TF60 SN Tech Guide

TF60-SN 09G/09M 09K - Overseas INDEX Introduction....................................................................................................... 3 Application Chart............................................................................................... 7 Pressure Testing................................................................................................. 8 Internal Wiring Harness..................................................................................... 12 Wiring Diagram................................................................................................. 16 Solenoid Operation and Testing......................................................................... 18 Case Passage Identification................................................................................ 23 Clutch Assemblies............................................................................................. 27 Sprag Rotation................................................................................................... 32 Fluid Specification............................................................................................. 33 ATSG Bulletins.................................................................................................. 35 Data Block Information..................................................................................... 48 Solenoid Amp Chart........................................................................................... 50 Clutch Adapt Re-Set........................................................................................... 53 Codes................................................................................................................. 57 Valve Body......................................................................................................... 60 Valve Body Mapping......................................................................................... 71 Hydraulic ScKematics........................................................................................ 86

AUTOMATIC TRANSMISSION SERVICE GROUP 18635 S.W. 107 AVENUE CUTLER BAY, FLORIDA 33157 (305) 670-4161 WWW.ATSG.BIZ

Copyright © ATSG 2009

WWW.ATSG.COM

2nd Printing November 2010

Introduction The TF60-SN is a front wheel drive 6 speed fully automatic electronically controlled transmission that is used in the BMW Mini Cooper, Volkswagen and Audi vehicles. This transmission is referred to as the TF60-SN, 09G, 09M and in some overseas vehicles an 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 and 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. This manual also reveals how easy it is to cross connect solenoids causing multiple shift complaints. But it also shows you how to get it right the first time saving you time and money and a headache you really do not need to have. You will also find detailed information on the valve body, sprag rotation, clutch pack stack ups, diagnostic OBD II and VAG codes, solenoid amp charts, valve body mapping for circuit tracing as well as a complete set of oil schematics. No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by 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 PETER LUBAN

WAYNE COLONNA

JIM DIAL

TECHNICAL SUPERVISOR

PRESIDENT

SENIOR CONSULTANT

GERALD CAMPBELL

DALE ENGLAND

TECHNICAL CONSULTANT


CLAY WICKHAM

ED KRUSE



ROLAND ALVAREZ

GREGORY LIPNICK



GREG CATANZARO

DAVID CHALKER



JON GLATSTEIN

JERRY GOTT


ECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP 18635 SW 107TH AVENUE CUTLER BAY, FLORIDA 33157 (305) 670-4161

Technical Service Information TF60-SN PRELIMINARY INFORMATION

The Japanese automatic transmission manufacturer AISIN Co., LTD is the developer of the FWD TF60-SN Transmission, a 6 speed fully automatic and computer controlled transmission. Vehicle applications known at the time of printing is as follows: AUDI AUDI AUDI BMW BMW SEAT SEAT SEAT VW VW VW VW VW VW VW

A2 A4 TT Mini Clubman Mini Cooper Altea Leon Toledo Beetle Eos Jetta Passat Tiguan Touran (Non US) Passat

2006-On 2006-On 2003-04 2008-On 2002-On 2004-On 2005-On 2004-On 2005-On 2007-On 2005-On 2006-On 2008-On 2003-On 2006-On

2.0L 2.0L 1.8L 1.6L 1.6L "1.4, 1.6, 2.0L" "1.6, 1.9, 2.0L" "1.8, 1.9, 2.0, 2.5L" "2.0, 3.2L" "1.9, 2.0, 2.5L" 2.0L "1.4, 2.0L" "1.6, 1.9, 2.0L" 3.6L

09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09G (TF-60SN) 09M (TF-60SN)

When Volkswagen engineers developed the transmission in conjunction with Aisin and adapted it to Volkswagen vehicles they gave it the 09G/09M designation. This transmission is very similar to the AF40-6 transmission but with two very significant differences. One is the B1 brake band has been eliminated and replaced with a B1 Clutch Pack. The other is the rear cover that gave access to the C/K2 clutch has been eliminated. As a result of this transmission being used in a variety of applications, the number of friction plates in a clutch pack will vary depending upon torque load. It uses the Lepelletier planetary system and is gear ratio sensitive requiring correct transmission interchange. The advantage of this Lepelletier arrangement is its simple, space-saving and lightweight design. lt combines a simple planetary gearset with a subsequent Ravigneaux arrangement. This makes six speeds possible with only five shifting elements. The computer controls both shift timing and shift feel with the use of solenoids. The computer monitors gear ratio through the Input and Output shaft Hall Affect Speed Sensors. It also can determine the rate of change and adapt the shifts as friction elements wear.

