sonnax TH400 Big Shaft Stator Support Tube Kit Instructions

sonnax TH400 Big Shaft Stator Support Tube Kit

Product Information

The Big Shaft Stator Support Tube Kit (Part No. 28154S-125) is a high- performance transmission component designed for use with the Sonnax Powerglide big shaft system. It is an essential part of the system and provides improved anti-rotation security and performance compared to OE-style stator tubes. The kit includes a stator tube with larger diameter and longer length anti- rotation serrations, ensuring a more secure fit. Additionally, pinning the stator tube to the pump cover can provide further anti-rotation security, although it is not always required. The kit also includes bushings, which are compatible with the 4L80-E front stator tube bushings (aftermarket part number 34036B). These bushings allow for front-to-rear movement of the input shaft without restricting lube flow.

Product Usage Instructions

Pump Cover Machining

1. Remove the original stator tube.
2. Drill the converter feed passage to .250.
3. Machine the pump cover per the dimensions provided in Figure

Bushing Installation

1. Use the provided stator tube bushings (compatible with aftermarket part number 34036B).
2. Insert the bushings into the pump cover bore, ensuring they are fully seated.
3. Check the fit of the bushings with the input shaft.
4. For final checks, refer to Sonnax big input shaft kit 353532-01K instructions.

Anti-Rotation Pinning

1. Use a 1/4 x 28 flat tip set screw for pinning the stator tube in cast iron pump covers.
2. Ensure that the pin does not go into the internal oil passages.
3. Begin layout when the stator tube is removed from the pump cover.
4. Pinning should be done between the sealing ring grooves, locating the center of the cast material between the internal oil passages.
5. Transfer this position to the outside of the drum support area between the sealing ring lands.
6. Mark this location and proceed with pinning as shown in Figures 8, 9, and 10. For more detailed information and instructions, please visit  www.sonnax.com/powerglide.

Big Shaft Stator Support Tube Kit
Part No.28154S-125

• Stator Tube
• Bushings (2)

NOTE: This kit is one of the essential components of the Sonnax Powerglide big shaft system. Using this system requires changing to a 35-spline turbine hub. For details, visit www.sonnax.com/powerglide

• Stator tube has larger diameter and longer length will be more secure than any OE-style stator tubes. Pinning the stator tube to pump cover provides additional anti-rotation security. This procedure is not always required but is commonly done. For details, see “Anti-Rotation Pinning” (Step 4, page 4 (Powerglide), page 7 (TH400).
• NOTE: Powerglide instructions on pages 1–4; TH400 instructions

Powerglide Instructions

Pump Cover Machining

• With original stator tube removed, drill converter feed passage to .250″ (Figure 2). When machining pump cover for stator tube, it is normal to break into this converter feed passage.
• Machine pump cover per dimensions (Figure 3).

Stator Tube Installation

•  Inspect pump cover internal passages for high clutch feed, converter return and cooler return/lube. To ensure adequate oil flow it may be necessary to enlarge internal passages with a die grinder.
•  If pinning stator tube to pump cover, layout pinning locations before pressing stator tube into pump cover. For details see page 4.
•  Place two marks on pump cover that align with center of converter return passage and center of cooler return/lube passage (Figure 4).
• Align two holes in stator tube with two marks on pump cover.
•  Press stator tube into pump cover so that front edge of serrations are just flush with recess on pump cover (Figure 2). The installed distance from the front edge of the stator tube to the recess on pump cover should be 4.180″ +/- .015″ (Figure 5)

Bushing Installation

NOTE: Stator tube bushings are common 4L80-E front stator tube bushings (aftermarket part number 34036B). The bushings are .500″ wide and, when installed, allow for about .120″ front-to-rear movement of the input shaft without restricting lube flow to the input shaft cross hole. If additional allowance for front-to-rear movement of the input shaft is desired, the bushings can be machined to .425″ width before installing.

