121810k Instructions

Chrysler 845RE,
ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT ®

PART NUMBER ZF8-ZIP QUICK GUIDE
Parts are labeled here in order of installation. See other side of sheet for details on kit contents.
installation Diagram
ZF8HP45 Upper
Valve Body
4
ZF8HP45 Lower
Valve Body
2
3
In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum
testing and additional repair options for higher mileage units or for repairing specific complaints which are beyond the
scope of this kit.
©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company ZF8-ZIP-Guide 10-15-19
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1
Chrysler 845RE, Quick Guide
ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT®
Kit Contents & Installation Steps
Step 1 eplace OE Pressure

R Step 5 Replace OE Accumulator
Regulator Sleeve Pistons
Packaging Pocket 1 Packaging Pocket 5
• Sleeve • Accumulator Pistons (7)
• Matching Springs (7)
Step 2 Replace OE Priming Valve

Step 6 Replace OE Solenoid
Place scarf-cut seal into shallow groove on valve. Rolling the seal into
a smaller diameter before placing the seal in the groove will help to
keep the seal surface below the valve diameter, allowing for easier
O-Rings
installation. Lubricate seal with Sonnax slippery stick O-LUBE. Packaging Pocket 6 For Outboard White & Orange Solenoids
NOTE: Due to the design changes on the Sonnax valve, • O-Rings, (8) 1 Extra 13.75 x 2mm thick
vacuum testing at the two inboard ports is not a valid
sealing test. The Sonnax valve requires balance fluid to
travel through the valve and push the seal outward to Packaging Pocket 7 For Inboard Brown Solenoid
conform to the worn bore.
• O-Ring (2) 1 Extra 17 x 1.5mm thick
Packaging Pocket 2
• Valve Packaging Pocket 8 For Inboard Orange Solenoids
• Seal
• O-Rings, (7) 1 Extra 18 x 2mm thick
Packaging Pocket 9 For Outboard Brown Solenoid
3 • O-Ring, (2) 1 Extra 17 x 1.5mm thick

Step eplace Internal
R
OE End Plugs Packaging Pocket 10 For Inboard White Solenoids
Place O-rings into shallow grooves on end plugs. Lubricate with Sonnax • O-Rings, (5) 1 Extra 18.25 x 2mm thick
slippery stick O-LUBE. Roll on bench to size. For installation or removal
ease, install with threaded end outboard.
Packaging Pocket 3
• Internal End Plugs (8)
• O-Rings (18) 2 Extra
Step 4 Replace OE End Plugs

Place O-rings into shallow groove on end plugs. Lubricate with Sonnax
slippery stick O-LUBE. Roll on bench to size. Install end plugs with small
stem outboard.
Packaging Pocket 4
• End Plugs (3)
• O-Rings (5) 2 Extra NOTE: The parts listed here may be protected by patent 8,794,108.
©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company ZF8-ZIP-Guide 10-15-19
Chrysler 845RE,
ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT ®
PART NUMBER ZF8-ZIP INSTALLATION & TESTING BOOKLET
Valve Body Identification This Zip Kit ZF8-ZIP is designed for ZF8HP45, ZF8HP55 and ZF8HP70 units only.
Torque Specifications Cautions

Mechatronic-to-Case Complete Valve Body-
Torque or Valve Body to-Case Electronics
Halves Bolts 10Nm/89 14Nm/10 ft-lb Do not use an ohm meter with more than .6 voltage supply. The TCM is capable
in-lb of limited solenoid adaptation without reprogramming. After any service, resetting
Plastic Oil Pan to Case adapts is suggested. In many instances, solenoids can be replaced with new OE or
10Nm/89 in-lb with qualified used. Original solenoids, if reused, should be returned to their same
location due to a learned flow rate by the TCM. Make every effort to avoid mixing
Clearance
up the solenoids.
Clutch clearance and material is critical (refer to OE
clutch travel specifications). These have fluid balanced Check the solenoid resistance (5.0 ohms at 20°C/68°F) with the circuit board removed.
clutch pistons.
Fluid
Complete Fill Required Service Fill Approx.
Technical Tips
9.5 qt./8 ltr. 4.2 qt./4 ltr.
Transmission Specifications & Reassembly Tips
Chrysler Fluid ZF Fluid
Mopar 6815795AA ZF Lifeguard 8
The red tag on pan shows the fluid type Mopar 6815795AA (green) and that fluid
temperature must be 122°F to check the level. Dry fill is approximately 8.5 qts./8.0l
Drive-Cycle Relearn (Figure 1).
Verify transmission fluid temp is 122°F, then perform 6–10
light throttle up and coast down shift cycles for partial relearn.
Zip Kit Instructions
Figure 1
1. Valve Body Removal from Case
a. Remove 14 bolts to drop valve body from case (Figure 2).
Fill & Check Plug
b. Remove 4 bolts and lift up metal bracket to release connector from TCM (Figure 3).
c. Remove connector from case (Figure 4).
d. Remove valve body from case. Note the location of B release tube in case under
valve body in case the tube comes out of its location when the valve body is
removed (Figure 5).
e. The valve body may have to pried down on the front end because of the
Drain Plug suction and output tubes (Figure 6)
Figure 2 Figure 3 Figure 4

