en- Homemade stand-tester for testing transmission solenoids -Transmission Solenoid Tester DIY-

 

     The Transmission Solenoid Tester allows professional testing of automatic transmission and DSG solenoids in any environment, even a garage or at home.

      The cost of the solenoid tester is about 250 dollars. Currently, the tester supports all known types of solenoids. The only limitations are the adapters.

        The device is designed for visual verification of the functionality of automatic transmission (AT) and DSG solenoids and is a cost-effective alternative to industrial solenoid testers. I personally use this device to repair "old style" 6T40 solenoids at home in a 17-story building, and have been doing so for 10 years.

         The DIY solenoid tester works by performing an air test on the solenoid and comparing the graph of the tested solenoid with the graph of a reference solenoid. Adapters are required for each specific solenoid model, which you can 3D print yourself by creating a design or ordering one from me. Currently, adapters are only available for 6T30, 6T40, 6T45 gen.1, 722.8-722.9, and 6HP26 transmissions. All adapter files are provided free of charge with the purchase of the tester.

        The complete automatic transmission solenoid tester kit includes the assembled device (13cm x 40cm) with a USB output, output wires with alligator clips for connecting to the tested solenoids, two power wires (12V positive and 12V negative), three control programs, and a T-fitting (one 1/8 NPT female thread and two 1/8 NPT male threads). The kit costs 250 dollars.

                  General view of the automatic transmission solenoid test stand kit

 

 

    

    The components of the automatic transmission solenoid testing stand can be conditionally divided into three parts: the pneumatic section, the solenoid adapter, and the electronic part.

    The pneumatic section is located on the compressor, and its task is to maintain air pressure with an accuracy of 0.5 atmospheres. A precision pressure regulator is used for this purpose. More details about it can be found on the assembly page.

 

   

   1 - Standard pressure regulator included with the compressor.

   2 - Valve that prevents air from escaping during pauses in the solenoid testing process.

   3 - High-precision (precision) pressure regulator IR2020.

   The adapter for testing the solenoid is a model printed on a standard FDM 3D printer. You can model the file yourself (I will later post a video on how to do this) or receive it along with the purchase of the device.

 

  

 

 

 

   The electronic part consists of an electronic device that plugs into the USB port of a computer, management software installed on the computer, and an electronic pressure sensor. It is also desirable to install an electronic manometer and a mechanical manometer for adjusting solenoids during repairs.

  The beneficial differences of the Transmission Solenoid Tester from industrial models are:

   1. Low equipment cost (the calculation does not include the cost of the computer!).

                       a) The assembled device board along with three versions of the Solenoid Valve Tester software costs 250 dollars.

 

  

 

                  b) Compressor (the most expensive purchase). I use the quiet compressor HYUNDAI HYC-1406S. This compressor has a low noise level during operation and does not require additional soundproofing of the room. The approximate noise level is shown in the photo… the average cost is 130 dollars.

                  c) Power supply of 12 volts, 13-16 amps, or 200 watts (costs around 20 dollars). Such power supplies are used in LED lighting systems.It is advisable to look for a power supply with a variable resistor mounted on the board for the most accurate adjustment of the voltage to 12.0 volts.

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      g) Precision pressure regulator. You can use the IR2020, which costs around 20 dollars (you can buy it here, not advertising). My exact regulator, the VEX1330, I bought for 23 dollars at the market. Pay attention to the inlet and outlet diameter of the openings and the diameter of the hole for the manometer (which can be plugged if not needed).

      h) Fittings and adapters costing a total of 10 dollars.

       i) 3D printer for printing adapters for various solenoids (you can use a friend’s printer or find a workshop in your city). With an approximate weight of one adapter being 40 grams, the cost of filament is about 1 dollar per piece (with an average filament price of 10 dollars per kg).

The total cost with the compressor is around 300 US dollars.

 

    2. In principle, the Solenoid Tester is a universal device for all types of solenoids used in automatic transmissions and DSG. It is only necessary to design and print an STL file for an adapter for a specific solenoid. Adapters for some solenoids are still not produced!

 

   

    3. The ability to independently create reference graphs for solenoids, using known working solenoids as references or obtaining reference graphs when purchasing the device.

    4. Since air is used in the tests, there is no oil—this is a significant advantage for keeping the work area clean. I use this tester at home in an apartment, dedicating one of the rooms for testing solenoids. (In the future, I plan to add a temperature sensor and a heater to enable testing solenoids in hot oil under garage repair conditions).