AUTOMATIC TRANSMISSION SERVICE GROUP

3


Selector Lever The appearance of the selector lever may vary for different vehicles however, the operation and the function remains the same with the use of the TF60-SN. The steering wheel paddles are available as options and it too can vary in appearance with different vehicles.

Selector Lever Positions and Operation P - Park Before the selector lever can be moved out of this position, the ignition must be switched on and the foot brake must be pressed. Additionally, the locking button on the selector lever must be pressed.

Lock Button

R - Reverse To shift into this gear, the locking button must be pressed. N - Neutral The transmission is in idle in this position. If the selector lever is in this position for a long time and the vehicle is driven at less than 3 mph (5 km/h), the foot brake must be pressed again to leave this position. D - Drive

Thumb Paddles Downshift Button (E439)

Upshift Button (E438)

In this position, the forward gears are shifted automatically. S - Sport The locking button must be pressed to shift into the selection range “S.” The control module selects gears automatically according to a “sporty” characteristic curve.

-

+ and The Tiptronic functions are performed in the right selector gate and at the steering wheel paddles.

4


+ ATSG


Tiptronic Upshift (E438) and Downshift (E439) Buttons on Steering Wheel These operational buttons are found in the steering wheel on the left and right side. Upshifting and downshifting occurs by operating these buttons. The shift signals are an input to the Transmission Control Module (TCM - J217) which in turn controls the shifting of the transmission. Signal Utilization If the Tiptronic buttons in the steering wheel are operated in automatic mode, the transmission control enters Tiptronic mode. If the buttons are not operated, the transmission control returns to automatic mode after a predetermined amount of time. Effect of Signal Failure In case of a signal failure, no Tiptronic functions are possible using the steering wheel buttons. Tiptronic Shifting Strategy - Automatic upshifting when maximum RPM is reached. - Automatic downshifting when the RPM’s fall below the minimum RPM. - Kick down downshifting - Acceleration from standstill in second gear by selecting 2nd before accelerating.

The driving conditions, as well as driving resistance such as climbing hills, or road profile as in curves and the driver type meaning the manner in which the driver is driving the car are all evaluated by the TCM and adapts accordingly. The basic parameters for the calculation of gear selection have not fundamentally changed compared to previous automatic transmissions. Due to constantly increasing integration of the transmission control with other vehicle systems such as the engine, ESP, or the steering angle, a large amount of information is available to better define the current driving conditions and the driving manner. Sport Mode “S” A performance oriented shifting program is available to the driver in selector lever position “S”. If the TCM recognizes the selector lever in the “S” position, the shifting characteristic curves are reallocated to higher engine speeds. This increases the driving dynamic. The DSP also adapts to driver input (driver type evaluation) and driving situations in the “S” position. The “S” mode contains the following characteristics: - If the selector is placed in “S” while driving with an unchanging accelerator pedal position, a downshift occurs within defined limitations. - To achieve a more direct reaction to the movements of the accelerator pedal, the torque converter lock-up clutch applies as soon as possible.

- Upshift prevention or downshift prevention. Dynamic Shifting Program (DSP) This automatic transmission has the latest generation Dynamic Shifting Program DSP.


5


Emergency Mode In mechanical emergency running mode, 3rd gear is always engaged.

40 50

System pressure is controlled to the maximum value; the shifting elements are pressurized to maximum shifting pressure. This results in a hard shift when engaging the driving mode. The torque converter lock-up clutch remains off.

30

PRNDS

20 10

60

Reverse gear is available (R-gear locking is not active).

60 50

If the transmission is already in 4th, 5th or 6th gear, the current gear is maintained until the selector lever is placed into the neutral position or immediately after an ignition cycle. When starting off, 3rd gear is always engaged whether the selector lever is in the D or S position.

