Vacuum Testing for Leakage

Why?
Wear occurs as valves repeatedly stroke in a pump or valve body casting. Eventually,
this wear creates increased clearance beyond what is necessary to maintain a proper
hydraulic seal. Once that occurs, the valve does not function properly and failure results.
There are many methods to check for and evaluate the severity of worn valves and bores:
valve body testers, visual inspection, wet air testing, measurement tools, wiggle/sag
(deflection) tests, etc. But vacuum testing offers many advantages over other inspection
techniques.

Cost. A vacuum test-stand has a very low initial cost and requires minimal
maintenance.
Quick & Easy. Vacuum testing is easy to learn and once your routine is
established, housings can be checked rapidly at the bench.
Quantitative. Vacuum testing provides you with a specific value (inches of
mercury) which correlates to valve/bore clearance. Experience allows you to set
pass/fail standards you can use to determine if there is too much wear for proper
functioning.
Repeatable. Following a routine calibration and easy test procedures, the system
provides repeatable results with negligible operator influence.
Quality Assurance. Wear induced circuit leaks mean failure. Leaks that are not
found lead to customer complaints and come-backs. Vacuum testing can quickly
check for unseen wear areas to prevent wasted rebuild time and money.

How does it work?

Essentially we are isolating or sealing a circuit, and attempting to pull air between the
valve spool and the bore. As air flow is intentionally restricted by tight clearances, we are
able to create, hold and read vacuum. Since we are rating a vacuum, the measurement
will be in inches of mercury, or negative pressure. In order to maintain a hydraulic seal,
there is very little design clearance between the critical valve spool and mating bore. As
wear occurs, this clearance increases. A perfect vacuum (no leakage points) will measure
29.9 of mercury, although that does change with elevation. As wear occurs and leakage
points are introduced, vacuum reading levels will decrease. So in checking valve
clearance, the vacuum loss is directly proportional to the amount of wear.

Where should I test?

Vacuum testing should be performed on a clean and dry valve body. You may use either
of the following approaches, depending on your situation.
Targeted testing:
If you have a specific complaint and there are valves you know are directly related to
certain codes or drivability complaints, you may choose to start there.

Sonnax 2010

General Testing:
If you do not know where to start or if you want to evaluate the valve body or pump
body more completely, begin by checking different circuits based on their level of valve
activity:

Active valves. The ones that are doing the most cycling in the bore are more than
likely the ones that will wear first.
Modulated valves. Valves that are reacted on by low resistance, modulated
solenoids tend to wear quickly. These valves oscillate in the bore in a relatively
narrow, somewhat consistent location.
Regulating valves. These valves are controlling pressures to a set parameter, and
wear will make the pressure out-of-spec and possibly set a code. Regulating
valves also typically operate in a relatively narrow section of the bore, creating
wear at the very location where sealing is the most critical.
On/Off valves. Examples include shift valves and manual valves, that dont move
as frequently, or dont oscillate in narrow linear sections of the bore.

The circuit or port being tested must be captive or sealable. Balance ports are great
locations to perform vacuum tests for this reason. Dense foam or rubber padding can be
used to help seal off circuits that are open to the opposite side of the casting. Sonnax
Wet/Air Test Plates make great tools for sealing off circuits for testing. Make sure that
while sealing a circuit/port for testing you do not seal off the neighboring port that would
supply the air source needed for leak detection, or a false high vacuum reading can result.
We recommend that you use a small amount of assembly lube around the worm tracks of
the circuit/port being tested. This provides a much better seal with the test plate,
especially if there are any knicks on the valve body surface.
Some valves are most accurately checked when they are in their operating, not rest,
position. Small check balls, washers or retainers can be used to position a valve into its
operating position prior to vacuum testing.

How do I set-up a vacuum test stand?

Setting up a vacuum test stand for your shop can be as simple or sophisticated as youd
like. With a trip to the hardware store, a couple of on-line purchases, and about an hour
of assembly time, you can create a simple vacuum test-stand for about $300. Or, for no
assembly time and one on-line purchase, you can order a complete system for under
$1000. The following 2 pages provide information for either set-up option.

