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I n s t r u c t i o n sHigh Performance TRANSMISSION Parts
PERFORMANCE
©2011 Sonnax Industries, Inc. 400-LB1 Rev:-, 400-LB1-IN 02-07-11
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
Line Pressure Booster Kit
Part No. 400-LB1•LargeRatioBoostAssembly•StrongerPressureRegulatorSpring•O-Rings(2)
400
1. DisassemblyDiscardtheoriginalboostsleeveandvalve,pressureregulatorspringandhorseshoe-shapedshim.RetaintheOEpressureregulatorvalve,springseatandretainingring.
2. Bore PreparationTheO-ringsincludedinthiskitprovideextrainsurancetowardpre-ventingcrossleaksandalwaysshouldbeinstalled.
a.Carefullyinspectsnapringgrooves,feedholesorboreedgesandde-burr ifnecessary to reduce cutting.Anon-abrasive tool suchasaradialwirebrush(Figure 1)worksbest,buttheborealwaysshouldbethoroughlycleanedafteranyde-burring.
b.Place the twoO-rings into thegrooveson theboost sleeve, rollsleeveoverbenchtoresizetheO-rings,thenpre-lubetheO-rings.SonnaxSlipperyStick™(O-LUBE)orDoorEase®areidealforthispurpose.
3. Installationa.Installthepressureregulatorvalve,springseatandpressureregula-torspring.Donotinstallhorseshoeshim.
b.Carefullypushthesleeveassemblyintothepumpbody,justdeepenoughtoinstalltheretainingring.
Figure 1
Radial Wire Brush
Large Ratio Boost Assembly
Stronger Pressure Regulator Spring
O-Rings
Figure 2
Large Ratio Boost Assembly
Stronger Pressure Regulator Spring
OE PR Valve
OE Spring Seat
Pump Cover
PERFORMANCEHigh Performance TRANSMISSION PartsLINE PRESSURE BOOSTER KIT 400-LB1 I n s t r u c t i o n S u p p l e m e n t
©2011 Sonnax Industries, Inc. 400-LB1 Rev:-, 400-LB1-IN 02-07-11
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2
Pump Tech
Good Pressure Depends on a Good PumpVerify Pump SpecificationsExcessclearanceequalslowpumpvolumeandpressure.
Check for Wear
Gear Pocket Clearance
.0007" to .0026" Check with feeler gauge and straight edge over pump face, or with Plastigauge and bolt complete pump together.
Outer Gear to Pump Body .005" max.
The Prescription for Optimum PressureStrongerpressureregulatorspringsraisepressureequalamountsatidleandmaximumpressure.Manyaftermarket“kit”springsareacompromise,raisingpressuretoomuchatidleandnotenough at maximum pressures (A in graph). Larger boostvalves,ontheotherhand,haveaprogressiveeffectonpressure,changingtherateofpressureincrease(Bingraph).
TheSonnaxlargeratioboostvalvesandstrongerpressureregu-lator springs are designed towork together.This is an idealcombination: smooth engagements and lower load on thepumpatidle,butagreaterincreaseinpressureasthetransmis-sionisworkedharder.
For a more in-depth look at raising line pressure, readThe Prescription for Optimum Pressure in the Sonnax onlinetechnicallibraryatwww.sonnax.com.
Increases in Line PressureStronger Springs vs. Larger Boost Valves
B
B
A
A
OEM SpringA - B -
Key
Aftermarket “Kit” SpringsSonnax Line Pressure Booster Kit
Low EPC/Torque Signal Pressure HighLo
wLi
ne P
ress
ure
Hig
h
Figure 4
Pump Body
Modulated Boost
Reverse Boost
Figure 3
Wearontipsofinnergearteethoronthecrescentmeanslowpressure.Inspectinsideofcrescent,areabetweensuctionanddischargeportsandtipsofgearteeth,forwear(Figure 3).Wearandexcessclearancereducespumpefficiency.