70

40

1/2

90 50

130

0

1/1

0

Operating Ranges of the Torque Converter Lock-Up Clutch Depending on driving mode, engine load and vehicle speed, the torque converter lock-up clutch is first regulated with a minimal slip and subsequently completely applied. During regulated operation, fuel consumption is reduced compared to a released torque converter lock-up clutch and drive comfort is improved compared to a fully applied clutch.

Towing When towing, the ATF pump is not operated, and therefore rotating components are not lubricated. To avoid severe damage to the transmission, the following conditions must be met: - The selector lever must be in the “N” Neutral position. - Towing speed must not exceed 31 mph (50 km/h).

Using Tiptronic in “S” mode, the torque converter lock-up clutch is applied as soon as possible. The direct power connection between engine and transmission improves sporty driving feel. In a climbing mode, the torque converter lock-up clutch applies in 2nd gear. When ATF temperature is above 130º C, the regulated apply feature is prohibited and an immediate apply occurs. This helps the ATF maintain a lower thermal load and cools it down.

For Jetta and Passat, if the battery is disconnected or discharged, the selector lever emergency release must be operated to shift the selector lever out of “P” into “N”.

Engine Load

- Vehicle must not be towed further than 31 miles (50 km). TCC - OFF

Regulated TCC Apply Vehicle Speed

6


Fully Applied TCC


Application Chart F1

K3 K1 B1

B2

K2

CLUTCH APPLICATION CHART Gear 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear Rev Gear

K1 X X X X

K2

Component K3 B1

B2 X*

F1 X

X X X X X

X X X

X

* The B2 clutch is applied in Tiptronic Mode 1st gear only for engine braking.

Copyright © 2010 ATSG

Figure 1


7


Pressure Taps

K1

K2

Lube

B2

TCC Release


Figure 2

8



Pressure Taps

2400. 7540 2024330a

K3


Figure 3


9


Pressure Taps

B1


Figure 4

10



Pressure Taps

Lube


Figure 5


11

Technical Service Information TF60-SN PRELIMINARY INFORMATION Wiring Harness from 8 terminal Case Connector (ISS, OSS & TFT)

Internal Harness

CCP6A09212

CCP6A09214

ABY6A09412

FBX6A08574

DCB6A09064

9173 T5

GAU6A06894

EO

OSS Blue Clip Connector (G195) ISS White Clip Connector (G182)

Transmission Fluid Temp. Sensor (G93)

Wiring Harness from 14 terminal Case Connector (All Solenoids)

ISS G182 The Transmission Input Speed Sensor is a Hall Affect that produces a signal from the lugs of the K2 Clutch Drum. The TCM uses this information to control adaptation and gear monitoring. Should this sensor fail, the Engine RPM sensor is use as a back up. Lock-up clutch apply strategy may be affected. OSS G195 The Transmission Output Speed Sensor is a Hall Affect that produces a signal from the lugs on the Parking Gear. The TCM uses this information for the Dynamic Shifting Program (driving condition evaluation), vehicle speed, shift points and gear monitoring. Should this sensor fail, the speed signal from the ABS Control Module is used as a back up. TFT G93 Transmission fluid temperature is used to influence main line pressure and converter clutch strategies. A replacement value is taken from the ECT should this sensor fail. TCC and adaptations usually cease which typically leads to harder shifting. Copyright © 2010 ATSG Figure 6

12



Solenoid Identification N91 (#4 Sol.)

N93 (#6 Sol.)

N92 (#5 Sol.)

N282 (#9 Sol.)

N283 (#10 Sol.)

N90 (#3 Sol.)

CCP6A09212

CCP6A09214

ABY6A09412

FBX6A08574

T5

GAU6A06894

9173

Hydraulic Pressure Sender # 2 (G194)

DCB6A09064

EO

Hydraulic Pressure Sender # 1 (G193) N89 (#2 Sol.)

N88 (#1 Sol.)