3 5
1
2 4 6 7 8
9
10
11
1 2 3
12
13 14 4 OSS
40 Torx Bolts Lift up metal bracket
Gently pull connector
to release connector
out of the case.
from TCM.
©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company ZF8-ZIP-Booklet 10-15-19
Chrysler 845RE, Installation & Testing Booklet
Figure 5
2. Valve Body Disassembly
B Release Rubber a. Disconnect three TCM harness retaining bolts (Figure 7).
Feed Tube b. Remove remaining five bolts to remove TCM from valve body
(Figure 8).
c. Gently pry TCM lifting up from valve body until removed
(Figures 9 & 10).
d. Remove 17 bolts to split valve body apart (Figure 11).
e. Pry valve body halves away from separator plate where indicated
(Figure 12).
NOTES: The separator plate has a bonded gasket which may
delaminate during disassembly (Figure 13). If any damage or
delamination to the gasket is present, a new separator plate
Figure 6 should be used.
These separator plates are specifically calibrated, requiring either the OE
valve body code or an identification number stamped on original plate
(Figures 13 & 14) for reorder. See Sonnax application chart for cross-
Suction reference numbers (Figure 14).
Tube
Gently pry sides, Lift TCM Up Figure 9

to lift up TCM from
valve body.
Output
Tube
Remove three TCM harness retaining bolts. Figure 7
1 3
2
ESD (Electro-Static
Discharge) WARNING!
Wear ground strap
when handling TCM.
3 Figure 8 Figure 10
TCM Removed
Remove five remaining TCM harness retaining bolts.
10-15-19 ZF8-ZIP-Booklet ©2019 Sonnax Transmission Company, Inc. • A Marmon / Berkshire Hathaway Company
Page 2 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
3. Installation 5 Figure 11
1
Install Zip Kit parts as shown on diagram of separate quick guide
sheet included in this Zip Kit. 4
2 3 6
See identification and locations of replacement OE solenoids
(Figures 15 & 16).
Sonnax recommends vacuum testing critical wear areas not covered
7 9
by this kit to determine whether additional Sonnax parts are 8
required (see pages 4–7).
10 11 12
13
14 15 16 17
Remove 17 remaining bolts.
Figure 12
Figure 15
Pry valve body halves away from separator plate.
Figure 13
A B C D E F G H
Solenoid Identification & Location Chart Figure 16 OE valve

body codes
Solenoid I.D. A B C D E F G H
EDS-7 EDS-2 EDS-5 EDS-4 EDS-3 EDS-6 EDS-1

ZF MV-1 LP TCC C E B D A
SOL SOL SOL SOL SOL SOL SOL SOL
Chrysler
Park LPS TCC C E B D A
Valve Body Separator Plate Application Chart Figure 14

OE valve
OE Valve Number Stamped on Order Sonnax Valve Body
body part
Body Code Original Plate Part Number Generation
number
A048/B048 1087-327-175 35740-048
ZF8HP45
A054/B054 1087-327-189 35740-054 &
ZF8HP70 Separator plate is same for ZF8HP45 & ZF8HP70.
A071/B071 1068-327-162
Critical Wear Areas & Vacuum Test Locations 20

25
30
15
0
10
5
NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to VACUUM
TEST
with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.
Upper Valve Body • ZF8HP45 Shown

