I wanted to make a post where I could assemble the assorted things I've found regarding the Aisin TF-80SC Transmission and its valve body problems from MY 2006 to MY 2007. I developed it over in the XC90 forum and it's now ready for "prime time" here in the R forum where it will get more exposure.
2006-2007 Volvo S60R GT
2006-2007 Volvo V70R GT
2006-2007 Volvo XC90 V8 (All Trims)
2007 Volvo XC90 3.2L (All Trims)
2007 Volvo S80 V8 (All Trims)
2007 Volvo S80 3.2L (All Trims)
Transmission Wiki - "It is designed to handle a maximum of 440 N·m (324.5 ft·lbf) of torque."
The Technical Deficiency:
From this post some details about the problem:This thread, from user MnOpRacInG, shows a tear down of a failing valve body. The worn bores and valves are clearly visible, as demonstrated in the photos below:What goes bad in the valve bodies is the bores in which the valves ride. They become worn out and cross leaks occur that no amount of reprogramming can compensate for. The TCM turns solenoids on and off to stroke valves to direct fluid to specific locations inside the transmission. When the valve bores are worn out that control of flow is no longer possible.
Here's the TNN regarding the valve body:
TNN43-53-2007-11-09 Title: Valve Body: Customer Interest - A/T - Harsh Shifts/False Neutrals/Shift Flare
2005- for XC90 V8
2006- for S60R/V70R
2007- for XC90 3.2 & S80
SUBJECT: TF80-SC, 6 Speed Automatic Transmission Fault Tracing Tips
REFERENCE: VIDA, TNN 40-02
Note: This TNN supersedes the previous 43-53, dated 12/21/2006. Information about speed sensor and valve body faults has been added. Please update your files.
This document summarizes customer complaints related to the 6 speed Automatic Transmission (TF80-SC) and should be used together with the information in VIDA.
Valve Body: The Valve Body should be replaced to address the following symptoms:
1. Customer complaints about 2-3 upshift quality. The shift may be described as harsh, or as a shudder. The symptom is usually more apparent during the first few minutes of driving after a cold start.
2. Customer complaints of shudder when slowing down, just before coming to a stop. The symptom may also be described as a harsh downshift just before coming to a stop.
3. Neutral condition in 4th, 5th & 6th gear; normal behavior in 1st, 2nd, 3rd & Reverse. One or more of the following DTCs (Diagnostic Trouble Codes) may be present in the TCM (Transmission Control Module): P073400, P073500, P072900, P089600.
4. Neutral condition in all gears except 5th & Reverse, usually with TCM P273300 set. DTCs for gear ratio(s) may also be set such as TCM P073000, P073100, P073200, or P073400.
5. Customer complaints of engine RPM flare at upshift or power-on downshift (kickdown) due to a worn modulator valve bore.
Note: Transmissions starting with serial number 06J and later already have the latest valve body which is designed to prevent these symptoms.
Aisin-Warner 09G Electronics - Anatomy of shift controls
AW 6 Speeds: Valve Body Diagnosis
Adjusting Clutch Control Valves on Aisin FWD 6-Speeds
Exploded View w/Part #'s - Says for FWD, but I believe it is the same.
Sonnax Valve Body Exploded View w/Part #'s
Here's the sources I'm aware of for replacement valve bodies:
2006/2007 S60R V70R and 2006/2007 XC90 V8/3.2L Automatic Geartronic Transmission Aisin Warner TF80SC Valve Body Rebuilt or New Replacement:
Volvo 31259456 - New - $1200
One Stop Gearbox Shop - New - ~$560 Shipped (or $456) (Need to confirm these are the updated design)
Cobra Transmission - New - $1,154.99
(Note: Per VNDETTA's discussion with Cobra, this is a new and updated Aisin Warner Valve Body without a Volvo sticker on the packaging.)
Ream Man Valve Bodies - Remanufactured - $674.48
Advantage European Auto Parts (Michigan) - Will Rebuild Your Valve Body - ~$600
RevMax Converters - Rebuilt - $749.00
Valve Body Direct - Remanufactured - Pricing Unknown
Sonnax - Remanufactured - Pricing Unknown
Before I ordered any of these, I would be absolutely sure to contact the vendor to verify correct fitment for your caR or V8.
The dealer charge for replacing a valve body is 4.1 hours labor.
