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Old 08-27-2008, 09:12 AM   #1 (permalink)
operationdirtymax
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E Shift Valve Sticking After Rebuild...help

I just finished installing a ats converter, pump kit ,shift kit, and c1 through c4 clutches in my allison 6 speed. The E shift valve in the valvebody keeps sticking and limping the truck into 4th gear. After using the sonnax alignment tool on 3 seperate occasions the problem was still there. We put a new oem valve body in and once again, problem was still there. Last night I took the valvebody back out used the sonnax tool on it and reinstalled. Guess what?? Still sticking and limping to 4th gear. Fluid has been changed every time the body come out, No contamination and every bolt tightend to spec. One thought I had was we didn't drill out the 2 exhaust holes in the spacer plate between the upper and lower valve body because a co-piolot is coming shortly and the directions noted not to drill these out. Could this have something to do with it..Any help would greatly be appreciated
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Old 09-02-2008, 01:07 PM   #2 (permalink)
operationdirtymax
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Ok,,just an update for everyone. I drilled out the exhaust holes in the spacer plate and used the bore sizing tool untill I was blue in the face. Run great for about 20 miles and then limped into 4th again. So back out the valvebody comes for the 1000th time.lol...ANY SUGESTIONS??
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Old 09-02-2008, 06:07 PM   #3 (permalink)
Acoombs
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Wow, sorry to hear about all the problems. I too had a problem w/ my e shift sticking, when your using to the sonnax reamer do you get to the point where it just drops in and out w/o hanging up? Thats what i had to do to get it to work properly on mine, are you using cutting fluid when using the reamer and a slide hammer?

It took me a good hour to get mine to slide freely. Good Luck.
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Old 09-03-2008, 01:08 PM   #4 (permalink)
operationdirtymax
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The instructions say to use tranny fluid with the reammer but yeah I have tried cutting fluid and and tranny fluid. The tool is pretty loose but i still have to tap it in toward the end of the bore. I'm going to give it another shot tonight. Thanks so much for your input.
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Old 09-03-2008, 01:51 PM   #5 (permalink)
Mike L.
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The Sonnax tool is not a reamer but a, go- no -go tool. It is a pain in the butt to use. Slide hammer is a must as it needs to be hammered in and out till the tool slides in freely.
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Old 09-03-2008, 10:57 PM   #6 (permalink)
gtmax
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I've found that it's the innermost (smaller) land that usually sticks. Clean the valve and you'll probably see where it's been hanging up. Using the Sonnax tool is a scary feat, as Mike says you're supposed to use a slide hammer and it's not a gentle procedure either--you'll swear that you're gonna break the casting.

We also have precision bore reamers that are in two sizes. If I run into a sticking "E" shift valve if the Sonnax tool doesn't go in without excessive force, I'll use the small reamer and follow up with the Sonnax tool. Usually it isn't necessary to use the larger reamer.

I haven't run into many sticking valves lately--usually only in really early units (01-03), or if there's been a major clutch or converter failure.
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Old 09-04-2008, 12:37 AM   #7 (permalink)
Mike L.
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I use the Sonnax tool as a tire stop.
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Old 09-04-2008, 04:18 AM   #8 (permalink)
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Quote:
Originally Posted by Mike L. View Post
I use the Sonnax tool as a tire stop.
LOL
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Old 09-04-2008, 05:17 PM   #9 (permalink)
operationdirtymax
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First off thanks for all of your input. I made a slide hammer at work yesterday..works like a dream..Prob put a solid hr on the E bore last night with the bore sizing tool. I can push it in with my hand untill the last 2 or so holes away from the spring end and then I have to tap it in with the hammer. I'm sure this is where it is hanging..I had a heck of a time un-sticking the valve last night. I'm headed back to the shop tonight to keep hit it a few more times and re-install the valvebody. If it sticks again I'm going to look for someone to send it to. Much more of this and I'll be in a mental institution
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Old 09-04-2008, 09:53 PM   #10 (permalink)
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Sonnax tool makes a great hitch pin in a bind as well
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