948te Zf9hp48 Zip in
948te Zf9hp48 Zip in
948te Zf9hp48 Zip in
identify castings
Manual
Valve
10 Solenoids
PBW
(Park By Wire)
ZF
Identification
installation Diagram
ZF9HP48 PBW ZF9HP48 PBC
Inner Valve Body Inner Valve Body
1 1
1 NOTE: These two locations
are not applicable to the
1 PBC Inner Valve Body.
5 5
4 4
3 3
3 3
2 2
2 2
1 1
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.
Packaging Pocket 2
• End Plugs (2) • O-Rings (6) 2 Extra
3 R
Step eplace OE A & F Dog Clutch
Sleeve & Plunger Valve
PBW: Two in outer valve body.
PBC: Two in outer valve body. Enlarge this hole with the .062" drill bit and install aluminum plug.
Install plunger valve into dog clutch sleeve and install the assembly
into bore.
CAUTION! Fits units with .227" dia. plunger valve only. Step 5b R
eplace OE Solenoid
Do not use if original plunger dia. measures .196".
Pressure Regulator
Packaging Pocket 3
Valve Lineup
• Sleeves (2) • Valves (2)
PBW: One in outer valve body.
PBC: One in outer valve body.
Remove and discard all OE bore components except retainer and end
Step 4 Replace OE Shift Valve plug. Insert Sonnax sleeve/valve assembly into bore. Sleeve should
be be installed with open end outboard. Valve should be installed with
System Pressure Valve spring stem outboard. Insert sleeve extension into bore with chamfer
and lube hole end inboard. Insert spring over valve spring stem.
Lineup Reinstall OE end plug and retainer.
PBW: One in inner valve body. NOTE: In some instances it may be necessary to remove a small
PBC: One in inner valve body. amount of material from the end of the sleeve extension to ensure
Remove and discard all OE bore components except the retainer. proper fit when installing OE end plug and retainer.
Insert Sonnax sleeve fully into bore with rounded end face slots facing
Packaging Pocket 6
outboard. Install Sonnax valve into sleeve with spring pocket facing
outboard. Install Sonnax spring and endplug. Secure with OE retainer. • Sleeve • Sleeve Extension • Valve • Spring
Packaging Pocket 4
The parts listed here may be protected by
• Sleeve • Valve • Spring • End Plug patent number 8,919,381.
Solenoid Identification
PBC and PBW solenoid configurations are different (Figure 1 & 2). The system Park D A Dog B System
Control Clutch Clutch Control Clutch Pressure
pressure solenoid on both valve bodies is normally high and has a white cap. The Solenoid Solenoid Solenoid Solenoid Solenoid
clutch pack control solenoids are normally low and have orange caps.
NOTE: These white and orange cap solenoids have the same snouts and can be PBC (Park by Cable) Solenoid ID Figure 2
installed in the wrong locations. The Dog Clutch Control solenoids are on-off
C F Dog
solenoids. The Park Control solenoid PBW and Limp Home solenoid PBC are Clutch Clutch Control E Clutch TCC
on-off solenoids. The Park Mechanical solenoid PBW is an on-off solenoid. Solenoid Solenoid Solenoid Solenoid
Transmission Fluid
1. The transmission fluid must be checked only when temperatures are between
37°C (99°F) and 45°C (113°F). See fluid check location (Figure 3).
2. Fill transmission with Mopar ZF 8 and fluid. Dry fill is 6.5L.
3. After filling, drive the vehicle as follows: Limp Home D A Dog B System
Mode Clutch Clutch Control Clutch Pressure
Solenoid Solenoid Solenoid Solenoid Solenoid
a. Apply the brakes.
b. Shift the transmission from Park to Reverse and Reverse to Drive 4- 5 times
Check the fluid level at the location shown or with Miller tool 10323A. Figure 3
See factory fill infomation for use.
c. Disable stop-start function.
d. Drive the vehicle up to minimum 45 mph then back to a stop 4-to-5
times. This way all gear changes can be achieved.
e. Connect the scan tool and select quick learn procedure and follow the
screen prompts to relearn and reset the clutch adaptive tables.
f. Refer to OE service bulletin 21-013-16-REVB for further instructions of Fluid check location
7
b. Gently pry valve body from case at two points shown with red arrows (Figure 7).
