Valve body / mechatronics

We offer valve block/mechatronics testing, diagnostics and reconditioning services. We restore the full mechanical, hydraulic and electronic efficiency of the hydraulic controller. We use state-of-the-art diagnostic equipment and repair technology, as well as top-quality spare parts. Each regeneration of mechatronics and valve block in our service centre is covered by a 24-month warranty with no mileage limit.

If you notice the first signs of gearbox problems, contact us - quick mechatronics repair will avoid more serious and costly failures.

Genesis and application.

Valve block (also referred to as the valve body, hydraulic controller or, in more recent developments, mechatronics) is a key component in the control system of automatic transmissions. Its history is closely linked to the evolution of the automatic transmission itself, which began to develop in the early 20th century.

The first automatic transmissions appeared in the 1930s. In 1939, General Motors introduced the Hydra-Matic transmission, considered to be the first mass-produced automatic transmission. Valve block was already an integral part of the gearbox, acting as a control for the flow of hydraulic oil.

In the following decades, automatic transmissions became more and more advanced. More gears were introduced and valve bodies became more complex. In the 1950s, valve bodies began to contain a greater number of valves that controlled the pressure of the hydraulic fluid in different parts of the transmission, allowing for smoother and more precise gear changes.

In the 1960s and 1970s, the first electronic components were introduced for automatic transmissions. Electronic control modules began to work in conjunction with valve blocks, enabling more precise and efficient control of gearbox operation. Valve blocks in this period became increasingly complex, containing more valves and more complicated hydraulic fluid flow channels.

In the 1980s and 1990s, the development of microprocessor technology led to even greater integration of electronics in automatic transmissions. Electronic control units (TCUs - Transmission Control Units) began to take over most of the control functions that had previously been performed by mechanical or pneumatic valves and adjusters. Valve blocks continued to play a key role, but their design had to be adapted to work with advanced electronic systems.

Today's automatic transmissions are complex systems in which valve blocks work with or are integrated into electronic control modules. Valve block integrated in the electronic control unit of the automatic transmission is called the mechatronics. Modern valve blocks and mechatronics have a number of sensors and precisely controlled solenoid valves, which are used to control the flow of hydraulic oil based on signals from the TCU. This makes it possible to achieve very smooth and fast gear changes, as well as reduced fuel consumption and greater reliability.

Choose your experience Turbo-Tec - use our services and find out that professional regeneration of mechatronics and specialised solenoid valve service is the guarantee of reliability for your gearbox.

Construction and principle of operation.

Valve block is one of the most important components of an automatic transmission, responsible for controlling the flow of the hydraulic fluid and thus controlling the gear shift. 

Valve block is usually made of cast aluminium, which provides lightness and corrosion resistance. Some of the more heavily loaded components may be made of more robust metal alloys. The housing contains numerous channels and holes that direct the flow of hydraulic fluid to the appropriate locations inside the automatic transmission. Inside the valve block, there are numerous valves of various types - ball valves, spool valves, solenoid valves. These are responsible for opening and closing the hydraulic channels in response to fluid pressure or electrical signals. Some valves have springs of varying size and strength that hold the valves in the required position or cause them to return to their original position when hydraulic pressure or current ceases. Each valve has a specific function, e.g. shift valves, pressure control valves, shut-off valves. With TCU-controlled solenoid valves, it is possible to precisely control the fluid pressure in the individual circuits. Therefore, regular solenoid valve service is an investment in the longevity of the gearbox.

Individual sections of the hydraulic block are separated and sealed by, among other things, a so-called separation plate. This is one of the main elements sealing the channels inside the valve block. Contemporary valve blocks and mechatronic units are also equipped with filters of various designs to catch possible contaminants in the oil. Newer design valve blocks, as well as mechatronic units, are equipped with a number of sensors such as input and output speed sensors, sensors for gear and clutch engagement (DCT/DSG), oil pressure, oil temperature, etc. This is why mechatronics repair i solenoid valve service must be carried out by specialised workshops.