Sonnax 2010

Fabricated Vacuum Test Stand Part Sources, Set-up and Calibration

Robinair 3cfm Vacuum Pump

www.testequipmentdepot.com

Assembly:
Assemble as shown in photo. Tubing from the vacuum pump should be run to the test stand at fitting 3a.
Tubing from the test stand fitting 3b should run to test plate, vacuum tips or calibration orifice.
Calibration:
The test stand should be calibrated before each use.
Use a .035 orifice (item #10) to calibrate your test stand. Place this orificed tubing section on the test
end of the tubing, then turn the pump on. Seal off the orificed tubing section with thumb, and adjust the
air bleed valve (4b) to 25 on the gauge. Unblock the end of the tubing and adjust the air flow valve (4a)
to read 5 on the gauge (6) as air is allowed to flow in through the .035 orifice. Repeat both steps.
The test stand is now calibrated for repeatable results. A perfect seal will be 25 on the gauge.
3

Sonnax 2010

Purchased Vacuum Test Stands and Source

ATS Automatic Transmission Service

http://atsdiagnostic.com

Model V100

Model V100C

Sonnax 2010

What should my test results be?

While a properly calibrated and maintained test stand will give consistent vacuum
reading results for a given circuit and amount of wear, evaluating those results will
require you to establish your own pass/fail criteria.
The pump, gauge and any calibration orifices used in specific equipment configurations
will greatly influence vacuum readings. Test results will vary depending upon how you
set-up your particular vacuum stand. Pass fail standards are specific to your set up and
process and they must also be based on your experience, quality sensitivity, warranty
concerns and cost/pricing structure.
We recommend that you keep a record of vacuum results for each valve body, at each
tested circuit/port location, so that youll be able to compare those results over time to
help determine for your own shop what is an acceptable vacuum reading for each
location. Pass/fail parameters are altered by the number of spools tested in a captive
circuit, spool diameter size, and contact length of the spool within its bore.

Sonnax 2010

Rebuild or Replace the Valve Body?

Valve bodies are getting more sophisticated in function, and by default more expensive to
diagnose and repair or replace. If you find the root cause of the transmission complaint to be in
the valve body, how do you make the decision on repairing it yourself, buying a new OEM valve
body, purchasing a rebuilt valve body, or pulling something out of your core pile?
Im sure a good chunk of that decision is based on the financials: cost of the valve body
replacement options, cost of kits if rebuilding in-house, cost of any specialized tools required,
and labor cost if you do the rebuild. Other considerations would include your warranty, and
what option will best ensure a rebuild that wont come back before the time or mileage run out.
How busy is your shop, and do you have the time to repair the valve body, or would your labor
hours be better put to a different job? How familiar are you with this valve body application, or
is the learning curve going to be too steep and expensive for the relatively few of these you
expect to see? Who owns the vehicle, and what are their driving habits and expectations?
Many of these decisions are going to be made day-to-day, and sometimes hour-to-hour. One day
it might be best to rebuild the valve body in-house, but for the guy pulling too much trailer with
too little truck, maybe a new OEM or remanufactured valve body with that companys warranty
is the right choice.
Some of the more financially based decisions can seem tricky to navigate. The following charts
show some basic return-on-investment calculation examples which can make this easier. These
can be adapted to fit your particular situation as well, and help you decide what valve body repair
or replacement option makes the best financial sense.

Reamer Cost Analysis over Time*

Cost for Reamer Kit(s)

$225

$225/75 reams = $3 Reamer Kit cost per ream

*based on 75 reams per tool life
Valve Body Rebuild or Replace Options
Valve Body
Valve Kit
Labor
Amortized Tool Kit

New
$900
$0
$0
$0

Remanufactured
$450
$0
$40
$0

In-House
$0
$45
$80
$3

Total Cost Per Valve Body

$900

$490

$128

So in this example, rebuilding in-house would save your shop $362 ($490-$128) compared to a
remanufactured valve body, and $772 compared to a new valve body! Use the templates on the
following pages to financially evaluate your next decisions on valve bodies. The results may
surprise you, and will hopefully lead to a better bottom line for your shop.
6

Sonnax 2010

Rebuild or Replace Valve Body Worksheet

Tool Cost Analysis Over Time
Tool #1
Tool #2
Tool #3
Total Tool Cost
Number of tool uses over time/life

$
$
$
$
#

Tool Cost Per Valve Body

(total tool cost / number tool uses)

Valve Body Rebuild or Replace Options

New
Valve Body
Valve Kit(s)
Labor
Amortized Tool Kit(s)
Total Cost Per Valve Body

$
$
$
$
$

Remanufactured
$
$
$
$
$

In-House
$
$
$
$
$

Tool Cost Analysis Over Time

Tool #1
Tool #2
Tool #3
Total Tool Cost
Number of tool uses over time/life

$
$
$
$
#

Tool Cost Per Valve Body

(total tool cost / number tool uses)

Valve Body Rebuild or Replace Options

New
Valve Body
Valve Kit(s)
Labor
Amortized Tool Kit(s)
Total Cost Per Valve Body

$
$
$
$
$

Remanufactured
$
$
$
$
$

In-House
$
$
$
$
$

Sonnax 2010

Critical Wear Areas

& Vacuum Test Locations
for

6R60 / ZF6HP Series,

TF-81SC and TR-60SN
Valve Bodies
Areas in red indicate vacuum test circuit/port location

Areas in black on exploded valve body views show retainer locations

Important!