Hydraulic Pressure Senders G193 and G194 The G193 and G194 are Normally Open transducers which closes when the K1or the B2 clutch circuit is charged. The G193specifically monitors the K1 clutch while the G194 monitors the B2 clutch. The use of these switches were eliminated in June of 2004. N88 and N89 Solenoid 1 (N88) and 2 (N89) are Normally Closed On/Off Solenoids and are used to control shifting of gears 4 through 6 and are sporadically and alternately activated during gear shifting. They are also used to control the B2 Brake apply in 1st gear Tiptronic mode for engine breaking. N90, N91, N92, N93, N282 and N283 Solenoid N92 controls the K1 clutch, Solenoid N91 controls the lock-up clutch apply in the torque converter, Solenoid N90 controls K3 clutch apply, Solenoid N93 regulates main line pressure, N282 controls K2 clutch apply and N283 controls the B1brake clutch apply. *See additional notes on page 52


Figure 7


13


Solenoid Case Connector

13

14 12 10 8 6 4

11 9 7 5 3 1

2

View looking into the 14 terminal transmission case connector

Solenoid Number

(Name)

Positive Meter Lead

Negative Meter Lead

Resistance

Terminal # (Wire Color)


(Ù Ohms)

Solenoid # 1

(N88)

1

(White)

Case Ground

10.0 - 16.0

Solenoid # 2

(N89)

2

(Black)

Case Ground

10.0 - 16.0

Solenoid # 3

(N90)

7

(Lt. Blue)

8

(Lt. Green)

4.0 - 8.0

Solenoid # 4

(N91)

11

(Lt. Green)

12

(Brown)

4.0 - 8.0

Solenoid # 5

(N92)

3

(Yellow)

4

(Purple)

4.0 - 8.0

Solenoid # 6

(N93)

13

(Green)

14

(Grey)

4.0 - 8.0

Solenoid # 9

(N282)

5

(Red)

6

(Blue)

4.0 - 8.0

Solenoid # 10 (N283)

9

(White)

10

(Black)

4.0 - 8.0

The internal wire colors are provided in the chart above.


Figure 8

14



TFT and RPM Sensor Case Connector

8 6 4

7 5 3 1

2

View looking into the 8 terminal transmission case connector Sensor ID

(Name)

Positive Meter Lead

Negative Meter Lead

Resistance



(Ù Ohms) 37.0 - 51.0 K Ù @ -30º C 5.0 - 8.0 K Ù @ 10º C

TFT (G93)

1

2

(Orange)

(Orange)

3.0 - 5.0 K Ù @ 25º C 230 - 265 Ù @ 110º C 100 - 120 Ù @ 145º C

(G182)

3

(White)

4

(Red)

5.0 M Ù*

OSS (G195)

5

(Tan)

6

(Blue)

5.0 M Ù*

PS1

(G193)

7

(N/A)**

Case Ground

Open

PS2

(G194)

8

(N/A)**

Case Ground

Open

ISS

The internal wire colors are provided in the chart above. *The ISS and OSS are Hall Affect Sensors and should be checked using a scope under operating conditions. The resistance values provided in the chart above came from new sensors. Resistance checks of these type of sensors at best would inform you of either open or grounded circuits within the sensor itself. ** Pressure Switches 1 and 2 are not from June 2004 and up. These are normally open switches and close when their respective circuits are charged. Copyright © 2010 ATSG Figure 9


15

Technical Service Information 8 Terminal Trans. Case Conn.

5

TCM J217

OSS

6 3

ISS

Typical VW Wiring

38 SP+ 14 Terminal Trans. Case Conn. N88

50 SP51 NIN+

4

39 NIN-

1

45 TFT +

S1

41

1

N89

TFT Sensor

S2

2

8

7 8

24 Press. Sw. 1 25 Press. Sw. 2

15

2

TFT N90

Some Models

S3+

30

7

S3 -

18

8 N91

Gear Lever Position Sensor

S4 +

5

11

S4 -

43

12

1 9 8

47 36 21

5

22

S5 +

3

3

7

10

S5 -

4

4

Tiptronic Switch

N92

N93

48

Data BUS On Board Diag. Interface

S6 +

31

13

S6 -

17

14

46 CAN-H CAN Communication

34 CAN-L Power Supply Relay

Fuse

27 IGN 28 IGN 3

Fuse

N282

S9 +

16

5

S9 -

32

6 N283

S10 +

4

9

S10 -

44

10

B+

2 1

GND

Battery Copyright © 2010 ATSG

Figure 10

16



TCM J215 Connector

View looking into the TCM (J217)

1

3

2

4

5

6

7

8

9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26

27

28

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

View looking into the 52 pin J217 connector Solenoid Number

(Name)

Positive Meter Lead

Negative Meter Lead

Resistance



(W Ohms)

Solenoid # 1

(N88)

