Sonnax Chrysler Info from Bob

Sonnax Chrysler Info from Bob Sonnax :The following information is compiled from post-rebuild drive-ability complaints, which may or may not be related to the converter ..
Converter Related "Tech"
by Bob Warnke

These Domestic unit complaints are categorized by vehicle application:

Daimler/ Chrysler, GM & Ford

Example: 670-1 identifies the transmission.

At as first correction:

• A,B,C, place the complaint in an order.

• "t" notes a concern as transmission related, c = converter related , v =vehicle related.

Compiled for Sonnax and Rebuilders by Bob Warnke, from Tech. calls and recorded sources. Rev. 05-15-02

Daimler/Chrysler Converter Conditions:



• No TCC apply

• Engine stalls on engagement

• TCC shudder


• At: Pump warpage, pump volume low are the most common problems.

• Bt: Installing a stronger TCC control spring will delay apply and often reduce shudder complaints.

• Cv: Bypass the cooler and re-test. If the problem is gone, the cooler may be restricted. If the problem still exists, check cooler flow to verify pump output.

• Dv: Chrysler has a TCC bypass wiring harness to prevent TCC solenoid control. Using this will reduce gas mileage! An alternative that ends with same results, is to block TCC apply valve toward solenoid.

• Ec: If you have low flow when-ever TCC is not applied and a large increase in flow with TCC electrical signal, the converter cover bushing may be too restrictive.

604-1 ( 41TE & 42LE)


• Harsh TCC apply or shudder

• TCC piston contacting the cover, piston warpage

• Converter friction material in the pan


• Ac: Bond TCC lining to cover or piston. Use a 400 degree bonding temp. with flow time of 10 minutes and 150-240 press psi. Use abrasive to grit blast the bonding surface. Aluminum oxide of 80 grit will result in a surface finish of Ra 75-150. The friction contact surface should be held to 25 Ra or better. The above suggestion is from Chrysler remanufacturing standards

• Bt : Replace the pressure regulator-reducing sleeve. (Sonnax part number 92835-07), was designed to insure converter feed

• Ct: Resurface the case and valve body until flat, with a stone or file and re-clean

• Dt: Remove both TCC control valves retained by the wide plate, verify their full stroke

• Et: To regulate TCC apply psi, install the Sonnax part # 92835-03K. This valve limits the maximum apply psi. to prevent piston fatigue and lining failure

• Ft: Resurface the pump stator, and recess the bolt threads. Push out stator tube & apply 518 Lock-tite to spline area. Re-press to OE position.

• Gc: Verify the converter cover bushing centers the turbine/input shaft. This is required to prevent sealing ring cross leakage.

• Hv: Verify cooler flow (at operating temperature) is at least .8 GPM at idle in OD, 1.7 TCC off and 1.9-2.0 TCC applied. See the Sonnaflow charts for further examples.

• Ic: Also refer to 604-3 suggestions



• Code 38, TCC shudder


• At: Excessive pump bushing to converter hub clearance. Strive for under .003", over.005" often is a problem

• Bt: Pump volume low due to excessive pump clearance. Set gear pocket depth clearance to a maximum of .002"

• Ct: '91 and latter units; defective/open flow by-pass valve. The Chrysler by-pass valve under the pump may stick open, which reduces pumps ability to keep TCC applied. See Sonnax# 92836-01K

• Dt: Verify cooler flow and pump quality with SonnaFlow. See 604-1Hv specifications

• Ec: Poor oil flow past the converter's front cover bushing, which supports the turbine hub.

• Ft: TCC valves hung up in valve body

• Gt: Filter o-ring can suck air, place an AXOD accumulator spring around a magnet and place it between oil pan and filter near o-ring area.

• Hc: Poor converter lining material or surfaces. See also 604-1 for specifics

• It: Either valve under the wide retainer sticking

• Jt: TCC feed hole plugged in the plate with gasket material



• TCC engine stall, stumble, premature apply or lining overheat


• Ac: Turbine cover bushing moved inward and restricting release oil flow from venting

• Bc: No or restricted oil flow past a turbine to cover bearing placed at that location

• Cc: Poor cover surface, excess piston to cover run-out

• Dc: urbine hub to piston o-ring leaking or piston to turbine hub score

• Ec: Balance piston and turbine as an assembly

• Fc: Re-true the cover and piston surfaces and remove component run-out

• Gc: Set piston travel to .025" to .035"

• Hv: Verify flex plate bolts have not dimpled the converter cover

• Ic: Piston damper spring contact with turbine or cover

• Jt: See also 604-1,B,D,F,H

• Kv: Cooler circuit restriction



• Repeated transmission or converter overheat


• Av: Can be caused by disabled engine temperature sensor.