There are multiple worm-track patterns for most valve bodies. While only
one is shown for each application in this information, it can be used as a
reference for other casting versions based on valve-to-circuit location

Important!

The most common wear locations that can be vacuum checked are
indicated in this information. This does not imply that wear can not be
present in other locations.

Important!

The springs and retainers have been intentionally left out of the vacuum
test location sheets for better clarity. All valve bore components are
shown in their resting position.

Sonnax 2010

6R60 / ZF6HP Series

Sonnax 2010

Solenoid Pressure Regulator Valve

Soft shifts, poor line rise
High line pressure during stall test.
Loss of 1-2 or 4-5 upshift
Delayed forward/reverse engagement
5-4 or 4-3 flare
Gear ratio codes

Critical Wear Areas and Vacuum Test Locations

6R60 / ZF6HP Series
Jaguar ZF6HP26M Illustrated
Lower Valve Body
Delay Accumulator Piston
Harsh 3-4 upshift
3-4 shuttle or gear
ratio code

Main Pressure Regulator Valve

Delayed or no reverse
Poor shift quality
Slip forward or reverse
Erratic or high/low line pressure

Bypass Clutch Control Regulator Valve

Converter overheat and low release
pressure
Excessive TCC slip or cycling RPM
Firm up/downshifts
TCC related codes

Converter Release Regulator Valve

Excessive TCC slip RPM and
related codes
Harsh lockup apply and release
Harsh downshifts
Converter overheat

Clutch A Control Pressure Regulator Valve

& Plunger Valve and Sleeve
Delayed or harsh forward engagement
Flare or neutral on 5-4 downshift
No 4-5 Shift
VFS 1/A solenoid control code

Lubrication Control Valve

Excessive cooler pressure
(ruptured hoses or cooler)
Bushing and/or planet
overheat
Clutch E Control Pressure Regulator Valve
Flare upshifts or downshift bind-ups
Excessive clutch overlap and clutch distress
Pressure control out of range codes
Coastdown neutral or harsh downshifts

10

Sonnax 2010

Critical Wear Areas and Vacuum Test Locations

6R60 / ZF6HP Series
Jaguar ZF6HP26M Illustrated
Upper Valve Body

Clutch D1 Control Pressure

Regulator Valve
Flare upshifts or downshift
bind-ups
Excessive clutch overlap
and clutch distress
Pressure control out of
range codes
Coastdown neutral or
harsh downshifts

11

Sonnax 2010

6R60 / ZF6HP Series

Jaguar ZF6HP26M Illustrated
Lower Valve Body

101

109
102

110

103

111

112

104

113

105
106

115

107

116

108

12

Sonnax 2010

6R60 / ZF6HP Series

Jaguar ZF6HP26M Illustrated
Upper Valve Body

201

204

202

205

203

13

Sonnax 2010

6R60 / ZF6HP Series Component Description and Location

Number
101
102
103
104
105
106
107
108
109
110
111
112
113
115
116

Location
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body
Lower Valve Body

Description
Manual Valve
Lubrication Control Valve
Converter Release Regulator Valve
Main Pressure Regulator Valve
Bypass Clutch Control Regulator Valve
Clutch E Latch Valve
Clutch E Control Pressure Regulator Valve
Clutch A Control Pressure Regulator Valve
Delay Accumulator Piston
Solenoid Multiplex Valve
Drive Enable Valve
Clutch D1 Latch Valve
Solenoid Pressure Regulator Valve
Clutch B Latch Valve
Clutch A Latch Valve

201
202
203
204
205

Upper Valve Body

Upper Valve Body
Upper Valve Body
Upper Valve Body
Upper Valve Body

Clutch B Regulator Valve

Clutch D2 Regulator Valve
Clutch D2 Latch Valve
Clutch C Regulator Valve
Clutch D1 Control Pressure Regulator Valve

14

Sonnax 2010

TF-81SC

15

Sonnax 2010

Critical Wear Areas and Vacuum Test Locations

TF-81SC Front Cover, Front Side

B1 Band Accumulator Piston

Visual wear check, also
Burned band
Slipping gears

16

Sonnax 2010

Critical Wear Areas and Vacuum Test Locations

TF-81SC Front Cover, Rear Side

C1 Clutch Control Valve

Flare upshifts
Downshifts bind up
Excessive clutch overlap
Clutch distress
Pressure control out of
range codes
Coast-down neutral or
harsh downshift