Perform Wet Air Test
Itisagoodideatoperformthewetairtestagain(Figure 4)afterinstall-ingtheSonnaxlinepressureboosterkit.Continuedleakageafterreplac-ingtheboostvalveandsleeveindicatescrossleakagebetweenthepumphalves,whichmaybewarped.Replaceorresurfacethepumphalvestoeliminatetheremainingleakage,oruseLoctite#518gasketeliminatoronthecircuitfromfeedtoboostsleeve.
Pump Housing Flatness .001"
Inspect for Wear
PERFORMANCEHigh Performance TRANSMISSION PartsLINE PRESSURE BOOSTER KIT 400-LB1 I n s t r u c t i o n S u p p l e m e n t
©2011 Sonnax Industries, Inc. 400-LB1 Rev:-, 400-LB1-IN 02-07-11
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3
Optional Shif t Tech
Too Much of a Good Thing Causes ProblemsMosttimeswhenafeedorificeisenlarged,thechangeinshiftfeelisfargreaterthanintendedandresultsinnuisanceharshshiftswhichmanycustomersdonotlike.Sonnaxkitsraiselinepressureinapro-gressivewaysothebiggestincreaseinpressureisathigherpressurerangeswhenitisneededmost.Thishasanoverallpositiveeffectonshiftfeelwithoutgeneratingcomplaints.
Sonnaxdoesnotrecommenddrillingfeedholesinalltransmissionsorrecommendspecificdrillsizesbecausetherearesomanydifferentoriginalcalibrationsandwhatworkswellinonemaynotworkwellinanother.Ifyoudowishtoenlargefeedorifices,wehaveprovidedthese guidelines tohelp youdeterminewhat drill size correspondswithaspecificpercentageincreaseinorificeareasoyouarelesslikelytocauseproblems.
Orifice Feed HolesTherearethreedifferentplates forthe400:the '89-laterseven-ballplateandtwoversionsofthesix-ballplate.Thedifferencebetweenthesix-ballplatesisthelocationofthe2-3hole.
Original Orifice Diameter
Enlarged Diameter Conservative Aggressive
+10% area
+ 20% area
+ 30% area
+ 40% area
+ 50% area
0.040 0.042 0.044 0.046 0.047 0.049
0.045 0.047 0.049 0.051 0.053 0.055
0.050 0.052 0.055 0.057 0.059 0.061
0.055 0.058 0.060 0.063 0.065 0.067
0.060 0.063 0.066 0.068 0.071 0.073
0.065 0.068 0.071 0.074 0.077 0.080
0.070 0.073 0.077 0.080 0.083 0.086
0.075 0.079 0.082 0.086 0.089 0.092
0.080 0.084 0.088 0.091 0.095 0.098
0.085 0.089 0.093 0.097 0.101 0.104
0.090 0.094 0.099 0.103 0.106 0.110
0.095 0.100 0.104 0.108 0.112 0.116
0.100 0.105 0.110 0.114 0.118 0.122
0.105 0.110 0.115 0.120 0.124 0.129
0.110 0.115 0.120 0.125 0.130 0.135
0.115 0.121 0.126 0.131 0.136 0.141
0.120 0.126 0.131 0.137 0.142 0.147
0.125 0.131 0.137 0.143 0.148 0.153
0.130 0.136 0.142 0.148 0.154 0.159
0.135 0.142 0.148 0.154 0.160 0.165
0.140 0.147 0.153 0.160 0.166 0.171
0.145 0.152 0.159 0.165 0.172 0.178
0.150 0.157 0.164 0.171 0.177 0.184
Orifice Feed Hole Guidelines
Donot drill feedholes too large.A small change in diameter canmakeabigchangeintheareaoftheholetheoilflowsthrough.Usethischarttodeterminedrilldiameterforanyincreaseinorificeareathatyouthinkbestsuitsthevehicle.