5 3
NOTE: There are numerous feed tubes which connect the valve body to the case
passages that are snug.
8
6 c. Once the valve body is free from the case, set it aside so the wiring harness
10
9 2 1 can be removed from internal case components.
Remove 10 valve body-to-case bolts from case d. Remove the 27 Torx bolt retaining the input and output speed sensors. Remove
using Torx 40. the 27 Torx bolt retaining the range sensor. Once these bolts are removed, the
harness and valve body can then be completely removed from the case (Figure 8).
Figure 8 2. V
alve Body Disassembly
a. Remove three 27 Torx bolts shown with the blue arrows. Remove the tan connector
shown from the dog clutch pressure sensor. Once these items are removed, gently
lift the harness up away from the solenoids. Gently pry all eight (A–H) of the feed
tubes from the valve body and set aside for reuse (Figure 9 & 10).
NOTE: Some of the feed tubes may be in the case.
Range Sensor
= 27 Figure 9 Figure 10
Torx Bolts F
Feed Tube
Identification
H
E
G
D A B C D
C
Speed Sensors
B A
F E H G
4. Reassembly
a. Verify small parts are installed in the correct location based on whether it is a
Separator plate ID location
PBC or PBW type valve body (Figures 12, 13 & 14).
b. Reinstall four solenoids into the valve body as well as reinstalling
Figure 13 Figure 14 the solenoid retaining bracket and four bolts and torque to
6Nm (53 in-lb) (Figures 16).
c. Verify the alignment pins are in the right location (Figures 12).
NOTE: The smaller diameter goes into the inner valve body first.
Remove these
Outer PBW Valve Body four solenoids
PBW (Park By Wire) PBC (Park By Cable)
Small part ID, Inner Valve Body Small part ID, Inner Valve Body
Outer PBW Valve Body Figure 17
Figure 15
Park By Wire: Park By Cable:
1094 327 118 1094 327 073
e. Install outer valve body over the alignment pins until it is flush with the
Range Sensor
separator plate.
f. Install the thirteen 27 Torx bolts and torque to 6Nm (53 in-lb) (Figure 11).
g. F
lip valve body assembly over and install wire harness over the solenoid
terminals. Install the three 27 Torx retaining bolts and torque to 5.7Nm (50
in-lb) (blue arrows) (Figure 9). Wire Harness
h. Install the 8 feed tubes into the locations shown with the red arrows
(Figures 9 & 10). Plug in the harness connector for the Dog pressure switch
as shown with the green arrow.
i. Once the tubes are installed into the valve body lubricate the O-rings where
Speed Sensors
they will be installed into the case.
5. Valve Body Reinstall Into Case Guide the linkage arm Figure 19
a. Install the range sensor and secure with 27 Torx bolt. Install the input and output into the park cylinder.
sensors and secure with 27 Torx bolt. Torque both of these bolts to 5.7Nm
(50 in-lb) (Figure 18).
b. Before installing the valve body onto the case be sure that the wiring harness sits
in the area with the dashed line so the harness does not get pinched (Figure 18).
c. Install the valve body onto the case, while guiding the linkage arm into the
park cylinder as shown with the blue arrow (Figure 19).
NOTE: It may be necessary to apply gentle force when mounting the valve body to
the case as the O-rings on the tubes may create some resistance.
d. Install the ten 40 Torx bolts (light blue arrows) and torque to 8Nm (71 in-lb)
(Figure 19).
e. Install the harness connector into the front valve body cover and install the
cover onto the case. Install the seven 40 Torx bolts and torque to 9.5Nm
(84 in-lb) (Figure 20).
OE Exploded View
Outer Valve Body • 948TE, PBC Shown
NOTE: Depending upon vehicle application, the OE springs shown may not be present.
Upper Valve Body Descriptions
101
102
103
105
106
OE Exploded View
Outer Valve Body • 948TE, PBW Shown
NOTE: Depending upon vehicle application, the OE springs shown may not be present. Upper Valve Body Descriptions
101
102
103
103**
104
105