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Discussion Starter #1 (Edited)
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.

Models affected:

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."
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The Technical Deficiency:

From this post some details about the problem:
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.
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:


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Here's the TNN regarding the valve body:

(Dated: 11-09-2007)
TNN43-53-2007-11-09 Title: Valve Body: Customer Interest - A/T - Harsh Shifts/False Neutrals/Shift Flare
MODEL/YEAR:
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.
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Documentation:

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
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Replacement Sources:

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
https://www.tascaparts.com/oem-parts/volvo-control-system-31259456

One Stop Gearbox Shop - New - ~$560 Shipped (or $456) (Need to confirm these are the updated design)
http://www.onestopgearboxshop.com/c...earbox-valve-body-genuine?variant=29160338054

Cobra Transmission - New - $1,399.99
https://cobratransmission.com/tf80sc-valve-body-volvo-305017-1
(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
http://www.reamman.com/products/149-tf80sc.aspx

Advantage European Auto Parts (Michigan) - Will Rebuild Your Valve Body - ~$600
http://www.advantage-european.com/

RevMax Converters - Rebuilt - $749.00
https://revmaxconverters.com/product/tf81-af21-ford-mazda-oem-rebuilt-updated-valve-body/

Valve Body Direct - Remanufactured - Pricing Unknown
http://www.valvebodydirect.com/aisin-warner-remanufactured-valve-body.php

Sonnax - Remanufactured - Pricing Unknown
http://www.sonnax.com/parts/3986-remanufactured-valve-body

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.
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Replacement Steps (S60R/V70R):
Thanks Laird for the Walkthrough

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.
(I would like input on the differences in how the job is done between models.)
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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."
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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.)
 

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I have an S80 V8 with that transmission. I've had the occasional weirdness with the shifts, but nothing like my dad's previous 06 S60R had. I wonder if part of it has to do with how the transmissions shifts between the two cars. The S80 is very lazy.
 

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2006-2008 TF-80SC Automatic Transmission Valve Body Issue & Serial Number Info

Oh man... Mine starts with 06A on my 2006. I dont have any hard shifts but I do have a light jolt right before coming to a stop. After I flushed the fluid it calmed down more tho. CaR manufacture date is 3.16.2006
 

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Oh man... Mine starts with 06A on my 2006. I dont have any hard shifts but I do have a light jolt right before coming to a stop. After I flushed the fluid it calmed down more tho
that's just masking the problem.
 

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If its a wear issue instead of a sticking issue, some new, non-broken-down oil with better viscosity is a good band aid that might buy you time till thicker lube can no longer correct it.

If its sticking, some fresh lube may help to dissolve some of the varnish and buy you some time as well.

Either way, if I was one of you guys with slushbox issues I'd sure as hell try some new lube to see how that works before I'd dig in to swap out an expensive throttle body.
 

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a defective part was installed from the factory, everything else short of replacement is a band-aid
 

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and starts to mess other things up...
 

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I had a Valve body rebuild kit installed and it really mad a difference, as the flushing is just a band aid. I'm also in the process of trying to find a way to build the TF80 without going through Level 10, which has not had a lot of positive reviews. I have been on the phone with all of the above sources for the valve body. It seams there are really only three manufactures of the parts in the USA. Will update here when we find out how well it holds up with the new higher HP motor going in.

Would like to here if anyone has done any upgrades to this transmission, as most of the cars this transmission cam in are not most built, think Ford Fusion, and 500
 

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Discussion Starter #10
I had a Valve body rebuild kit installed and it really mad a difference, as the flushing is just a band aid. I'm also in the process of trying to find a way to build the TF80 without going through Level 10, which has not had a lot of positive reviews. I have been on the phone with all of the above sources for the valve body. It seams there are really only three manufactures of the parts in the USA. Will update here when we find out how well it holds up with the new higher HP motor going in.

Would like to here if anyone has done any upgrades to this transmission, as most of the cars this transmission cam in are not most built, think Ford Fusion, and 500
Have any info on what it takes to swap out?