41

(Black/Violet)

1or2

(Brown)

10.0 - 16.0

Solenoid # 2

(N89)

15

(Black/Grey)

1or2

(Brown)

10.0 - 16.0

Solenoid # 3

(N90)

30

(Yellow/Violet)

18

(Yellow/Green)

4.0 - 8.0

Solenoid # 4

(N91)

5

43

(Yellow/Blue)

4.0 - 8.0

Solenoid # 5

(N92)

42

(White/Violet)

6

(Violet/Green)

4.0 - 8.0

Solenoid # 6

(N93)

31

(Grey)

17

(Green/Grey)

4.0 - 8.0

Solenoid # 9

(N282)

16

(Brown/Violet)

32

(Green/Violet)

(Blue/Green)

(Blue)

44

(Violet/Yellow)

4.0 - 8.0 4.0 - 8.0


4

TFT (G93)

45

(Violet)

8

ISS

(G182)

51

(White)

39

(Brown)

5.0M

OSS (G195)

38

(White)

50

(Green)

5.0M

PS1

(G193)

24

(Violet/Grey)

1or2

(Brown)

Open

PS2

(G194)

25

(Green/Grey)

1or2

(Brown)

Open

(Violet/White)

See chart P.12

External harness wire colors are provided in the chart above and may vary depending on year, make Copyright © 2010 ATSG and model of vehicle. Figure 11


17


Solenoid Details

N90 - N92 - N93 - N282 - N283 Solenoid Operation

Solenoid Off

Solenoid On

X

X

50

50

X

C4

C4

.032”


Figure 12

18



Solenoid Details

N91 Solenoid Operation

Solenoid Off

Solenoid On

X

X

X

X

Solenoid Feed .032”

38 2D

X X

GAU6A06984

Solenoid Off

Solenoid On


Figure 13


19


Bench Testing the SLT and Shift Control Solenoids (N90 - N92 - N93 - N282 - N283)

5.6 mV

RPM

5.0 - 5.6 W W

W mA A

V

mA A

V

OFF

V A

mA

COM

W RPM

1

C4

50

+

2

OFF 12-21 W Bulb

C4

50

Valve should stroke

ON


Figure 14

20



Bench Testing the SLU Solenoid (N91)

5.6 mV

RPM

5.0 - 5.6 W W

W mA A

V

mA A

V

OFF

V A

mA

COM

W RPM

1

2D

38

+

2

OFF

GAU6A06984

12-21 W Bulb

2D

38

Valve should stroke

GAU6A06984

ON


Figure 15


21


Bench Testing S88 and S89

11 - 15 W

12.7 W mV

RPM

W mA A

V

S88 and S89 are Normally Closed Solenoids. Without electricity the inlet port is blocked and the outlet port is open to exhaust.

mA A

V

OFF

V A

mA

COM

W RPM

Ex In

Out

X OFF

ON Solenoid should open Copyright © 2010 ATSG

Figure 16

22



Passage I.D.

Pump Inlet

Pump Outlet

Blocked by Pump

B1

Front Planet Lube (1)

K1 K3

TCC Release

Cooler Return To VB (8) Through Pump

TCC Apply To Cooler from VB (1) Differential Lube From VB (1)

Case passage ID with the heat exchanger attached to the transmission

TCC Release Pressure Tap

B2

Lube

K2

K1 Pressure Tap To B1 Pressure Tap



TCC Apply


TCC Release K3 K1

B1

Pump Outlet

Pump Inlet Copyright © 2010 ATSG

Figure 17


23


Passage I.D. Converter Case Cover

Cooler Return Pipe To VB (2) Through Pump Trans Cooler Cooler Return To VB (1) Through Pump


Cooler In From VB (5) Differential Lube From VB (3) To Cooler From VB (3)

Differential Lube From VB (2)

Pipe To Cooler From VB (4)

Transmission Case Cover

To B1 Pressure Tap Cooler Return To VB (4) Through Pump

7

Cooler Return To VB (7) Through Pump Front Planet Lube (2) K3

TCC Apply K1 B1 To Cooler From VB (2)

TCC Release

Blocked Pump Inlet Pump Outlet by Pump Figure 18

24




Passage I.D.

