T R A N S M IS S ION PART S Instructions
Solenoid Switch Valve Plug Kit
Chrysler 40TE, 40TES, 41AE, 41TE, 41TES, 42LE, 42RLE, 45RFE, 545RFE, 62TE, 65RFE, 66RFE, 68RFE 41TE Valve Body
Part No.
92835-02K
• Inner Plug • Outer Plug
OE Solenoid Switch Valve
Patent No. 7,001,300
Inner Plug
NOTE: Fits bores containing OE switch valve with .420" dia. large spool only (see main illustration).
Outer Plug
OE End Plug
*OE spool diameter MUST measure .420".
62TE Valve Body
45RFE Valve Body
Solenoid Switch Valve Bore
Solenoid Switch Valve Bore
NOTE: Large spool of OE switch valve must be .420" dia. (main photo). If spool measures .420", continue installation. If spool measures .453", STOP! This Sonnax kit cannot be used. Instead, install Sonnax oversized solenoid switch valve plug kit 92835-22K after reaming bore with Sonnax tool 92835-RM22.
1. Disassembly a. Remove OE retainer, end plug and switch valve plugs and set aside. b. Remove OE switch valve and measure large spool. If large spool is .420" dia., proceed to step "c". If spool measures .453", STOP and see note above. c. If OE switch valve spool measures .420" dia., discard OE switch valve plugs. Keep OE switch valve, end plug and retainer for reuse. 2. Prepare Bore a. Buff out bore to remove any ridged aluminum. b. Ensure all debris has been cleared and cleaned from valve bore and body.
TECH TIP!
TECH TIP: These valve bodies commonly warp and allow pressure to escape the switch valve circuit. Recommend flat-sanding the casting to ensure pressure is properly contained.
©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
92835-02K-IN 01-26-17 Page 1
T R A N S M IS S ION PART S Instructions
SOLENOID SWITCH VALVE PLUG KIT 92835-02K
3. Installation & Assembly a. Reinstall OE solenoid switch valve.
Sonnax Switch Valve Plugs
b. Install Sonnax switch valve plugs. Outer plug has a slight chamfered edge on one side; this side must face outward (Figure 1).
Figure 1 Outer Plug
c. Insert OE end plug into bore and secure with OE retainer. 4. Final Testing Vacuum testing at the port(s) indicated holds the recommended minimum 16 in-Hg (Figures 2, 3 & 4).
Inner Plug Chamfered Edge Faces Outboard
Figure 2
Figure 3
Block this area while vacuum testing.
Figure 4
20 20
15
10
25
5
0 30 VACUUM TEST
16"-Hg
41TE Valve Body
©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
20
15
25
15
10
25
10
5
0 30 VACUUM TEST
5
0 30 VACUUM TEST
16"-Hg 16"-Hg
45RFE Valve Body
65RFE Valve Body
92835-02K-IN 01-26-17 Page 2