C3 Clutch Control Valve

Flare upshifts
Downshifts bind up
Excessive clutch overlap
Clutch distress

SSD
C2 Clutch Control Valve
Flare upshifts
Downshifts bind up
Excessive clutch overlap
Clutch distress

SSC

SSF

Pressure control out of

range codes

SSE

Pressure control out of

range codes

B1 Band Control Valve

Harsh downshifts
Flare on 1-2, 2-3, 5-6
upshift
B1 band distress
Firm 3-2, 2-1 and 6-5
coast downshift
Drivability changes with
operating temperature

Main Pressure Regulator Valve

and Boost Valve Assembly
Excessive pressure in
reverse
Fluid and converter lining
overheat
Bushing failure
Poor line rise in Drive or
Reverse

17

Sonnax 2010

18

Sonnax 2010

Critical Wear Areas and Vacuum Test Locations

TF-81SC Middle Casting, Rear Side

Secondary Regulator valve

Overheating of fluid,
bushings and converter
Harsh reverse engagement
TCC slippage / RPM surge
Poor shift quality
High/low SLT pressure

19

Sonnax 2010

Critical Wear Areas and Vacuum Test Locations

TF-81SC Rear Cover, Front Side
C3 Clutch Accumulator Piston
See next page

Lockup Clutch Control Valve

and Plunger Valve Assembly
Harsh downshifts
RPM surging on coast or
light acceleration
Overheated fluid
Converter apply/release
complaints
Converter slip codes

Solenoid Modulator Valves

DTCs P0734, P0735, P0729
Slippage or shock on kickdown
Slippage in steady driving 4th, 5th
or 6th gear
(1) feeds PCA, SSD/C1, and
TCC solenoids

Line Pressure Accumulator Piston

See next page

(2) feeds SSA, SSB, SSC/C3,

SSE/B1, SSF/C2 solenoids

C2 Clutch Accumulator Piston

See next page

20

Sonnax 2010

Critical Wear Areas and Vacuum Test Locations

TF-81SC Rear Cover, Rear Side
C1 Accum

C3 Accum

Clutch/Line Pressure
Accumulator Pistons
Visual wear check, also
Delayed engagements
Slipping in forward gears
Burned clutches

Solenoid Modulator Accumulator Pistons

Visual wear check, also
Reduced throttle signal oil or solenoid
feed oil pressure
Shift complaints and codes

C2
Accum

Line
Accum
1

21

Sonnax 2010

104
TCC
105

SSD
SSC

106

103

SSF
SSE

102

107

101
PCA

TF-81SC FRONT COVER

FRONT SIDE

22

Sonnax 2010

104
TCC

SSD
103

SSC
SSF

102

105

SSE

101

107
PCA

TF-81SC FRONT COVER

REAR SIDE

23

Sonnax 2010

106

215

214

216

213

217

212

218

211

219

210

209

208
220

TF-81SC MIDDLE CASTING

FRONT COVER SIDE

24

Sonnax 2010

214

215

213

216

212

217

211

218

210

219

209

208
220

TF-81SC MIDDLE CASTING

REAR COVER SIDE

25

Sonnax 2010

324

325

323
326

322

327

321

328
329

TF-81SC REAR COVER

FRONT SIDE

26

Sonnax 2010

330
331

332

333

TF-81SC REAR COVER

REAR SIDE
27

Sonnax 2010

TF-81SC Component Description and Location

Number
101
102
103
104
105
106
107

Location
Front Cover
Front Cover
Front Cover
Front Cover
Front Cover
Front Cover
Front Cover

Description
Main Pressure Regulator Valve and Boost Valve Assembly
B1 Band Control Valve
C3 Clutch Control Valve
Manual Valve
C1 Clutch Control Valve
C2 Clutch Control Valve
B1 Band Accumulator Piston

208
209
210
211
212
213
214
215
216
217
218
219
220

Middle Casting
Middle Casting
Middle Casting
Middle Casting
Middle Casting
Middle Casting
Middle Casting
Middle Casting
Middle Casting
Middle Casting
Middle Casting
Middle Casting
Middle Casting

Sequence Valve
Secondary Pressure Regulator Valve
B1 Signal Valve
C3 Signal Valve
C2 Relay Valve
B2/C2 Switch Valve
C1 Shift Valve
B1/C3 Control Valve
Lockup Relay Valve
B1/C3 Relay Valve
B1/C3 Shift Restrict Check Valve
B1/C3 Switch Valve
Cutback Valve

