062" dia. drill bit. Remove any burrs. If using straight
plug, insert into orifice and peen on both sides of plate. If using optional
• Sleeve • Valve small rivet, insert into orifice and using wire cutters, snip the stem end of
the rivet if/as necessary to provide for a small head once peened in place.
Peen the rivet in place on head side of plate also. After peening on both
sides of the plate, ensure plate will still fit flush on mating surfaces.
Step 6 Replace OE Large End Plug Packaging Pocket 11

CAUTION!: O-ring for this large end plug goes on • Orifice Plugs, .062" dia. (2) 1 Extra
outboard spool! • Drill Bit, .062" dia.
• Rivets (3) 2 Extra
Packaging Pocket 6
• End Plug, Large • O-Rings, Large (2) 1 Extra The parts listed here may be protected by
patent number 8,919,381.

©2022 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U660E-ZIP-Guide_B 07-28-22

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 Toyota/Lexus U66OE, U660F
ZIP KIT ®
PART NUMBER U660E-ZIP INSTALLATION & TESTING BOOKLET

TCM Initialized/Memory Reset

The U660E TCM learns the performance of the vehicle and adapts the transmission accordingly. When significant transmission or engine
repairs are made, the TCM needs to be initialized and/or have the memory reset in accordance with the chart in Figure 2. These procedures
require use of Toyota’s Techstream scan tool or their PC-based version of the scan tool, Techstream lite.

Figure 1 Automatic Transaxle Parts Replacement Chart Figure 2

Transaxle
Memory
Replaced Parts Compensation Road Test
(Learned Values)
Code
Automatic Transaxle
Input Reset
Assembly
Valve Body Assembly Initialize Necessary Reset
Shift Solenoid Valve
Necessary
SL1 and/or SL2
Shift Solenoid Valve
Initialize Necessary Reset
SL3 and/or SL4
QR Code Label
Input
with Transaxle TCM* - Possible
(into the new TCM)
TCM/ECU Compensation
Code TCM* - Impossible Necessary
Location
* Note: If possible, read the transaxle compensation code from the previous TCM.

Input Transaxle Compensation Code 5. Enter the menu items in the following order:
The transaxle compensation code is a unique, 60-digit alphanu- Powertrain / ECT / Utility / A/T Code Reset
meric value found on the QR label at the top of the transmission 6. Press “Next” again to proceed.
(Figure 1). Inputting an incorrect code into the TCM may cause 7. Press “Exit.”
shift shock.
1. Shift the shift lever to Neutral or Park.
Road Test
1. Warm up the engine.
2. Connect Techstream to the DLC3 (diagnostic link connector).
2. From a standstill, achieve highest possible speed with the
3. Turn ignition switch on (do not start the engine).
accelerator pedal opened no more than 15%. Keep the
4. Turn tester on. accelerator pedal angle steady while driving the vehicle.
5. Enter the menu items in the following order: 3. Repeat the previous step until shift shock no longer occurs.
Powertrain / ECT / Utility / A/T Code Registration.
4. From a standstill, achieve highest possible speed with the
6. Select “Set Compensation Code.” accelerator pedal opened 25% or more. Keep the accelerator
7. Register the compensation code: pedal angle steady while driving the vehicle.
a. Press “Input” 5. Repeat the previous step until shift shock no longer occurs.
b. Type in code. Press “OK.”
8. Verify the displayed value is the same as that on the QR label. Memory Reset
9. Press “Next” to set the code to the TCM. This procedure resets the TCM memory so it can memorize new
performance information.
Initialize Transaxle Compensation Code 1. Turn the ignition switch off.
This procedure resets the code and, combined with a road test, 2. Connect the Techstream to the DLC3.
allows the TCM to relearn.
3. Turn the ignition switch on.
1. Shift the shift lever to Neutral or Park. 4. Turn Techstream main switch on.
2. Turn the ignition switch off. 5. Enter the menu items in the following order:
3. Connect Techstrean to the DLC3. Powertrain / ECT / Utility / Reset Memory.
4. Turn ignition switch on and push Techstream main switch on. 6. Press “Next” to confirm reset.