Action and control of modern valve blocks and mechatronics units is based on the use of input signals from a number of sensors that monitor the operating status of the automatic transmission, engine and driver requests. On the basis of these electronic gearbox control unit TCU sends control signals to the solenoid valves to engage the appropriate gear. Depending on the gearbox type, the solenoid valves can manage other functions such as controlling individual clutches (DCT/DSG), activating the Lock-up clutch in the converter, opening or closing the oil cooling circuit or activating the parking lock. By appropriately directing the oil flow through the various channels and valves, the pressure in the individual sections of the gearbox changes. Changes in hydraulic pressure cause actuators (e.g. pistons, clutches, forks) to move, resulting in gear changes or activation of other functions. 

How is the regeneration of solenoid valves and mechatronics carried out?

Valve block or mechatronics is disassembled and pre-cleaned. All components are visually inspected for visible damage such as cracks, wear or corrosion. If there is no such damage, the block/mechatronics is assembled with new seals and then tested on a special test table. In the event of too large a deviation from the required values, the block or mechatronics is disassembled into parts for thorough verification of its individual components. Valves, channels of the hydraulic block are thoroughly verified, and the tightness of individual hydraulic circuits is checked. In case of a lack of tightness, it is possible to restore it after machining a hole in the block housing and using an oversized control valve. Another way is to replace the damaged part of the block housing or to use a complete, brand-new valve block/mechatronics. One of these solutions is required in the event of severe mechanical or electronic damage to the valve block/mechatronics. This approach ensures that mechatronics repair will be carried out comprehensively and without compromising on quality.

Other types of damage are electrical/electronic faults. It is not uncommon to encounter problems with electronic components of the system such as sensors or the automatic transmission controller. In some cases, it is possible to replace or repair the faulty components. If this is not possible, the only solution is to replace the controller or the complete valve block/mechatronics with a brand new one. After replacing the controller with another one, we perform a software cloning operation, so that the next controller is immediately properly programmed and ready for operation.

Reconditioned valve block/mechatronics is pressure tested to check that all valves and ducts are operating correctly under the correct hydraulic pressure. The test takes place under real operating conditions simulating different driving scenarios to ensure that it is operating correctly throughout the operational range.

Make use of our services - comprehensive regeneration of mechatronics and specialised solenoid valve service w Turbo-Tec is your guarantee of reliability, safety and comfort on the road. Thanks to our many years of experience and modern repair technologies, we restore even the most demanding systems to full working order.

Causes and types of damage

Symptoms that may indicate a defective valve body/mechatronics:

1. Lack of smooth gear changes - delays, jerks or gear changes that are too abrupt.
2. No gear change or limited gear change, no gears.
3. No response or delayed response when switching between P-R-N-D modes.
4. Jerks or bumps when switching between P-R-N-D modes.
5. Lack of transmission - the engine revs up but the vehicle does not start.

In such situations, rapid diagnosis and specialist solenoid valve service or full mechatronics repair. Delaying intervention can lead to extensive damage and, ultimately, costly failure of the entire gearbox.

If you notice the symptoms mentioned above, do not risk further operation of your vehicle - make an appointment for professional diagnostics and regeneration of mechatronics w Turbo-Tec.

The most common valve body/mechatronics failures are:

1. Damaged or worn valves, solenoid valves.
2. Leaking, worn or damaged seals.
3. Mechanical damage - scratches, cracks, deformation.
4. TCU software problems.
5. Problems with electronic components.

Why choose Turbo-Tec?

By choosing to work with Turbo-Tec, you are guaranteed the highest quality of service:

• more than 20 years' experience in the remanufacturing and repair of automotive components,
• modern diagnostic and testing facilities,
• a specialised team of gearbox and mechatronics experts,
• 24 months guarantee for each service, with no limit on kilometres,
• serving both private customers and garages throughout Europe.

Choose confidence and experience - regeneration of mechatronics in Turbo-Tec means safety and comfort for many thousands of kilometres.

Contact Turbo-Tec - your mechatronics remanufacturing expert

If your car shows symptoms of automatic transmission failure, don't wait for the problem to get worse. Benefit from the experience of specialists Turbo-Tec. We are a proven partner in services such as regeneration of mechatronics, comprehensive mechatronics repair whether professional solenoid valve service.

Give us a call or visit our service centre - we'll restore your gearbox to full working order and give you a smooth, breakdown-free drive.