General Repair Information

Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. 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 service information, are summarized here.

Safety Precautions 

Observe the following to avoid personal injury and vehicle damage:

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 

For the ATF maintenance intervals, refer to Maintenance, Diagnosis .

Only use the ATF listed as a replacement part in the Parts. Other fluids can cause malfunctions or transmission failure.

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

Transmission Control Module -J217- 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 Wiring Diagram.

Information on the "Transmission 09G" 

For additional information on the 09G automatic transmission, refer to the Self-Study Program, 851503, 6-Speed Automatic Transmission 09G/09M, Design and Function

Special Tools 

A complete list of special tools and shop equipment used in the repair manual can be found at the beginning of each repair information and at the end of each repair group under "Special Tools".

On smaller fasteners with minimal tightening specifications, uncertainties often exist. For these fasteners the Torque Wrench 1783 - 2-10 Nm V.A.G 1783 can be used.

Transmission 

The "automatic transmission 09G - 6-speed" has six 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.

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

Transmissions With and Without Filler Tube 

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

You also do not need the old filler 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.

To drain, the overflow tube is removed.

• After installing, check ATF level and fill. Refer to ATF LEVEL, CHECKING AND FILLING .
• For fluid capacity, refer to the Maintenance, Diagnosis or Maintenance, Diagnosis or Maintenance, Diagnosis .

Seals, Gaskets and Oil 

• Always replace the O-rings, seals and gaskets.
• Flange shaft, torque converter and selector shaft seals are illustrated as shaft seals.
• After removing the seals, check the sealing surfaces on the housing or shaft for burrs resulting from removal or damage.
• Coat O-rings with clean ATF before installing them to prevent crushing the O-rings during installation.
• Use ATF only. Other types of lubricants cause faults to occur in the transmission hydraulics.
• Before installing the seal rings, lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with Grease G 052 128 A1.
  Fig 4: Identifying Oil Seals Sealing Lips

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• The open side of the seals point toward the fluid to be sealed in.
• Checking the ATF level. Refer to ATF LEVEL, CHECKING AND FILLING .

Bolts and Nuts 

• Loosen or tighten bolts and nuts for the covers or housings diagonally.
• The tightening specifications stated apply to non-lubricated nuts and bolts.
• Use a wire brush to clean the threads of bolts that were installed using liquid locking fluid. Install the bolts using liquid locking fluid AMV 185 101 A1.
• Clean the threaded holes for the self-locking bolts or for the bolts coated with liquid locking fluid. Otherwise there is a risk that the bolts will shear the next time they are removed.
• Always replace 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 the connector or open electronic components directly.

Guided Fault Finding, OBD and Test Instruments 

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

Perform Guided Fault Finding  using the Vehicle Diagnostic Tester. Refer to TESTER, CONNECTING .

Guided Functions  finds the ATF temperature quickly. Refer to TESTER, CONNECTING .