Volkswagen 09G 09M Automatic Transmission Repair Manual
The Japanese company AISIN Co., LTD is the manufacturer and developer of the Front Wheel Drive TF60SN transaxle, which is a 6 speed, fully automatic and electronic controlled transaxle. Volkswagen engineers were also involved, in conjunction with Aisin, in the development process for their vehicles and they gave it the 09G/09M designation. BMW gave it the designation 6F21WA for their Mini-Cooper.
The 09G/09M transaxle is used in a wide variety of applications and engine sizes. As a result, the number of friction plates, planetary ratios, intermediate ratios and final drive ratios will vary depending on torque load requirements of the specific vehicle. The TF60SN transaxle uses a gear ratio sensitive system, requiring the correct transaxle interchange. The TF60-SN is used in the BMW Mini Cooper, Volkswagen and Audi vehicles. This transaxle is referred to as the TF60-SN, 09G, 09M, 6F21WA and in some overseas vehicles as 09K. As a result there are a variety of different case and part configurations. Some of these units have the heat exchanger attached to the transmission while others use a remote heat exchanger. This alters the case, case cover and the valve body and if incorrect parts are used, severe planetary failure will occur. This manual covers these differences so that this mistake will not happen to you.
The 09G/09M transaxle uses a Lepelletier arrangement, using a simple planetary coupled with a Ravigneaux planetary. This arrangement makes six forward speeds and reverse possible, with only five clutch packs and one freewheel.
This manual contains the procedures necessary to diagnose, rebuild and/or repair the 09G/09M transaxle and is intended for automotive technicians that are familiar with the operation of automatic transmissions.
- GENERAL DESCRIPTION AND VEHICLE APPLICATION CHART
- COMPONENT APPLICATION CHART
- IDENTIFICATION TAG LOCATION AND INFORMATION
- SPEED SENSOR INFORMATION
- PRESSURE SWITCH AND FLUID TEMPERATURE SENSOR INFORMATION
- SOLENOID LOCATIONSAND IDENTIFICATION
- INDIVIDUAL SOLENOID FUNCTION AND FAILURE RESULT
- SOLENOID OPERATION
- SOLENOID APPLICATION CHART
- PASS-THRU CASE CONNECTORSAND WIRE HARNESS’
- CASE CONNECTOR TERMINAL IDENTIFICATION
- CASE CONNECTOR INTERNAL COMPONENT RESISTANCE CHARTS
- TCMCONNECTOR INTERNAL COMPONENT RESISTANCE CHARTS
- TRANSAXLE RANGE SWITCH OPERATION AND DIAGNOSIS
- STANDARD AND TIPTRONIC SHIFT QUADRANTS
- TYPICAL WIRE SCHEMATIC
- DIAGNOSTIC TROUBLE CODE DESCRIPTION
- TORQUE CONVERTER CLUTCH OPERATION
- PRESSURE TAP LOCATIONS AND IDENTIFICATION
- PRESSURE SPECIFICATIONS
- TRANSAXLE OIL COOLER INFORMATION
- OIL PASSAGE IDENTIFICATION
- CHECK FLUID LEVEL AND FLUID REQUIREMENTS
- OIL PAN “STAND-PIPE” DIFFERENCES
- OIL PAN AND OIL PAN GASKET DIFFERENCES
- OIL FILTER DIFFERENCES
- TRANSAXLE DISASSEMBLY.
- COMPONENT REBUILD
- CONVERTER COVER ASSEMBLY.
- TRANSAXLE CASE ASSEMBLY.
- OIL PUMP ASSEMBLY.
- K3 CLUTCH HOUSING ASSEMBLY.
- K1 CLUTCH HOUSING ASSEMBLY.
- K2 CLUTCH HOUSING ASSEMBLY.
- REAR PLANETARY ASSEMBLY.
- FRONT PLANETARY ASSEMBLY.
- CENTER SUPPORT ASSEMBLY.
- TRANSFER DRIVEN GEARAND FINAL DRIVE ASSEMBLY .
- VALVE BODYASSEMBLY.
- TRANSAXLE FINAL ASSEMBLY.
- B2 CLUTCH CLEARANCE MEASUREMENT
- F1 ROLLER CLUTCH FREEWHEEL DIRECTION
- B1 CLUTCH CLEARANCE MEASUREMENT
- TRANSAXLE END-PLAY MEASUREMENT
- CONVERTER INSTALLED MEASUREMENT
- THRUST WASHER AND BEARING IDENTIFICATION
- TORQUE SPECIFICATIONS
- “UPDATED” TRANSAXLE CODE INFORMATION