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