An in-process method of diagnosing the spool wear of hydraulic servovalves was explored. The diagnostic method discussed in this paper is for force-control hydraulic servo systems. The key principle used is that pressure sensitivity of a servovalve drops as the valve spool wears out so that it is possible to determine the spool condition by monitoring pressure sensitivity. A diagnostic algorithm was developed and evaluated through numerical simulation and experiments. Two major steps of diagnosis are the evaluation of null bias of the servovalve and the approximation of pressure sensitivity, both of which could be successfully done during normal operation of a servo system. The difference between a new servovalve and a worn valve could be clearly detected in-process, and the diagnostic test was found to be repeatable.