NOTE: Do not use this information for ZF8HP55
NOTE: Critical wear areas and vacuum test
units as valve locations and porting differ. See
locations shown for ZF8HP45 and ZF8HP70 only.
page 8 for ZF8HP55 information.
Holding Valve B2
• B Clutch burned
• 5-6 Flare
TC Pressure Valve
• Coastdown clunk
• Harsh TCC apply
• Excess TCC slip
B2 Clutch NIC Valve • TCC codes & overheating
• Delayed engagement • TCC lining failure
• No Forward • Low lube oil flow
• NIC (Neutral Idle Control) • Low TCC release pressure
concerns Replace with Sonnax Part No.
• Gear ratio & solenoid codes 35740-18K
• No Reverse Requires F-35740-TL5 & VB-FIX
• B Clutch burned
• Flare/Harsh shifts 
Replace with Sonnax Part No.
35740-22
Requires F-35740-TL22 & VB-FIX
Holding Valves A & D Position & Default

• Bump/Flare shifts Position Valves
• Burnt clutches • Delayed Forward & Reverse
• Gear loss • Delayed engagement
• Gear ratio & solenoid codes
35740-20K
End Plugs
Test with dampener • Soft/Flare/Harsh shifts
Accumulator Pistons upside down and test • Burnt clutches
• Downshift clunk plate orifice off center
from rubber piston end • Pressure loss
• Firm shifts Replace with Sonnax Part No.
• Erratic EDS solenoid control and/or EDS codes 35740-30K
95740-15K Contains 7 sets

End Plugs (3) =
Patent No. 8,794,108

Internal End Plugs (8) =
Critical Wear Areas & Vacuum Test Locations 20

25
30
15
0
10
5
NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to VACUUM
TEST
with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.
Lower Valve Body • ZF8HP45 Shown units as valve locations and porting differ. See
NOTE: Critical wear areas and TC Switch Valve
vacuum test locations shown
• No lockup • No TCC release
for ZF8HP45 and ZF8HP70 only. TCC Valve
• Engine stall • TCC codes
• Excess TCC slip • Converter shudder & TCC slip • TCC codes
• Premature TCC apply • Overheated converter • Poor fuel economy
Main PR Sleeve
• Soft/Harsh TCC apply Replace with Sonnax Part No. 35740-13K
• Harsh shifts Requires F-35740-TL13 & VB-FIX
• Erratic/High line pressure
35740-05
• Restricted converter/lube flow Requires F-35740-TL5 & VB-FIX
Clutch Valve B1

35740-03
Test both • Slip on take off
passages
together. • Gear ratio errors

Close this passage on • B Clutch burned
the other side with
the palm of your hand.
Close port on
opposite side
Main PR Valve when testing.
• Harsh/Soft shifts
• Erratic/High line pressure
• Burnt clutches
Holding Valves
• Restricted converter/lube flow
• Broken parts due to
B1, C & E
excessive line pressure • Bump/Flare shifts
Replace with Sonnax Part No. • Burnt clutches
35740-01K • Gear loss
Test both
Requires F-35740-TL & VB-FIX Test both passages • Gear ratio & solenoid codes
passages together. Replace with Sonnax Part No.
together.
35740-20K
Park Pawl
Release Valve
• Park will not release
Clutch Valve D
• Park position errors
• Gear ratio errors 4-8th Gears
• Slips in Reverse
• D Clutch burned
Clutch Valve A
• Slip in Drive or Reverse
Remove spring when
testing. Center valve • Gear ratio codes
spool in opening. • A Clutch burned



Priming Valve End Plugs

• Delayed engagement
• Soft/Flare/Harsh shifts
• Wrong gear starts
Clutch Valve C Clutch Valve E • Burnt clutches
• Flare/Harsh/Neutral shifts
• Pressure loss
• Gear ratio & solenoid codes • Slip on take off • Slip on 1-2
• Gear ratio codes • Gear ratio codes Replace with Sonnax Part No.
• Gear loss
35740-30K
Replace with Sonnax Part No. • C Clutch burned • E Clutch burned
35740-21K

End Plugs (3) =


Internal End Plugs (8) =
OE Exploded View
Upper Valve Body • ZF8HP45 Shown
NOTE: Valve lineup locations shown
for ZF8HP45 and ZF8HP70 only.
101
105
102
103 106
104
Upper Valve Body Descriptions

