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INTRODUCTIONAUDI, JETTA, PASSAT,09G/09M Transaxle AUTOMATIC TRANSMISSION SERVICE GROUP18635 S.W. 107 AVENUECUTLER BAY, FLORIDA 33157(305) 670-4161 1 No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form orby any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,without written permission of Automatic Transmission Service Group. This includes all text illustrations,tables and charts. The information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy.Copyright © ATSG 2010 1st Printing March, 2010 We wish to thank Volkswagen® for the information that has made this booklet possible. GABE DE LOS REYES TECHNICAL CONSULTANT DALE ENGLAND FIELD SERVICE CONSULTANT ED KRUSE TECHNICAL CONSULTANT WAYNE COLONNA PRESIDENT PETER LUBAN TECHNICAL CONSULTANT JIM DIAL TECHNICAL CONSULTANT GREGORY LIPNICK TECHNICAL CONSULTANT RICHARD GRAHAM TECHNICAL CONSULTANT JON GLATSTEIN TECHNICAL CONSULTANT DAVID CHALKER TECHNICAL CONSULTANT ROLAND ALVAREZ TECHNICAL CONSULTANT GREG CATANZARO TECHNICAL CONSULTANT GERALD CAMPBELL TECHNICAL CONSULTANT The Japanese company AISIN Co., LTD is the manufacturer and developer of the Front Wheel Drive TF60SNtransaxle, which is a 6 speed, fully automatic and electronic controlled transaxle. Volkswagen engineers werealso involved, in conjunction with Aisin, in the development process for their vehicles and they gave it the09G/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 loadrequirements of the specific vehicle. The TF60SN transaxle uses a gear ratio sensitive system, requiring thecorrect 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 aresult there are a variety of different case and part configurations. Some of these units have the heat exchangerattached to the transmission while others use a remote heat exchanger. This alters the case, case cover and thevalve body and if incorrect parts are used, severe planetary failure will occur. This manual covers thesedifferences so that this mistake will not happen to you.The 09G/09M transaxle uses a Lepelletier gear set arrangement, using a simple planetary coupled with aRavigneaux type planetary. This arrangement makes six forward speeds and reverse possible, with only fiveclutch packs and one freewheel.This manual contains the procedures necessary to diagnose, rebuild and/or repair the 09G/09M transaxle and isintended for automotive technicians that are familiar with the operation of automatic transmissions. INDEXAUDI, JETTA, PASSAT,09G/09M 2 Copyright © ATSG 2010 AUTOMATIC TRANSMISSION SERVICE GROUP 18635 S.W. 107 AVENUECUTLER BAY, FLORIDA 33157(305) 670-4161 3 4 56 8 91011131416 1819 20 22 24 25 27 28 30 31 32 37 38 39 40 42626365697276 808487 8889100102102109110121122124124GENERAL DESCRIPTION AND VEHICLE APPLICATION CHART ....................................COMPONENT APPLICATION CHART ..................................................................................... IDENTIFICATION TAG LOCATION AND INFORMATION ...................................................SPEED SENSOR INFORMATION .............................................................................................. PRESSURE SWITCH AND FLUID TEMPERATURE SENSOR INFORMATION .................SOLENOID LOCATIONS AND IDENTIFICATION ................................................................. INDIVIDUAL SOLENOID FUNCTION AND FAILURE RESULT ..........................................SOLENOID OPERATION ............................................................................................................SOLENOID APPLICATION CHART .......................................................................................... PASS-THRU CASE CONNECTORS AND WIRE HARNESS' ..................................................CASE CONNECTOR TERMINAL IDENTIFICATION .............................................................CASE CONNECTOR INTERNAL COMPONENT RESISTANCE CHARTS ...........................TCM CONNECTOR 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 REBUILDCONVERTER 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 GEAR AND FINAL DRIVE ASSEMBLY .......................................VALVE BODY ASSEMBLY ...................................................................................................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 ................................................................ 