General Repair Information

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in this repair information, are summarized here.

Transmission 

The 6 speed automatic transmission 09G has 6 hydraulically controlled forward gears. By passing the torque converter slip, 2nd, 3rd, 4th, 5th and 6th gears become mechanically driven gears if the lockup clutch is closed.

Torque Converter 

The torque converter is equipped with a slip controlled torque converter lockup clutch. The lockup clutch closes depending on load and speed. The 2nd, 3rd, 4th, 5th and 6th gears can be mechanically driven (without slip).

Automatic Transmission Fluid 

Automatic Transmission Fluid (ATF) is a permanent fill. As far as maintenance is concerned, the ATF does not need to be replaced.

Use only the ATF listed as a replacement.

The ATF levels inside the planetary gear and inside the final drive are checked and filled at the same time.

Transmission Control Module with Fuzzy Logic 

Determining the driving situation and driving resistance dependent shift point occurs automatically.

Advantages: 

• It is shifted depending on consumption
• Maximum engine output is always available
• Individual adaptation of shift points in all driving situations
• Gear shift points are infinitely variable

Control Modules 

The installed locations of all vehicle control modules and other useful information can also be found in the "WIRING DIAGRAM".

Automatic Transmission 09G 

Design and Function 

851503 6-Speed Automatic Transmission 09G/09M Design and Function

Tools 

A list of special tools and workshop equipment required for repair procedures can be found at the beginning of each repair procedure.

With smaller fasteners with a minimal tightening specification, uncertainties often exist. For these fasteners, torque wrench (5-60 Nm) V.A.G 1783 can be used.

Transmission 

• Do not run the engine and do not tow the vehicle if the transmission cover is removed or if there is no transmission fluid inside the transmission.
• Always clean the connection points and the area around them first, and then loosen them.
• When installing the transmission, make sure the alignment sleeves are correctly installed between the engine and transmission.
• Place removed parts on a clean surface and cover them so that they do not get dirty. Use foil and paper. Use a lint free cloth.
• Only install clean components: Remove the replacement parts from their packaging just prior to installing them.
• Carefully cover or plug unpacked components if repairs cannot be performed immediately.
• With the transmission removed, secure the torque converter so that it cannot fall out.

Transmission, With and Without Fill Tube 

Fig 1: Identifying Example Of Filler Tube Installed In Older Transmissions

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Here, for example, is a fill tube -arrow- as it was installed in older transmissions. This tube has been omitted.

You also do not need the old fill hole with the red cap because the ATF is drained and filled at the lower hole when necessary. The height of this overflow tube corresponds to the height of the ATF level.

Fig 2: Identifying Example Of Filler Tube Installed In Transmissions

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

To drain, the overflow tube is removed. 

• After installing, check the ATF level and top off. Refer to ATF LEVEL, CHECKING AND FILLING .
• Capacities, refer to CAPACITIES .

Seals, Gaskets and O-rings 

• Always replace the O-rings, seals and gaskets.
• Before installing the radial shaft seal, lubricate the sealing lips and the space between them with sealing grease for seal G 052 128 A1.
  Fig 3: Identifying Oil Seals Sealing Lips

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• The open side on the seal faces the oil.
• Check the ATF level after installing.

Bolts and Nuts 

• Loosen or tighten bolts and nuts on covers or housings diagonally.
• The tightening specification stated apply to non-lubricated nuts and bolts.
• Clean the threads of bolts that were applied with locking fluid using a wire brush. Install the bolts with liquid locking fluid AMV 185 100 A1.
• Clean all threaded holes with a thread tap to remove any locking fluid residue. Otherwise the bolts could shear the next time they are removed.
• Always replace the self locking nuts and bolts.

Electrical Components 

You have probably received a electrical shock at one time, when touching a metal item. The reason behind this is the electrostatic charge to the human body. This charge can damage the electrical components on the transmission and the selector mechanism.

-- Touch a grounded object, such as, a water pipe or a vehicle hoist, before working on electrical components. Do not touch connectors or open electronic components directly.

Guided Fault Finding, On Board Diagnostic (OBD) and Test Instruments 

Fig 4: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Before beginning any service work on the automatic transmission, determine the cause of the damage using "Guided Fault Finding".

Guided Fault Finding  is performed using the vehicle diagnosis, testing and information system VAS 5051B. Refer to TESTER, CONNECTING .

Guided Functions  allows you to find the ATF temperature as quickly as possible. Refer to TESTER, CONNECTING .