Pump Inlet

Pump Outlet

Blocked by Pump

B1


K1 K3

TCC Release

External Cooler Return To VB (2)

TCC Apply To External Cooler from VB (1)

Cooler Lube Filter

Case passage ID with the heat exchanger (cooler) separate from the transmission


TCC Release Pressure Tap

B2

Lube

K2

K1 Pressure Tap To B1 Pressure Tap

To External Cooler Through Pump (6)


TCC Apply


TCC Release K3 K1

B1

Pump Outlet

Pump Inlet Copyright © 2010 ATSG

Figure 19


25

Technical Service Information TF60-SN PRELIMINARY INFORMATION To external Cooler From Pump (9)

Passage I.D. Converter Case Cover

To external cooler (5)

External Cooler Return To VB (1)

Differential Lube From VB (3) To External Cooler From VB (3)


Pipe To External Cooler From VB (4)

Transmission Case Cover

To B1 Pressure Tap To external Cooler Through Pump (7) 7

To external Cooler From Pump (8) Front Planet Lube (2)

TCC Apply

K3 K1 B1 To External Cooler TCC From VB (2) Release

Blocked Pump Inlet Pump Outlet by Pump Figure 20

26




K1 Clutch Drum Assembly


Figure 21


27




Figure 22

28





Figure 23


29


B1 Clutch Brake Assembly B1 Clutch Brake Assembly

This end face pump. The piston to apply this clutch is in the pump. There is no snap ring as the caged piston return spring assembly sits between the piston and the cushion plate retaining the assembly.

Cushion Plate (Sits like a cone

)

3

2.4mm (0.95”)

2.9mm (0.113”)

Bottom Plate is stepped with stepped side down


Figure 24

30



B2 Clutch Brake Assembly B2 Clutch Brake Assembly

3.6mm (0.142”) 2

Piston sits in the bottom of the case

3.1mm (0.122”)


Figure 25


31


Sprag Rotation F1 Low One-Way Clutch

Outer race held stationary by case

Inner race should rotate in a clockwise direction (The front planetary is integral to the sprag’s inner race. Using the carrier’s pockets as shown, the inner race rotation can be easily checked by hand )


Figure 26

32



VW Technical Data Manufacturer

AISIN Co., LTD. Japan

Transmission Type

Electro-hydraulically controlled 6-speed planetary gear with hydrodynamic torque converter and traction controlled torque converter lock-up clutch for front wheel drive and transverse installation.

Control

Hydraulic control module (Valve Body) in oil sump with an external electronic control module. Dynamic Shifting Program (DSP) with separate Sport program in “Position S” and the Tiptronic shifting program for manual gear change (optional with Tiptronic steering wheel)

Torque Performance

Up to 332 lbs-ft (450 Nm), depending on version

Intermediate drive for code letters GSY/GJZ

No. of teeth 52/49 = 1.061

Final Drive GSY

No. of teeth 61/15 = 4.067

Final Drive GJZ

No. of teeth 58/15 = 3.867

ATF Specification

G 052 025 A2

Filing amount

7.4 quarts (7.0 liters) [initial fill] lifetime filling

Weight

Approximately 182 lbs. (82.5 kg).

Length

Approximately 13.8 inches (350 mm)

Spread

6.05

Depending on engine type, overall ration is configured as 5+E transmission or as a 6 speed transmission For the 5+E transmission, the highest speed is reached in 5th gear. The 6th gear reduces engine speed, improves driving comfort and reduces fuel consumption: For the 6 speed transmission configuration, the higest speed is reached in 6th gear. The 6th gear lowers transmission gear ratio and increases driving dynamics. Figure 27


33


Fluid Level

Check and Fill Plug

Fluid Level Stand Pipe


Figure 28

34


Technical Service Information TF60-SN NO 4th, 5th, 6th OR REVERSE Complaint: After transmission service which required solenoid harness removal, the vehicle no longer has 4th, 5th, 6th or Reverse. When the external wiring harness is unplugged from the transmission, reverse gear is obtainable. Cause:

Solenoid N88 and N89 were accidently cross connected.

Correction: Switch the connector to their appropriate positions. The white wire connector goes to solenoid N88 and the black wire connector goes to the N89 solenoid (See Figure 29). Note: Many solenoids may be easily cross connected causing a variety of shift or no shift complaints. Refer to pages 36 for another example of incorrect cross connect mistake.