©2022 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U660E-ZIP-Booklet_B 07-28-22

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 Toyota/Lexus U66OE, U660F ZIP KIT® Installation & Testing Booklet

Figure 3
Solenoid Energized
Clutch & Brake Application When selector position in manually operated.

Selector Position C1 C2 B1 B2 B3 F1 SL1 SL2 SL3 SL4 SLU SLT SL

P-Park X X
R-Reverse X X X X
N-Neutral X X
D, S6-1st X X X X
D, S6-2nd X X X X X
D, S6-3rd X X X X X
D, S6-4th X X X X X
D, S6-5th X X X X X
D, S6-6th X X X X X
S1-1st/Manual X X X

Removal Bolts
Zip Kit Instructions Bolt Color Bolt
Code Length
1. Valve Body Removal
A Red 25mm
a. With the valve body still in the transmission, remove the 11 bolts (Figure 4).
B Green 30mm
b. Remove the case connector and internal wire harness assembly from the trans-
mission as part of the valve body. C Blue 35mm
D Yellow 45mm
2. Valve Body Disassembly E Pink 55mm
a. Disconnect and remove counter gear/turbine speed sensor and valve body
bolts (Figure 5). Torque all to 8 ft-lbs

b. Disconnect case connector from all seven solenoids. Remove case connector
assembly retaining bolt, bracket and connector/harness assembly (Figure 6). Case connector and internal Figure 4
c. Remove four indicated bolts (Figure 7) and pressure switch and TFT sensor wire harness assembly.
assembly.
C B A
d. Remove eight indicated bolts (Figure 8), solenoid brackets, solenoids, small
and large cover plate.
e. Remove remaining eight bolts (Figure 9) and line pressure relief spring and ball.
D 
B
3. Installation
Install Zip Kit parts as shown on diagram of separate quick guide sheet included in
this Zip Kit.
E
NOTE: Special rebuilding tips for steps 3, 4 and 10 are on page 8 of this booklet.  B B B B
Sonnax recommends vacuum testing critical wear areas not covered by this kit to B
determine whether additional Sonnax parts are required (see pages 4–5).

4. Valve Body Reassembly

a. Reinstall the eight bolts (Figure 9) and line pressure relief spring and ball. e. Connect and reinstall counter gear/turbine speed
b. Reinstall the solenoid brackets, solenoids, small and large cover plate and sensor and valve body bolts (Figure 5).
eight bolts (Figure 8). f. When reinstalling the valve body, first temporar-
c. Reinstall pressure switch and TFT sensor assembly and four bolts (Figure 7). ily tighten the two bolts marked () in Figure 4
as they are positioning bolts.
d. Reinstall case connector assembly retaining bracket, bolt and connector/harness
assembly (Figure 6). Attach wire harness from bracket and connect to all seven
solenoids.

07-28-22 U660E-ZIP-Booklet_B ©2022 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company

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 Toyota/Lexus U66OE, U660F ZIP KIT® Installation & Testing Booklet

Connector/Harness
Disassembly &
Counter Gear/Turbine Figure 5 Figure 6
Speed Sensor Assembly Reassembly Bolts
Bolt Color Bolt
Code Length
Release
A Red 15.5mm

H B Green 16mm
D C Lt Blue 25mm
D Yellow 50mm
G
D E Pink 55mm
F Dk Blue 60mm
G Orange 70mm
Disconnect Turbine Speed Sensor
H Teal 75mm
I Brown 80mm

