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Symptoms:
  • Code 628
  • Excess cooler circuit oil loss
  • Lube failures
  • No lockup
  • TCC cycling
  • TCC surge
Cause:

A worn bypass clutch control sleeve allows regulated converter charge and cooler circuit oil leakage.

Correction:

These tightly toleranced, wear-resistant assemblies restore proper clearance to maintain hydraulic control.

4F50N, AX4N

Bypass Clutch Control Plunger Valve Kit

Part No.

96206-03K

Bypass Clutch Control Plunger Valve Kit
  • 96206-03k_combo

  • Bypass Clutch Control Plunger Valve Kit

Small_96206-03k_combo Small_96206-03k

4F50N, AX4N

Bypass Clutch Control Plunger Valve Kit

Part No. 96206-03K

  • Plunger Valve
  • Sleeve

.486" OE large spool diameter

Complaint:

  • Code 628
  • Excess cooler circuit oil loss
  • Lube failures
  • No lockup
  • TCC cycling
  • TCC surge

Cause:

A worn bypass clutch control sleeve allows regulated converter charge and cooler circuit oil leakage.


Correction:

These tightly toleranced, wear-resistant assemblies restore proper clearance to maintain hydraulic control.

Vehicles with an AX4N, 4F50N transmission frequently have excessive cooler circuit loss as well as torque converter clutch apply and release problems. These complaints can be caused by severe wear of the bypass clutch control sleeve, allowing regulated converter charge and cooler circuit oil leakage. This oil is fed to the lube circuits, cooler, TCC and into the sleeve to help maintain the TCC in the release position. If the sleeve is worn, oil will exhaust past the plunger valve to the sump, thus compromising the balance, but more importantly, leaking critical cooler oil. Sonnax has developed two tightly toleranced bypass clutch control sleeve and plunger valve kits, 96206-03K and 96206-13K, to eliminate these problems.

  • Precision sleeves are manufactured from highly wear-resistant aluminum.
  • The aluminum plunger valves are hard-coat anodized to prevent wear.
WARNING:

Original OE plunger valve must be measured. Match replacement to the OE size.

OE spools .486" and .415": Use 96206-03K.

OE spools .496" and .415": Use 96206-13K.

Mismatched replacement sleeve & plunger will cause TCC apply and other engagement issues

Related Parts

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Valve Body Layouts

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.

Valve Body Layout Ford AX4N/4F50N
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