CCP6A09212

CCP6A09214

ABY6A09412

DCB6A09064

FBX6A08574

T5

N89 Black Wire (#2 Sol.)

9173

GAU6A06894

EO

N88 White Wire (#1 Sol.)


Figure 29


35

Technical Service Information VW/AUDI 09M/09M TF60-SN NO REVERSE NEUTRALS IN THIRD

COMPLAINT:

After overhaul, VW and Audi vehicles equipped with the 09G/09M transaxle may exhibit a complaint of No reverse and a neutral on the upshift to third gear.

CAUSE:

The cause may be, that during overhaul the internal harness for the solenoids was routed incorrectly allowing the Red and Blue wires, which are supposed to be connected to N282, to be easily connected to N90, and the Lt. Green and Lt. Blue wires, for N90 to be connected to N282 (See Figures 31 and 32). Refer to Figure 30 to see the Solenoid and Clutch application chart. Notice that N90 is Off when the K3 Clutch is On, also notice that N282 is On in both reverse and third gear which causes the no reverse and the neutral in third.

CORRECTION: To correct this condition, refer to Figure 32 and ensure that the internal harness for the solenoids is routed like shown. Figure 33 shows the terminal layout for all the solenoids and also gives all the wire colors for each individual solenoid. The chart can also aid in terminal identification if the wire colors are different than what is listed.

36


Technical Service Information

SOLENOID LOCATIONS N91 (#4 Sol.)

N93 (#6 Sol.)

N92 (#5 Sol.)

N282 (#9 Sol.)

N283 (#10 Sol.)

N90 (#3 Sol.)

CCP6A09212

CCP6A09214

FBX6A08574

DCB6A09064

N89 (#2 Sol.)

9173 T5

GAU6A06894

ABY6A09412

EO

N88 (#1 Sol.)

SOLENOID & CLUTCH APPLICATION CHART Pressure Control Solenoids

Gear 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear Rev Gear

Component N92 N282 N90 N283 N93 N91 K1 K2 K3 B1 B2 F1 S-5

S-9

S-3

S-10

S-6

Off Off Off Off On On On

On On On Off Off Off On

On On Off On Off On Off

On Off On On On Off On

PWM PWM PWM PWM PWM PWM PWM

S-4

PWM PWM PWM PWM PWM

On On* On On On On On On On On On On On On On

* The B2 clutch is applied in Tiptronic Mode 1st gear only for engine braking.


Figure 30


37

Technical Service Information INCORRECT Internal Harness Routing Transmission Fluid Temp. Sensor (G93)

CCP6A09212

CCP6A09214

ABY6A09412

FBX6A08574

DCB6A09064

GAU6A06894

EO

9173 T5

OSS Blue Clip Connector (G195)

Wiring Harness from 8 terminal Case Connector (ISS, OSS & TFT)

Solenoid #3 (N90)

Solenoid #9 (N282)


ISS White Clip Connector (G182)

Note: When the harness is routed incorrectly, the Red and Blue wires, which are supposed to be connected to N282, can be easily connected to N90, and the Lt. Green and Lt. Blue wires, for N90 can be connected to N282.

Figure 31

CORRECT Internal Harness Routing

Solenoid #3 (N90)

Solenoid #9 (N282)

Transmission Fluid Temp. Sensor (G93)

CCP6A09212

CCP6A09214

ABY6A09412

FBX6A08574

DCB6A09064

GAU6A06894

EO

9173 T5

OSS Blue Clip Connector (G195)

Wiring Harness from 8 terminal Case Connector (ISS, OSS & TFT)

09M models route the upper and lower harnesses from the right side of the valve body with a hold down bracket.