SL3 Solenoid SL1 Solenoid SL2 Solenoid SLU Solenoid Figure 7 J Purple 85mm
(PCSC) (PCSA) (PCSB) TCC & B2 Brake
B1 Brake C1 Clutch C2 Clutch 5.0–5.6 ohm Torque all to 8 ft-lbs
5.0–5.6 ohm 5.0–5.6 ohm 5.0–5.6 ohm (White &
Black Wires) SLT Solenoid
(Blue & (Pink & (Orange &
SL4 Solenoid Black Wires) Black Wires) Line Pressure
Black Wires)
(PCSD) 5.0–5.6 ohm
B3 Brake (Grey &
Black Wires)
5.0–5.6 ohm
(Green &
Black Wires)
SL Solenoid
• Lockup Relay Valve
• B2 Brake Clutch
Apply Control Valve
J
J J • Reverse Sequence
C
Valve
11–15 ohm
(1 Blue Wire)

Pressure Switch &

TFT Sensor Assembly

CAUTION!: Do not interchange solenoids. If SLU and

SLT are interchanged, this will cause both line and TCC
All solenoid resistance values at 20oC/68oF. apply issues. SLT has five slots, SLU has four slots.

Figure 8 Figure 9

B D D
F
D

E I G
I I I

I E C
E E

Line pressure relief spring and ball.

©2022 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U660E-ZIP-Booklet_B 07-28-22

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 Toyota/Lexus U66OE, U660F ZIP KIT® Installation & Testing Booklet

Critical Wear Areas & Vacuum Test Locations

Drop-In Zip Valve™
Parts Available
NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to with an arrow.
Springs are not shown for visual clarity. Low vacuum reading indicates wear and Sonnax parts are noted for replacement.

For specific vacuum test information, refer to individual part

Upper Valve Body 20
25
15
10
5 instructions included in kits and available at www.sonnax.com.
30 0
VACUUM
TEST

B1 Accumulator Piston B2 Accumulator Piston

• Burnt B1 brake clutches • Forward Slip • Burnt B2 brake clutches • Flare/Harsh shifts
• Flare/Harsh shifts • Burnt clutches • Delayed Reverse with harsh engagement
Replace with Sonnax Part No. • Burnt clutches
47740-11K* Replace with Sonnax Part No. 47740-11K*

C1 Accumulator Piston
• Delayed Forward • Forward slip
B3 Accumulator Piston • C1 Clutch burned • Harsh Forward
• Burnt B3 brake clutches • Flare shifts
• Flare/Harsh shifts • Burnt clutches
Replace with Sonnax Part No.
• Delayed Reverse with harsh engagement 47740-12K*
Replace with Sonnax Part No. 47740-11K*

C2 Accumulator Piston


• Burnt C2 brake clutches • Forward Slip

Secondary Pressure
• Flare/Harsh shifts • Burnt clutches
Regulator Valve
Replace with Sonnax Part No.
• TCC codes • TCC shudder • Lube failures
47740-11K*
• TCC apply & release concerns
• Bearing/Bushing failure
Replace with Sonnax Part No.
47740-26K Requires F-47740-TL26 & VB-FIX Test: Test this port
with valve blocked
inboard .125" with
OE retainer.
Reverse Sequence Valve
• Delayed Reverse Test: Test this port with valve
blocked outboard .125" with
• Low Reverse pressure OE retainer and sealing port
• Burnt B2 or B3 brake on back with thumb.
 

Test: Test each port with valve blocked

Lockup Relay Valve outboard .125" with OE retainer.
• TCC apply & release concerns
• TCC slip codes
• Overheated transmission Lockup Control Valve
• TCC slip codes • RPM fluctuation
• TCC apply & release concerns
Lockup Control Boost • Harsh downshifts
Assembly Replace with Sonnax Part No.
• TCC apply & release concerns 47740-30K Requires F-47740-TL30 & VB-FIX
• TCC slip codes • Burnt converter
• Overheated Fluid
Replace with Sonnax Part No. Converter &
47740-06K* Lube Relief Valve
End Plugs
• Burnt brake clutches • Shift concerns • Overheating • Repeated converter failure
• Lockup concerns • Burnt clutches • TCC slip • TCC slip codes
Replace with Sonnax Part No. Replace with Sonnax Part No.
47740-21K*  NOTE: Several Locations =  47740-60K Requires 47740-TL60

*Items with an asterisk (*) are included in this Zip Kit.

