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Symptoms:

  • 4th Clutch burned
  • Bind-up
  • Failsafe mode
  • Codes 841, 868, 871, 988, 1775, 1776
  • Engine stall (41 & 42 series)
  • No lockup (41 & 42 series)
  • OD clutch burned
  • TCC apply & release concerns (41 & 42 series)

Cause:

Bore wear at solenoid switch valve plugs allows critical pressure loss and causes plugs to hang up in the bore.

Correction:

Recover hydraulic control and prevent valve sticking by installing the patented Sonnax solenoid switch valve plug kit.

WARNING!

Measure large spool diameter on OE switch valve as shown here to verify which Sonnax part will fit the unit being repaired. Some Chrysler switch valves measure .420” dia. and others .453” dia. Sonnax offers repairs for both sizes.

Part OE Large Spool Dia. Part No. Tool Required
Standard-size kits address low to moderate bore wear. Oversize kits address excessive bore wear.
Oversized Solenoid Switch Valve .420" 92835-21 F-92835-TL
Oversized Solenoid Switch Valve Plug Kit .420" 92835-18K F-92835-TL18
Oversized Solenoid Switch Valve & Plug Kit .420" 92835-32K F-92835-TL32
Solenoid Switch Valve Plug Kit .420" 92835-02K None
Oversized Solenoid Switch Valve & Plug Kit .453" 92835-31K F-92835-TL31
Oversized Solenoid Switch Valve Plug Kit .453" 92835-22K 92835-RM22
Valve body reaming fixture VB-FIX required.
These oversized valve kits and their associated tool kits are still available. However, for improved reaming experience, results, and ease of use, it is recommended that oversized valve kit 92835-32K and associated tool kit F-92835-TL32 be used instead.

40TE, 40TES, 41AE, 41TE, 41TES, 42LE, 42RLE, 45RFE, 545RFE, 62TE, 65RFE, 66RFE, 68RFE

Solenoid Switch Valve Plug Kit
Part No. 92835-02K

Fits bores containing OE switch valve with .420" dia. large spool only.

You need this if... View Instructions

Solenoid switch valve plugs in listed Chrysler transmissions cause bore wear as they oscillate and stroke during operation. This wear allows pressure loss and cross-leakage, and often permits the plugs to cock and hang up in the bore. This can result in failsafe mode, various codes, bind-ups, and burnt 4th or overdrive clutches. In 41 and 42 series units, TCC concerns can result, including engine stalling due to improper lockup. Installing patented Sonnax solenoid switch valve plug kit 92835-02K restores normal operation and control to this circuit.

  • Patented Sonnax plugs redesigned to prevent cocking
  • Annular grooves help center plugs in bore to prevent future side-load wear
  • Inner Plug
  • Outer Plug

Sonnax valve body layouts provide a detailed overview of individual units making it quick and easy to determine what’s available for the specific valve body you’re working on. See all Sonnax valve body layouts.

Chrysler 45RFE, 545RFE, 65RFE, 66RFE, 68RFE Valve Body Layout

45 545 68rfe thumb

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You need this if...

Vacuum testing at the port(s) indicated fails to hold the recommended minimum in-Hg., or if wear is visually detected.

  • 92835 02k in test41te
  • 92835 02k in test65rfe
  • 92835 02k in test45rfe