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Transmission Valve Kit Guide

The document provides instructions for replacing the pressure regulator valve in GM 6L45, 6L50, 6L80, and 6L90 transmissions. The transmission must be removed from the vehicle to access the pump cover where the pressure regulator valve and boost assembly are located. The instructions describe disassembling the old valve, rerouting the balance feed passage by drilling a new orifice, installing the new Sonnax pressure regulator valve and boost assembly, and performing a final vacuum test to ensure the valve holds the recommended minimum vacuum.

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Mohamed Ahmed
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254 views2 pages

Transmission Valve Kit Guide

The document provides instructions for replacing the pressure regulator valve in GM 6L45, 6L50, 6L80, and 6L90 transmissions. The transmission must be removed from the vehicle to access the pump cover where the pressure regulator valve and boost assembly are located. The instructions describe disassembling the old valve, rerouting the balance feed passage by drilling a new orifice, installing the new Sonnax pressure regulator valve and boost assembly, and performing a final vacuum test to ensure the valve holds the recommended minimum vacuum.

Uploaded by

Mohamed Ahmed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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T R A N S M IS S ION PART S

Instructions

GM 6L45, 6L50, 6L80, 6L90


Pressure Regulator
Valve Kit
6L80 Pump
Part No. Cover

104520-03K
• Valve
• Checkballs (2)  1 Extra
• Drill Bit

Checkball

Valve

Drill Bit

NOTE: In GM 6L45, 6L50, 6L80 and 6L90 units the pressure regulator Checkball Figure 1
valve and boost assembly are located in the pump cover. Transmission
must be removed from the vehicle to access pump and replace the
pressure regulator valve.

1. Disassembly
a. Remove OE retaining pin, boost assembly and
springs and save for reuse.
b. Remove and discard OE pressure regulator valve.

2. R
 eroute Pressure Regulator Balance
Feed Passage
a. Locate OE balance feed orificed cup plug and
adjacent inboard balance port for the pressure
regulator valve. Figure 2

b. Drop one Sonnax 1/8" aluminum checkball Drill Bit


into OE orificed cup plug. Drive checkball into
cup plug with appropriately sized punch. Stake
cup plug to prevent checkball displacement (Figure 1).
c. Using included Sonnax drill bit, bore a new orifice from the 6L80 Pump
Cover
cup plug bore to inboard balance port at an approximate
45° angle. Starting drill bit on countersunk surface of cup
plug bore works best (Figure 2).
d. Clean bore thoroughly, removing all debris and chips.

©2015 Sonnax Industries, Inc. 104520-03K-IN 03-13-15


800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
T R A N S M IS S ION PART S
PRESSURE REGULATOR VALVE KIT 104520-03K Instructions

3. Installation & Assembly


Figure 3
a. Install Sonnax pressure regulator valve.
b. Reinstall OE springs (smaller first, then larger).
c. Reinstall OE boost assembly or replace with Sonnax boost valve kit,
available separately. 18"-Hg

d. Secure valve train components with OE retaining pin.


15
20 10
25 5

4. Final Testing 30
VACUUM
TEST
0

Vacuum testing at the port(s) indicated holds the recommended minimum


18 in-Hg (Figure 3).

6L80 Pump
Cover

©2015 Sonnax Industries, Inc. 104520-03K-IN 03-13-15


800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2

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