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 Toyota/Lexus U66OE, U660F ZIP KIT® Installation & Testing Booklet

B1 Apply Boost Assembly

Middle Valve Body • Lower Side • 2nd and 6th Gear shift concerns
• B1 brake clutches burned
B1 Apply Control Valve Replace with Sonnax Part No.
• 2nd and 6th Gear shift concerns 47740-19K*
• B1 brake clutches burned
Note: Seal port on Test: Block this port
back when testing. and port on back
when testing. Test: Test this port
with valve blocked
Primary Pressure inboard .218" dia.
checkball.
Regulator Valve
• Erratic/Soft/Harsh shifts Note: Seal
• Low line pressure/rise port on back
when testing.
Clutch Control Valve
• Clutch slippage
• 4-5 Flare/Harsh


• High line pressure in Reverse
• Delayed Neutral to Drive
• Burnt brake clutches
• Delayed Reverse
• High line pressure
• Low converter pressure Replace with Sonnax Part No.
47740-22K
• Burnt clutches
Requires F-47740-TL22 & VB-FIX
Replace with Sonnax Part No.


47740-02K Requires F-47740-TL2 & VB-FIX

C2 Clutch Apply
Sequence Valve Control Valve
Note: Seal • 3-4 Flare
• Shift concerns port on back
• Burnt clutches/brakes when testing. • C2 Clutch Burned


• 4-5-6 Slip
Replace with Sonnax Part No.
47740-63K
B2 Apply Control Valve Requires F-47740-TL63 & VB-FIX

• B2 Clutch burned • No Reverse

• Delayed Reverse • Reverse slip
Replace with Sonnax Part No.
47740-27K Requires F-47740-TL27 & VB-FIX Middle Valve Body
• Upper Side
B2 Control Valve
• Delayed/Harsh Reverse Note: Seal when
• Double bump Reverse engagement testing B1 apply
• No Manual 1st • B2 Clutches burned control valve.
Replace with Sonnax Part No.
47740-35K Requires F-47740-TL35 & VB-FIX
Note: Seal when
testing B1 apply Note: Seal when
boost assembly. testing pressure
Solenoid Modulator Valve regulator valve.
• Shift concerns • Solenoid performance codes
• TCC apply & release concerns Reverse Boost
Replace with Sonnax Part Nos. Assembly
47740-41K or • Delayed Reverse
47740-24K Requires F-47740-TL24 & VB-FIX • Low line rise in Reverse
• B2 Brake clutches burned Note: Seal when
Replace with Sonnax Part No. testing B2 apply
control valve.
47740-17K*

*Items with an asterisk (*) are included in this Zip Kit.

©2022 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U660E-ZIP-Booklet_B 07-28-22
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5
 Toyota/Lexus U66OE, U660F ZIP KIT® Installation & Testing Booklet

OE Exploded View
Upper Valve Body
NOTE: Depending upon vehicle application, the OE springs shown may not be present.

Upper Valve Body Descriptions

I.D. No. Description

Lockup Control Valve (inboard) 108
101
Lockup Control Boost Assembly (outboard)
102 Lockup Relay Valve
103 Reverse Sequence Valve 107
104 Secondary Pressure Regulator Valve
105 B3 Accumulator Piston 106
106 B1 Accumulator Piston
107 B2 Accumulator Piston
108 C1 Accumulator Piston
109 C2 Accumulator Piston
110 Lube Relief Check Valve
111 Converter Relief Check Valve