6-Ball Plate Version 1
2-3
6-Ball Plate Version 2
7-Ball Plate
Identifies the 7-Ball Plate
2-3
Identifies the 6-Ball Plate
Identifies the 6-Ball Plate
1-2
1-2 1-2
1 Hole Identifies Version 2
2-3
2 Holes Identifies Version 1
PERFORMANCEHigh Performance TRANSMISSION PartsLINE PRESSURE BOOSTER KIT 400-LB1 I n s t r u c t i o n S u p p l e m e n t
©2011 Sonnax Industries, Inc. 400-LB1 Rev:-, 400-LB1-IN 02-07-11
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 4
Recommended Sonnax Products
Line Pressure Booster Kits
Hydraulic Booster Kits Sonnaxhydrauliclinepressureboosterkitscontainstrongerpressureregulatorspringsandlargeratioboostvalvesdesignedtoworktogethertopro-videprogressivepressureincreasesasdrivingconditionsbecomemoredemanding.Sonnaxspringsareapproximately10%strongerthanOEandmoreconservativeinimpactthanotheraftermarket“kit”springs.
Electronic Booster Kits Chrysler45RFE,545RFEand68RFEunitsareuniquebecausetheyutilizeatrueclosed-looppressurecontrolsystem:thecomputerreadslinepressureatalltimesthroughafullrangepressuresensor.Thismeanstraditionalmethodsofraisinglinepressurewillhavenoeffectbecausethecomputersimplyre-adjuststhepressureuntilthevoltagesignalfromthepressuresensormatcheswhatthecomputerwantstosee.Sonnaxelectroniclinepressureboostersalterthepressuresignalsenttothecomputer,causingthecomputertoraiselinepressure.Thesekitsareidealforheavydutyandmodifiedvehiclesandevenstocktransmissionswhenalittleextrapressureisdesired.TheboosterinstallseasilybetweenthepressuresensorandvehicleharnessusingOE-stylesealedconnectors.
Pump Bushing34034T-01
WornbabbitpumpbushingsinGMPowerglide,350,400andAllison®AT540unitsallowtheconverterhubandinnerpumpgeartomoveoff-center,causingdamagetothepumpgearsandpumphousingcrescent.Sonnaxpumpbushing34034T-01isadirectreplacementpartthatisbetterfittingthanOE.Extremelywear-resistant,thisTeflon®(PTFE)-linedKryptonite™bush-inghelpsmaximizethelifeoftheseolderandincreasinglyrarepumps.
Pressure Regulator Valve Kit34910-03K
High-mileagevehicleswitha400oftenexperiencepoorlinepressurecontrolduetoawornpressureregulatorbore.Thiswillresultinhighcoolerpressureandconverter,crankshaft,and/orfrictionelementfailure.Thisborewearcanbeverifiedbytestinglinepressureandwetairtestingthepump.Thishardenedsteelvalvecontinuouslyoscillateswithinthecast-ironpumpbore,resultinginwear.Balancelinepressureisthenallowedtoleakpastthevalveandexhausttothesump.Thispreventsthepressureregulatorvalvefrommovingcompletelytothelowerlinepressureposition.TheSonnaxPRvalvekit34910-03Keliminatestheseproblems.
Forward Clutch Hub34322-01
Replacementforwardclutchhub34322-01fitstheGM400,425and4L80-Eforwardclutchassembly.ThishubismadefromanAISI1045steelforging.
No Walk-Out Oversized Case Bushing34006-SP
TheOEcasebushinginvehicleswitha400or4L80-Etransmissiontendsto“walkout”ofthehousingbore.Thisallowsthebushingtowanderintotheextensionhousing,leavestheoutputshaftunsupported,andmayruinthegovernorgearandcausecasedamage.TheSonnaxnowalk-outoversizedcasebushing34006-SPisspeciallydesignedtoremaininthecasebore.
Pump Bushing 34034T-01
PR Valve Kit 34910-03K
Forward Clutch Hub 34322-01
No Walk-Out Oversized Case Bushing 34006-SP
Part No. UnitHydraulic Booster Kits4R100-LB1 E4OD, 4R100
4L60E-LB1 4L60-E, 4L65-E, 4L70-E*
4L60E-LB2 4L60-E, 4L65-E, 4L70-E**
700R4-LB1 4L60 (700-R4), 200-4R
400-LB1 400
4L80E-LB1 4L80-E, 4L85-E
4T65E-LB1 4T65-E
350-LB1 350
4R70W-LB1 AODE, 4R70W, 4R75W
Electronic Booster Kits44957-LB1 68RFE
44957-LB2 45/545RFE
*Early-style pump **Late-style pump