3 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information The Japanese company AISIN Co., LTD is themanufacturer and developer of the Front Wheel DriveTF-60SN transaxle, which is a 6 speed, fullyautomatic and electronic controlled transaxle.Volkswagen engineers were also involved, inconjunction with Aisin, in the development processfor their vehicles and they gave it the 09G/09Mdesignation. BMW's designation for the same unit is6F21WA. US and Overseas Vehicle applications,known at time of printing, are shown in Figure 1.The 09G/09M transaxle is used in a wide variety of applications and engine sizes. As a result, the numberof friction plates, planetary ratios, three or four pinioncarriers, transfer gear ratios and the final drive ratioswill vary depending on torque load requirements of the specific vehicle. The 09G/09M transaxle uses agear ratio sensitive system, requiring the correcttransaxle interchange, if that becomes necessary.There are also versions of this transaxle that have an Integral Cooler bolted directly to the transaxleconverter cover and pipe engine coolant to thetransaxle. Some versions have a Remote mountedcooler and pipe transaxle fluid to the cooler. Thisaffects changes to the case, converter cover, valvebody and spacer plate. None of these parts areinterchangeable with one another.This transaxle is very similar to the AF40-6transmission but with 3 very significant differences.One is the B1 brake band has been eliminated andreplaced with a B1 clutch pack. Second is the rearcover that gave access to the C/K2 clutch has beeneliminated. Third the Transmission Control Module(TCM) is mounted external from the transaxle whichmakes typical electrical diagnosis available to thetechnician.The TCM controls both shift timing and shift feelwith the use of eight solenoids. The TCM monitorsgear ratio through the input and output shaft hall effectspeed sensors. It also can determine the rate of changeand adapt the shifts as the friction elements wear.All TF-60SN (09G) transaxles use a Lepelletier gearset arrangement, which consists of a simple planetarywith the sun gear splined to the pump stator coupledwith a Ravigneaux type planetary. This allows the sungears and the planetary pinions of the Ravigneauxplanetary gear-set to be driven at different speeds.This arrangement makes six forward speeds andreverse possible, with only five clutch packs and onefreewheel.Refer to Figure 2 for the component locations and theclutch application chart for each gear. GENERAL DESCRIPTION Figure 1 Copyright © 2010 ATSG VEHICLE APPLICATION CHARTVEHICLEYEARENGINEVWAISIN AUDI A3 AUDI A4 AUDI TT AUDI TT BMW Mini Clubman BMW Mini CooperSEAT Altea (Non US)SEAT Leon (Non US)SEAT Toledo (Non US)Volkswagen BeetleVolkswagen TransporterVolkswagen JettaVolkswagen Passat/Passat WagonVolkswagen Passat/Passat WagonVolkswagen Tiguan (Non US)Volkswagen Touran (Non US) 2006-Up 2006-Up 2003-06 2004-08 2008-Up 2002-Up 2004-Up 2005-Up 2004-Up 2004-Up 2006-Up 2005-Up 2006-Up 2006-Up 2008-Up 2003-Up 2.0L 2.0L1.8L 2.0L, 3.2L(V6)1.6L1.6L1.8L, 1.9L, 2.0L, 2.5L1.9L, 2.0L, 2.5L1.9L, 2.0L, 2.5L 2.0L, 3.6L,1.4L, 2.0L1.6L, 1.9L, 2.0L1.4L, 1.6L, 2.0L,1.4L, 1.6L, 2.0L,1.6L, 1.9L, 2.0L,09G09G09G09G6F21WA6F21WA09G09G09G09G09K 09G09G09M 09M 09GTF60SN TF60SN TF60SN TF60SN TF60SN TF60SN TF60SN TF60SN TF60SN TF60SN TF60SN TF60SN TF60SN TF60SN TF60SN TF60SN 4 Copyright © 2010 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information COMPONENT APPLICATION CHART K3Clutch K1Clutch B1Clutch F1 RollerClutch K2Clutch B2Clutch CLUTCH APPLICATION CHART Gear1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear6th Gear Rev GearTransfer Gear Ratio, Codes GSY, GJZ, FXA, (Driven=52T/Drive=49T) Ratio = 1.061 Final Drive Gear Ratio, Codes GSY, FXA, (15T/61T) Ratio = 4.067 Final Drive Gear Ratio, Codes GJZ, (15T/58T) Ratio = 3.867 K-1ClutchOnOnOnOnOnOnOnOnOnOnOnOnOn K-2Clutch K-3Clutch B-1Clutch B-2ClutchOn*On**On**On**On** Hold4.1484.044 2.3702.3711.5561.556 1.1551.1590.8590.8520.6860.676 3.3943.193 F-1 RollerClutchTorqueConv.Clutch Engine1.6L, 2.0L Ratio*** Engine1.8L, Ratio**** * The B-2 Clutch is applied in Tiptronic Mode 1st gear, only for engine braking.** During normal driving operation, the Torque Converter Clutch may be applied in 3rd thru 6th gear.*** Transaxle Codes (GSY 1.6L) and (GJZ 2.0L).**** Transaxle Code (FXA 1.8L). Figure 2