.218" dia. Checkball

105

104 109

.393" dia. Checkball

.218" dia. Checkball

103

102

101

110

111

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 Toyota/Lexus U66OE, U660F ZIP KIT® Installation & Testing Booklet

Middle Valve Body

.393" dia.
Checkballs

Filter
201

202
.218" dia.
Checkball 203

204
.393" dia. Checkballs

Filter
205

206

207

208

209

Middle Valve Body Descriptions

I.D. No. Description

B1 Apply Control Valve (inboard)
201
B1 Apply Boost Assembly (outboard)
Primary Pressure Regulator Valve (inboard)
202
Reverse Boost Assembly (outboard)
203 Sequence Valve
204 Clutch Control Valve
205 C2 Clutch Apply Control Valve
B2 Apply Control Relay Valve (inboard)
206
B2 Apply Control Valve (outboard)
B2 Control Valve (inboard)
207
B2 Control Relay Valve (outboard)
208 Manual Valve
209 Solenoid Modulator Valve

©2022 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company U660E-ZIP-Booklet_B 07-28-22

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 Toyota/Lexus U66OE, U660F ZIP KIT® Installation & Testing Booklet

Additional Technical Tips for Installation Steps 3, 4 & 10

from the Quick Guide
Narrow Bore Length Large Outer Chamfer Figure 10 Step 3 Replace OE Small
End Plugs
The large outer chamfer on the small end plug bores
makes the outer bore too narrow for an O-ring to seal
properly. The Sonnax O-ringed end plugs require the
O-ring to seal at the bore inboard of the retainer port.
To prevent O-ring shear during assembly, the sharp
edge must be broken. This can be done by inserting
Retainer Port
a narrow file or small screwdriver through the retainer
Sharp Edge
port and reworking the edge (Figure 10).
Modified Edge
To install the O-ringed end plug after the edge has been
End Plug Location Modified End Plug Location modified, place the O-ring in the narrow plug groove.
Lubricate the plug and O-ring with O-Lube and roll
on bench to size. Carefully push the plug into the
Figure 11 bore. As the O-ring contacts the modified edge, gently
Retainer compress the exposed portion with a small screwdriver
blade inserted through the retainer port.

Step 4 Replace OE Solenoid

Wide
Setting Middle Modulator Valve Lineup
Setting
Two
Tri-Lobed During disassembly of OE solenoid modulator
End Plug
Spooled lineup, note location of the tri-lobed end plug
End Plug
(if applicable) retainer (Figure 11). This adjusts
solenoid modulator pressure. Follow options A–D if a
Narrow Setting
tri-lobed end plug is used.
Two OE Solenoid Modulator
End Plug Variations OE Tri-Lobed End Plug If a standard two-spooled end plug is used, proceed to
option E.

Selective Shims Figure 12 Option A: If OE retainer is installed at the most narrow
location, no Sonnax shims are required.
Option B: 
If OE retainer is installed at the middle
spool location, one Sonnax shim is required.
Solenoid Modulator Valve Lineup Option C: If OE retainer is installed at the widest spool
location, two Sonnax shims are required.
Option D: 
Shims should be placed over valve spring
Replace with
Figure 13 stem, between valve spool face and spring
Sonnax Small
O-Ring Case
(Figure 12).
Connector Option E: For standard two-spooled OE plug, do not
& Internal NOTE: Sonnax end
Wire plug can be swapped use any shims. Install as pictured (Figure 12),
Harness
Assembly end for end for best omitting the shims.
fit of sleeve in bore.

Step 10 Replace OE O-Rings on

Pressure Switch Case Connector & Fluid
& TFT Sensor
Assembly
Temperature Sensor
Replace with Replace the O-rings in the case connector and internal
Sonnax Large
O-Ring wire harness assembly, as well as in the pressure switch
and TFT sensor assembly as shown in these locations
(Figure 13).

07-28-22 U660E-ZIP-Booklet_B ©2022 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company

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