• Bv: Defective TPS



• TCC cycling at light throttle between 32-40 mph.


• At: Use 7176 Chrysler oil

• Bv: Reflash or install latest updated controller

• Ct: Bond lining to piston or cover, do not use floating friction clutch.

• Dt: Install pressure control sleeve # 92835-07

• Et: Inspect TCC valves for complete stroke

• Ft: Install a #99 plate ID. valve body, available from OEM.

• Gv: Defective thermostatic elements, engine or transmission & front/input speed sensors or connectors.

42RE/RH -1


• TCC shudder or Erratic cycling


• Av: Probe the connector ground for erratic electronic control. Isolate possible distributor bushing, TPS or sensitive/dirty mass air flow sensor

• Bt: TCC valve bore badly worn

• Ct: If converter is marginal, a 94 or latter body with boost tube will raise converter apply psi by approx. 10% over line psi. when in 4 th and/or TCC applied.



• No TCC after transmission rebuild

• Slow converter fill or repeated lube failure


• At: Mismatced pump halves; large (44RE) and small (42RE) suction ports

• Bt: Mismatched large suction port case with small port valve body

• Ct: This condition can be found quickly as very low SonnaFlow.

• Dt: Switch valve stuck open towards spring

• Et: Separator plate not algned properly, bolt torque pulls plate away from switch valve.



• Delayed engagement together with ballooned converter


• At: Worn pressure regulator reducing valve, aggressively drilled line to lube



• TCC cycling on-off, erratic TCC at hot or cold ranges


• Av: Temperature sensor wiring/terminals defective. (element harness in wiring loom or in cooler line) Transmission operating too hot (TCC & 4 th canceled). Inspect cooler, lines and operating conditions at load.

• Bv: A cooler that returns fluid at a very cool temp. causes pan or line sensor to cancel TCC and 4 th .



• Excessive TCC slip, repeated converter lining failure, codes 740 etc.


• Av: Radiator, trans cooler, inter-cooler, cooler lines restricted. Note: A good pump with the large diameter cooler lines will Sonnaflow up to 2.9 GPM at TCC apply and 1.6-1.9 TCC off. Refer to the various Sonnaflow charts.

• Bt: Excessive line pressure, elevates

• Cv: High loads, high input torque



• Rapid or repeated converter friction failure

• Soft TCC, No TCC apply or clutch not releasing


• Ac: Bond lining where OE was floating (see 604-1AC)

• Bc: Alter converter stall on diesel units. Contact Torque Converter Rebuilders Association (TCRA) for stator modification which improves lining life

• Ct: Adjust line to maximum of 80 psi. (idle drive) install Sonnax switch valve # 22771A-01K, follow directions on exhaust slot modifications

• Dv: Verify cooler flow minimum is .7 gpm idle in drive, 1.6 gpm TCC off cruise and 1.8-2.1 gpm TCC applied.

• Et: Install a quality teflon seal on the turbine shaft, air check circuit from the end of input through case port for cross leakage.

• Fc: Verify the turbine to cover bushing/bearing is centering the turbine correctly

• Gt: Resurface the pump stator, and recess the bolt holes in pump body.

• Ht: Set up pump pocket to gear side clearance at max. of .0015" or replace the pump assembly. Pump tolerance critical!

• It: OE had some turbine shafts with feed hole too small. Inspect or update

• Jv: Cover may be distorted from torque stress. Install Sonnax billet cover



• Sensitive TCC in-out


• Av: Defective TPS, suggest automatic replacement after 50k.

• Bt: Open the exhaust slot in the separator plate, See instructions with Sonnax # 22771A-01

• Cv: Additional transmission cooler may reduce return oil temperature to a degree that thermal pan sensor disengages TCC.

• Dv: TCC cycling or sensitive below 65 mph. Vehicle may need TCM updates (replacement) to eliminate sensitive program of TPS and VSS.



• TCC stalls engine in reverse


• Av: Verify cooler flow is not restricted with Sonnaflow (see 47Re-1 Dv for specs)

• Bt: Problem generally related to release oil flow. Open the release exhaust circuit outer circuit of switch valve.

• Ct: Reseal the turbine shaft rings at the stator, air check flow of input shaft

• Dt: Insure oil flow of release circuit in the converter is not restricted