Replacement Steps (S60R/V70R):
Thanks Laird for the Walkthrough(I would like input on the differences in how the job is done between models.)I removed the bumper cover, since that takes 5 minutes, this allows excellent access from below.
Remove air guide, both if you have them.
Remove the tranny coolant lines.
Remove the air-box, fake battery cover and IC to TB tube.
Remove front motor mount bolt (on top of mount)
Remove the pump on the frame rail by removing two bots and the whole bracket.
Put jack-stands under the rear sub-frame brackets and loosened the rear SF bolts.
Floor jack with a block of wood under the engine, bit of tension.
Removed front SF bolts to allow SF to sag out of the way.
Drain fluid (save or measure)
Remove VB cover (clean clean clean)
Take a few pictures, even though it'd be hard to screw up the wiring.
Don't lose the metal lock plate that goes with the top left sensor.
8 bolts (10nm) and you will get a fair amount of fluid when you remove the bottom two bolts and internal cover plate.
Clean tranny surface.
Install (the new one) and ensure that everything is hooked up and tight. Don't forget to get the shift arm and link hooked up on top.
Permatex (gasp) grey RTV $5.99 or the , "pick a manufacturer" RTV re-labeled as VOLVO, $$$$, your choice. Follow the directions. (Editor Note: Personally recommend Volvo Sealant)
Put everything else back together except what's in your way of refilling and wait 24 hours.
Fill and drive.
Smile at yourself in the mirror and/or pat yourself on the back.
How to find the transmission serial #:
On the R's, the transmission serial number can be found by looking behind the airbox below the intake tube. There's a metal tag on top of the transmission which has the serial number. It looks like this:
There's a similar metal tag on top of the transmission of the V8's. Here's a photo which shows the location. It's taken while standing next to the driver's side wheel well of the XC90:
***Image Link Broken***
Also, from this post you can find the transmission serial number on V8's by:
"With a good flashlight on a cold engine compartment, stick your head over the near side of the brake fluid reservoir and look straight down.
White sticker with the SN. Just toward the front of the sticker (toward front of car) is the metal plate with the same SN."
Serial # Samplings (Model - Production Date - Serial # Prefix):
2008 XC90 V8 Sport - 5/7/2008 - 08B
2008 XC90 V8 - 10/?/2007 - 07E
2007 S60R - 05/?/2007 - 07C
2007 XC90 V8 Sport - 4/?/2007 - 07B
2007 S80 V8 - 5/4/2007 - 07A
2007 XC90 V8 - 4/?/2007 - 07A
2007 S60R - 3/?/2007 - 07A
2007 V70R - 3/?/2007 - 07A
2007 XC90 V8 Sport - 3/9/2007 - 06M
2007 V70R - 3/?/2007 - 06M
2007 S80 V8 - 02/?/2007 - 06M
2007 V70R - 2/?/2007 - 06L
2007 V70R - 2/?/2007 - 06L
2007 S60R - 1/?/2007 - 06L
2007 S80 V8 - 1/?/2007 - 06L
2007 S80 V8 - 12/?/2006 - 06K (Canadian)
2007 S60R - 12/15/2006 - 06J
PLEASE, HELP US FILL THIS GAP!
2007 XC90 V8 Sport - 01/03/2007 - 06H
2007 XC90 3.2L - 11/?/2006 - 06H
2007 XC90 V8 - 11/27/2006 - 06G
2007 XC90 V8 Sport - 11/22/2006 - 06G
2007 S60R - 11/?/2006 - 06G
2007 V70R - 11/?/2006 - 06G
2007 XC90 - 10/?/2006 - 06G
2007 S60R - 7/17/2006 - 06G
2007 XC90 V8 - 11/?/2006 - 06F
2007 V70R - 10/?/2006 - 06F
2007 V70R - 8/?/2006 - 06C
2007 XC90 V8 - 6/?/2006 - 06C
2007 S80 V8 - 6/?/2006 - 05M (Sweden)
2007 V70R - "March 2006" - Pre-06J (Waiting on exact info)
2006 S60R - 3/16/2006 - 06A
2006 S60R - 1/24/2006 - 05K
2006 V70R - 9/?/2005 - 05G
2006 V70R - 8/?/2005 - 05G
(Please contribute to this record. I'd like to see if we can track down a definitive cutoff date.)