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Valve Body Repair U660E U660F (Toyota Camry Avalon Sienna / Lexus ES350 RX350)

Valve Body Repair U660E U660F (Toyota Camry Avalon Sienna / Lexus ES350 RX350)
Price: €94.05
Quantity: Add to Wish List





Total in stock: 19978 pcs

Brand: MAKTRANS

Product Code: U660VBREBUILD

Weight: 10.00 kgs

U660E (U660F -all-wheel drive version) - a modern 6-speed automatic transmission, developed in 2006 by the Japanese company Aisin Warner, is installed on the front and all-wheel drive Toyota (Camry, Avalon, Sienna) and Lexus (ES350, RX350)  cars with engines from 2.2 to 3.5 liters. In our market, it is mainly found on the Toyota Camry V40 3.5L and Lexus ES350.

Soon the gearbox gained a reputation as a rather problematic unit, even cars with low mileage became frequent visitors to car service centers - the rubber pistons were the first to fail, then with a run of about 70-90 thousand problems arose with the C1 C2 drum - the friction plates and the drum itself burned, as a result assembly replacement required.

But truly serious problems await owners with a mileage of 150-200 thousand - the friction lining of the torque converter is erased (it is still equipped with a lock piston, while competitors in the face of Mercedes and ZF have been using friction plates for 6-speed automatic transmissions for a long time) and abrasive  material enters the valve body, solenoids and the hydroplate itself suffer as a result.

Another weak point is the Counter Drive gear bearing, which is installed in the housing and is fixed by the locking ring. Since the U660 mainly works in tandem with powerful motors and drivers often prefer an aggressive driving style - this bearing breaks the seat, which leads to catastrophic consequences - chips on gears, broken planetary gears, thrust bearings, turn into metal dust and destroy the hydraulic part of the box .

In this article, we will examine in detail just such a classic case. The housing bearing fell apart and wear products (in the form of small metal particles) fell into the oil and destroyed the valve body, we will deal with its repair.

                                                                                                                       The consequences of bearing failure

Repair beginning


First we consider pricing. The cost of repairing the valve body is not fixed, it consists of the cost of work and consumables, so if you contact the service on time, there will be savings. The repair calculation looks like this:

Works Price
Diagnosis (disassembly, washing, vacuum testing, visual inspection and inspection of plungers for jamming)  100$
Testing solenoids on the stand - 5$ per piece. U660  contains 7 solenoids. 35$
Solenoid regeneration - 40$ per piece.  4 solenoids  regeneration. 160$
Reaming valvebody channels and installing oversized valves. Reaming of one hole is  - 20$, plunger - 10-12.50$.  2 plungers and 1 booster installing. 72.50$
Assembly (valve body gaskets- free of charge) and final inspection Free of charge

 

The result was $ 367.50, but here options are possible, if the solenoids were not repairable, you would have to install a set of solenoids for $ 200.

                                                                                                This is how the valve body looks like, oil turned black due to metal dust

 

Disassembling. We disconnect the wiring from the solenoids and extremely carefully unscrew and remove the temperature and speed sensors, they can be easily damaged

We remove the solenoids. On some valve bodies, it is enough to unscrew the solenoid latch and simply remove it, in the case of the U660E this will not work, you often need to knock it out. At the end of the nozzle of the solenoid there is an adjustment screw, you do not need to beat it, you can completely break it. We look how it is correct:

 

Knocking out

 

Immediately you can manually check the solenoid for jamming. If you consider how much the valve body is dirty, there is a chance that the plunger will jam, in this case- repair / replace the solenoid immediately, checking on the stand will be ecessive.

We disassemble completely. The gray mass on paper pads is metal dust, we immediately throw it away. If you repair the valve body yourself and there is a chance that the repair will be delayed - it is better not to wash the metal separator plates, just blow it with air and wipe it well. If it is degreased, rust will quickly begin to appear, which will be difficult to get rid of.

Solenoids diagnostics and repair.

We disassemble to the end and take parts of the valve body to the washing machine. We begin to check and repair the solenoids. Maktrans specialists have developed a solenoid regeneration technology which consists in replacing the original plunger with a plunger of its own production. This is possible if there is no wear out in the nose of the solenoid. At the same time, our plunger significantly exceeds the original one in the strength of the anodized coating, which means it has a large working resource. We install it in the stand and begin testing.

By analyzing the graphs, the master understands which solenoids need repair. The graph in the photo above is the basis for repair, but in this case it is necessary to disassemble and watch all the solenoids, since there will be shavings in each. We disassemble using a special tool:

 

Scratched plunger (it gives steps on the graph)

We prepare the plunger. Preparation consists of planishing, for reliability - since the gap between the surface of the installed plunger and the wall of the hole in which it works is very small. After polishing, the plunger is inserted into the nose of the solenoid and is checked for smoothness by hand, there should be no wedging.

 

If the plunger has passed the test, we rinse the solenoid, collect and close it on the press

We put the regenerated solenoid in the stand and test it, below you can see the perfect schedule. Repeat the operation for each solenoid.

Hydraulic part repair

We take the washed plates and, as always, blow them well with air, if the liquid remains inside, it may affect the vacuum test

 

Vacuum test beginning

Vacuum showed the following problem valves::

  1. Modulator valve
  2. Secondary pressure valve
  3. Booster valve

We will ream the holes and install oversized valves manufactured by Maktrans. Own production reamers are used. In order to be able to proceed with the reaming, you need to completely disassemble the plates and take out the valve (at the same time we check for jamming - it happens that the vacuum does not show problems, but in reality the plunger is stuck and does not work), springs, end caps, stopper, etc.

We begin to disassemble, immediately take out the booster and look, as a rule, the wear inside the booster is visible to the naked eye - in this case it happened, this is the weak point of all Toyota valve bodies.

 

Checking  B2 valve, it jams.Oversized. valve will be installed. B2 is generally a common problem in the U660, and it is difficult to diagnose, problems with it depend on the temperature regime. Normally, reverse gear disappears when heated.

We have dismantled it to the end. Sometimes there is a problem with end caps, they are deformed and damaged during the extraction process - when assembling, we put new ones

 

Now we use the machine for reaming hydraulic plates.

We expose the plate to the required distance using the guide, fix it with a clamp and cut it

After reaming the hole, the plate goes back to the washing machine, you need to get rid of the chips that remained inside the channels. It is necessary to wash, blow, insert the oversized valve and repeat the vacuum test.

Vacuum test showed an excellent result - the tightness of the channel + plunger pair was restored. In the same way we ream the remaining holes and check. The problem can be not only in the plunger, on which there are scuffs or wear of the coating, the channels inside the valve body are also damaged, now we will show how it looks. Reaming and installing an enlarged plunger also solves such problems:

 

We have already prepared plates and regenerated solenoids, we can mount them.  So we take valve body gaskets and begin.

 

Assembly

 

We assemble to the end, tighten the screws observing the tightening torques, install the solenoids and wiring

The valve body is ready to be installed on a car and will work like new, without any complaints. Maktrans gives a 1 year warranty on the repair of a valve body WITHOUT mileage limitation. Before installing the valve body in the box, it is imperative to flush the cooling system, replace the oil and filter. In the event of a major overhaul, torque converter repair is required.

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