321
322
323
324
325
326
327
328
329
330
331
332
333

Rear Cover
Rear Cover
Rear Cover
Rear Cover
Rear Cover
Rear Cover
Rear Cover
Rear Cover
Rear Cover
Rear Cover
Rear Cover
Rear Cover
Rear Cover

Solenoid Modulator Valve #1

Lockup Control Valve and Plunger Valve Assembly
C3 Clutch Accumulator Piston
C1 Clutch Accumulator Piston
Forward Accumulator Piston
C1 Relay Valve
C2 Clutch Timing Valve
Solenoid Modulator Valve #2
Engine Brake Engagement Valve
Solenoid Modulator Accumulator Piston #2
C2 Clutch Accumulator Piston
Solenoid Modulator Accumulator Piston #1
Line Pressure Accumulator Piston

28

Sonnax 2010

TR-60SN

29

Sonnax 2010

Critical Wear Areas and Vacuum Test Locations

TR-60SN Top Casting

Solenoid Regulator Valve

(K3/B1/K2 Clutches, N89, N88)
DTC P0734, P0735, P0729
Slippage or shock on kickdown
Slippage in steady driving in 4th,
5th or 6th gear

Solenoid Regulator Valve

(TCC, EPC, K1 Clutch)
DTC P0734, P0735, P0729
Slippage or shock on kickdown
Slippage in steady driving in 4th,
5th or 6th gear

Lockup Clutch Control Valve

RPM surging on coast or
light acceleration
Harsh downshifts
Overheated fluid

Secondary Regulator Valve

Overheating fluid & converter
Bushing failure
Harsh reverse engagement
TCC slippage/surge

K1 Accumulator Piston
Visual wear check
Burned K1 clutch
Delayed engagement
Slipping in forward gears

30

Sonnax 2010

Critical Wear Areas and Vacuum Test Locations

TR-60SN Bottom Casting

K2 Accumulator Piston
Visual wear check
Burned clutch
4th-6th gear slippage

B1 Accumulator Piston
Visual wear check
Burned clutch
Slipping gears

K2 Clutch Control
Valve
B1 Clutch Control
Valve
K3 Clutch Control
Valve
K1 Clutch Control
Valve

EPC Accumulator Piston

Low line pressure
Soft or slipping shifts

K3 Accumulator Piston
Burned clutch
Delayed reverse

Flare upshifts or
downshift bind-ups
Excessive clutch
overlap and clutch
distress
Pressure control out
of range codes

Main Pressure Regulator Valve

Excessive reverse pressure
Fluid & converter lining
overheat
Bushing failure

31

Sonnax 2010

209
208

210

211

207

206
212

213
205
214
204

215

203
216

202

217

218

201

TR-60SN TOP CASTING

32

Sonnax 2010

N88

N89
107

106

K2/N282

108

B1/N283

109

110

K3/N92

K1/N90

105

111

EPC/N93
104

112
TCC/N91

103
113

102

TR-60SN BOTTOM CASTING

33

Sonnax 2010

TR-60SN Component Description and Location

Number
102
103
104
105
106
107
108
109
110
111
112
113
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218

Location
Bottom Casting
Bottom Casting
Bottom Casting
Bottom Casting
Bottom Casting
Bottom Casting
Bottom Casting
Bottom Casting
Bottom Casting
Bottom Casting
Bottom Casting
Bottom Casting

Description
K3 Clutch Accumulator Piston
EPC Accumulator Piston
K1 Switch Valve
Forward Engagement Accumulator Piston
B1 Accumulator Piston
K2 Clutch Accumulator Piston
K2 Clutch Control Valve
B1 Clutch Control Valve
K3 Clutch Control Valve
K1 Clutch Control Valve
No. 1 Relay Valve
Main Pressure Regulator Valve Assembly

Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting
Top Casting

K1 Clutch Accumulator Piston

K3/B1 3-Way Check Valve
N283 (B1) Switch Valve
N90 (K1) Switch Valve
K3 Control Valve
B1 Control Valve
K2 Control Valve
B2 Control Valve
B2 Regulator Valve
Pressure Modifier Valve
No. 2 Relay Valve
B2 Port Control Valve
B1 Relay Valve
Solenoid Regulator Valve (K3, B1, K2, N89, N88)
K3 Relay Valve
Solenoid Regulator Valve (TCC, EPC, K1)
Lockup Clutch Control Valve and Plunger Valve Assembly
Secondary Regulator Valve and Plunger Valve Assembly