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Symptoms:

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

Cause:

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

Correction:

Recover hydraulic control and prevent valve sticking by reconditioning the bore and installing the patented Sonnax oversized solenoid switch valve and 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, 65RFE, 66RFE, 68RFE

Oversized Solenoid Switch Valve & Plug Kit
Part No. 92835-31K

Fits bores containing OE switch valve with .453" dia. large spool only.


You need this if... View Instructions

Solenoid switch valves and 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 overdrive or 4th clutches. In 41 and 42 series units, TCC concerns can result, including engine stalling due to improper lockup.

Reconditioning the bore and installing patented Sonnax oversized solenoid switch valve and plug kit 92835-31K restores vital clearances for renewed operation and control.

  • Patented Sonnax plugs redesigned to prevent cocking
  • O-ringed end plug positively seals bore
  • Annular grooves help center valve and plugs in bore to prevent future side-load wear
  • Hardcoat anodized aluminum valve and plug combat premature wear
  • Solenoid Switch Valve
  • Inner Plug
  • Outer Plug
  • End Plug
  • O-Ring

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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 31k in 41te test
  • 92835 31k in 45rfe test