I included the wiki information about the transmission being designed for 325 ft-lb because almost any tuning will drive the R above that number but we don't hear much (or anything?) about physical breakdowns of the transmission.
 

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Doesn't the P* use the same tranny? And they make 500nm... I doubt Volvo/AW would spend the R&D to beef up a transmission they're phasing out.
 

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It's a revamped trans with a more efficient cooling system. And even with that it's pretty much maxed out on the P*

Sent from my XT1575 using Tapatalk
 

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I had a Valve body rebuild kit installed and it really mad a difference, as the flushing is just a band aid. I'm also in the process of trying to find a way to build the TF80 without going through Level 10, which has not had a lot of positive reviews. I have been on the phone with all of the above sources for the valve body. It seams there are really only three manufactures of the parts in the USA. Will update here when we find out how well it holds up with the new higher HP motor going in.

Would like to here if anyone has done any upgrades to this transmission, as most of the cars this transmission cam in are not most built, think Ford Fusion, and 500
Did you get that transgo kit installed? If I remember right it was only around $100ish. It take that over an iffy rebuilt

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I'm sure it's the same transmission, but with different internals.
it is not a TF-80SC. It comes up as a variant in VIDA. like TF-81 or something...
 

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Did you get that transgo kit installed? If I remember right it was only around $100ish. It take that over an iffy rebuilt

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I had ARD do it last year, They used the AW factory rebuild and this is what they did

Shift solenoid kit. Includes SLT, TCC, B1, C1, C2, C3 1 ( PArts wich were just under $600.00)
Install shift solenoid kit 4.20 hours Labor

Before the upgrade I was able to brake boost to about 4K then go, After I can only get it to 2500 rpm and it will hold it there. This was one of the best upgrades I have done to the car. I will post what we find in the hopes of saving people some money. I can say STAY away from the Level 10 ECu flash. A total waste of 200.00 . When I called them today I got no details just 'Sure our transmission will hold 500 awhp "
 

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So you purchased two kits essentially? The AW and transgo? I'm just trying to plan for the worst and I've seen alot of so-so reviews from rebuilders

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Discussion Starter #18
Anyone who has a late-06, 07, or early-08 of any vehicle which has the TF-80SC, I'd really like to add your production date and transmission serial to the list to see if we can track down a cut-off date for the bad valve bodies. Thanks for those I've received so far.
 

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The production date of my 07 SR was around March 2006. I've checked the transmission serial and it does not have the updated valve body. And the caR drives like it, too. Looks like it's about a grand to get this issue fixed.


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I had ARD do it last year, They used the AW factory rebuild and this is what they did

Shift solenoid kit. Includes SLT, TCC, B1, C1, C2, C3 1 ( PArts wich were just under $600.00)
Install shift solenoid kit 4.20 hours Labor

Before the upgrade I was able to brake boost to about 4K then go, After I can only get it to 2500 rpm and it will hold it there. This was one of the best upgrades I have done to the car. I will post what we find in the hopes of saving people some money. I can say STAY away from the Level 10 ECu flash. A total waste of 200.00 . When I called them today I got no details just 'Sure our transmission will hold 500 awhp "
Ron we have talked about level ten before. I wouldn't give them a cent of my money. It was a LONG time ago but they got busted "building" the W4A33 in the auto AWD Talon, laser, and Eclipse. They would charge like $5,000 for a full trans with converter that was supposed to be "fully built" but in the end they were just doing a basic OEM level stock rebuild. They only thing that saved their asses in this case is that particular trans is fairly stout even from the factory.

My thoughts on the Volvo 6 speed GT auto trans are that it is pretty stout trans, way better than the 5 speed auto that it replaced. I'm not sure about if anyone actually makes a good billet high stall converter, we may be stuck with a re stalled stock unit other than that and having to do the VB fix these auto boxes seem to take a bunch of abuse.

If you wanted to go full balls out trans build you could do a high quality OEM rebuild like the Sonax stuff, and cryogenically treat the hard parts along with shot peening them or WPC process them. You could have a serious trans with out any fancy billet replacement parts. But I would not go down that path until I blew up a stock trans first.
 
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