I.D. ZF Chrysler
Description
No. Valve Name Valve Name
101 Holding Valve B2 HV-B2 HV-B2
Clutch Valve B2 - B Clutch NIC
102 KV-B2 CV-B2
(Neutral Idle Control)
103 Holding Valve A HV-A HV-A
104 Holding Valve D HV-D HV-D
105 Torque Converter Pressure Valve WD-V TC-V
Position Valve (Outboard) Pos-V, Pos-V,
106
Default Position Valve (Inboard) PosD-V PosD-V
OE Exploded View
Lower Valve Body • ZF8HP45 Shown 201
NOTE: Valve lineup locations shown

for ZF8HP45 and ZF8HP70 only.
203
202
205
204
Lower Valve Body Descriptions
I.D. ZF Valve Chrysler
Description
No. Name Valve Name
Main Pressure Regulator LP-V (Inboard)
201 SYS-DR-V
Valve and Sleeve RED-V (Outboard)
202 Torque Converter Switch Valve SV-WD SV-TC
203 Torque Converter Clutch Valve WK-V TCC-V
204 Clutch Valve B1 KV-B1 CV-B1
205 Holding Valve B1 HV-B1 HV-B1
206 Priming Valve DR-RED-V PR-V
207 Park Pawl Release Valve PS-V Park-V
208 Holding Valve C HV-C HV-C
209 Clutch Valve C KV-C CV-C
210 Clutch Valve E KV-E CV-E
211 Holding Valve E HV-E HV-E
212 Clutch Valve D KV-D CV-D
213 Clutch Valve A KV-A CV-A
209 210 212 213
211
206 207 208
OE Exploded View • ZF8HP55 Shown
NOTE: Do not use this information for ZF8HP45 and

NOTE: Valve lineup locations
ZF8HP70 units as valve locations and porting differ.
shown for ZF8HP55 only.
See pages 4 – 7 for this information.
Upper Valve Body Upper Valve Body Descriptions

I.D. ZF Valve
Description
No. Name
103
101 Holding Valve D HV-D
102 Holding Valve A HV-A
103 Holding Valve B2 HV-B2
102
104 TC Pressure Valve WD-V
104
202 Lower
Valve Body
101
203
201
204 205
206
Lower Valve Body Descriptions

I.D. No. Description ZF Valve Name
201 Manual Valve
202 Pressure Regulator Valve SYS-DR-V
203 TC Switch Valve SV-WD
204 TC Clutch Valve WK-V
205 Clutch Valve B1 KV-B1
206 Holding Valve B1 HV-B1
207 Priming Valve DR-RED-V
208 Holding Valve C HV-C
209 Clutch Valve C KV-C
210 Clutch Valve E KV-E
211 Holding Valve E HV-E
212 Stationary Aluminum Valve SV-1
213 Clutch Valve D KV-D
214 Clutch Valve A KV-A
207 209 211 213 214
208 210
212

121810k Instructions

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121810k Instructions

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Chrysler 845RE,

ZF8HP45, ZF8HP55, ZF8HP70 ZIP KIT ®

Kit Contents & Installation Steps

Step 1  eplace OE Pressure

Step 2 Replace OE Priming Valve

Packaging Pocket 9 For Outboard Brown Solenoid

3 • O-Ring, (2) 1 Extra 17 x 1.5mm thick

Step 4 Replace OE End Plugs

Torque Specifications Cautions

Figure 2 Figure 3 Figure 4

Gently pry sides, Lift TCM Up Figure 9

Remove three TCM harness retaining bolts. Figure 7

Pry valve body halves away from separator plate.

Solenoid Identification & Location Chart Figure 16 OE valve

EDS-7 EDS-2 EDS-5 EDS-4 EDS-3 EDS-6 EDS-1

Valve Body Separator Plate Application Chart Figure 14

Critical Wear Areas & Vacuum Test Locations 20

Upper Valve Body • ZF8HP45 Shown

Holding Valves A & D Position & Default

Critical Wear Areas & Vacuum Test Locations 20

Priming Valve End Plugs

Requires F-35740-TL20 & VB-FIX

Upper Valve Body Descriptions

NOTE: Valve lineup locations shown

209 210 212 213

OE Exploded View • ZF8HP55 Shown

NOTE: Do not use this information for ZF8HP45 and

Upper Valve Body Upper Valve Body Descriptions

Lower Valve Body Descriptions

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Step 1 eplace OE Pressure

Step 2 Replace OE Priming Valve

Packaging Pocket 9 For Outboard Brown Solenoid

3 • O-Ring, (2) 1 Extra 17 x 1.5mm thick

Step 4 Replace OE End Plugs