•  Install front bushing into stator tube until lightly seated against shoulder in stator tube bore (Figure 5).
•  Install rear bushing to a depth of .025–.050″ from rear of stator tube (Figure 5). Bushing will not be entirely past bore chamfer.
•  Check fit of bushings with shaft.
•  For final checks, refer to Sonnax big input shaft kit 353532-01K instructions.

Anti-Rotation Pinning

NOTE: Use a 1/4 x 28 flat tip set screw when pinning the stator tube in cast iron pump covers.

• To make sure the anti-rotation pin does not go into the inter-nal oil passages, begin layout when stator tube is removed from pump cover. Pinning between the sealing ring grooves starts by orienting the pump as shown (Figure 6) and then locating the center of the cast material between the internal oil passages. Transfer this position to the outside of the drum support area between the sealing ring lands. Mark this loca-tion (Figure 7).
•  I t is possible to add a second anti-rotation pin. Pinning at this location starts by orienting the pump as shown (Figure 8) and then locating the center of the cast material between the internal oil passages. Transfer this position to the outside of the drum support area 5/16″ below the thrust washer surface of the pump cover. Mark this location (Figure 9).
  1. F ollow directions for installing stator tube (Step 2, page 3).
  2. With stator tube installed, pre-drill pin location with a 3/16″ (.187″) drill bit through the casting and through the inside wall of the stator tube.
  3.  Follow up with final drill size of #3 (.213″) through the casting and through the inside wall of the stator tube.
  4. With a common 1/4 x 28 tapered tap, tap hole until the tip of the tap is seen inside the tube. Clean the chips and test fit the set screw. Re-tap and fit the set screw until the tip of screw is seen slightly entering the bore when tightened (Figure 10).
  5.  Install screw for final time with Loctite® or equivalent.
  6.  Grind set screw tip so it is just flush with inner bore of stator tube.

TH400 Instructions

1. Pump Cover Machining

a. Machine pump cover per dimensions (Figure 13).
NOTE: The Ø1.450/1.50″ undercut can be machined after stator tube installation; see step 2f, page 6.
2. Stator Tube Installation

•  I nspect pump cover internal passages for cooler feed and cooler return. To ensure adequate oil flow it may be neces-sary to enlarge internal passages with a die grinder.
•  If pinning stator tube to pump cover, layout pinning loca-tion before pressing stator tube into pump cover. For details see page 7.
•  Place a mark on the pump cover that aligns with the cooler feed passage (Figure 14)
•  Align front hole of stator tube (nearest to serrations) with the mark on the pump cover.

Bushing installation

•  Install one bushing into the stator tube, approximately .600″ deep from machined recess on rear of pump (Figure 15).
•  Check fit of bushing with shaft.
  NOTE : Installed bushing may cover rear stator tube hole (farthest from serrations). This is acceptable since that hole is not used in the TH400.

Anti-Rotation Pinning

Note: Use a 1/4-28 flat tip set screw when pinning the stator tube in cast iron pump covers.

•  To make sure the anti-rotation set screw does not go into the internal oil passages, begin layout when stator tube is removed from pump cover. Pinning between the sealing ring grooves starts by orienting the pump as shown (Figure 16), and then locating the center of the cast material between the internal oil passages. Transfer this position to the outside of the drum support area between the sealing ring lands. Mark this location (Figure 17).
• Follow directions for installing stator tube (Step 2, Page 5).
• With stator tube installed, pre-drill pinning location with a 3/16″ (.188″) drill bit through the casting and through the inside wall of the stator tube.
• Follow up with final drill size of #3 (.213″) through the casting and through the inside wall of the stator tube.
• With a common ?∕₄–28 taper tap, tap the hole until the tip of the tap is seen inside the tube. Clean the chips and test fit the set screw. Re-tap deeper and fit the set screw until the tip of the screw is seen slightly entering the bore when tightened (Figure 10).
• Install set screw for final time with Loctite or equivalent.
• Grind set screw tip so it is just flush with inner bore of stator tube.

References

• Sonnax | Transmission, Torque Converter & Driveline Parts
• Powerglide High Performance Upgrades | Sonnax

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