ISS White Clip Connector (G182)


38

Figure 32



14 TERMINAL CASE CONNECTOR AND INTERNAL HARNESS I.D.

13

14 12 10 8 6 4

11 9 7 5 3 1

2

View looking into the 14 terminal transmission case connector

Solenoid Number

(Name)

Positive Meter Lead

Negative Meter Lead

Resistance



(WOhms)

Solenoid # 1

(N88)

1

(White)

Case Ground

10.0 - 16.0

Solenoid # 2

(N89)

2

(Black)

Case Ground

10.0 - 16.0

Solenoid # 3

(N90)

7

(Lt. Blue)

8

(Lt. Green)

4.0 - 8.0

Solenoid # 4

(N91)

11 (Lt. Green)

12

(Brown)

4.0 - 8.0

Solenoid # 5

(N92)

3

4

(Purple)

4.0 - 8.0

Solenoid # 6

(N93)

13 (Green)

14

(Grey)

4.0 - 8.0

Solenoid # 9

(N282)

5

(Red)

6

(Blue)

4.0 - 8.0


9

(White)

10

(Black)

4.0 - 8.0

(Yellow)


Figure 33


39

Technical Service Information TF60-SN SLIPPING 3-4 OR NEUTRAL 3-4 COMPLAINT: Before or after a transmission rebuild, the transmission exhibits a slipping or flared 3-4 shift or a neutral shift into 4th followed up by going into a failsafe condition. CAUSE:

At the bottom of the case, there is a steel ring sleeve that is pressed on to the aluminum case (See Figure 34). This ring sleeve contains K2 clutch apply pressure. The K2 clutch is applied for 4th, 5th and 6th gears. This sleeve with the K2 clutch sealing rings becomes loose and can spin. Depending upon how loose or how much it has spun determines the severity of the 3-4 shift complaint.

CORRECTION: If the case has not been severely damaged by the sleeve spinning around, ATSG has sleeves that were manufactured in the Netherlands which have a slightly tighter fit as well as K2 clutch drum pilot bushings. The repair is to dress up the case, heat up the sleeve and carefully place the sleeve into position. These sleeves are also available through Sonnax.

K2 CLUTCH STEEL SEALING RING SLEEVE


Figure 34

40


Technical Service Information TF60-SN LOSS OF LUBRICATION Complaint: An apparent loss of lubrication fluid causing premature failure of the transmission’s drivetrain immediately after a main case or valve body exchange. Cause:

There are two different style lubrication systems with the TF60-SN (09G/09M) transmissions. One has the cooler known as the heat exchanger mounted on the converter housing case while the other has a remote cooler with push in cooler pockets in the main case as seen in figure 35. As a result, there are two different main case and valve body to case spacer plate configurations due to the re-routing of the cooler circuit. Figure 36 shows the matching spacer plate to case with the heat exchanger attached to the transmission. Figure 37 shows the match set for a remote heat exchanger. If a mismatch of valve body to main case occurs lubrication fluid is lost causing immediate failure to the drive train.

Correction: Make the necessary repairs to the drivetrain and use a matched main case and valve body for the style lubrication system being worked on.


41


Converter housing case half with heat exchanger.

Trans Cooler

Cooler Return Cooler In

Converter housing case half without heat exchanger.

To external heat exchanger (Cooler) (cooler line pockets are in the main case)

External heat exchanger (Cooler) return


Figure 35

42



Main case half for a heat exchanger mounted on the converter housing.

Heat exchanger (Cooler) Return

To heat exchanger (cooler) mounted on the converter housing case half.

Main spacer plate to case for a case which has an attached heat exchanger

Heat exchanger (Cooler) Return into the valve body for lubrication distribution


Figure 36


43


Main case half for a remote heat exchanger.

External Heat Exchanger (Cooler) Return To Remote Heat Exchanger (Cooler)

Cooler Lube Filter

Main spacer plate to case for a case which has a remote heat exchanger

Remote heat exchanger (Cooler) Return into the valve body for lubrication distribution


Figure 37

44


Technical Service Information VW/AUDI 09M/09M TF60-SN HARSH REVERSE THIRD &FIFTH GEAR COMPLAINT: Before or after overhaul, vehicles equipped with the 09M/09G-TF60-SN transmission may exhibit a complaint of harsh Reverse, Third and Fifth gear when hot. CAUSE:

The cause may be, a worn bonded balance piston located in the K3 Clutch drum. See the cross-sectional view in Figure 38. Explanation: The balance piston function is to hold "counter" or "back" pressure on the K3 Apply piston. The balance piston is fed from the lube circuit, and its purpose is to provide a small amount of pressure to assist the release of the K3 Clutch. It also acts as an accumulator during application of the K3 Clutch. See Figures 39 and 40. The bonded piston has three notches where the retaining snap ring is located allowing a controlled leak of this pressure, and when the bonded rubber is worn this will allow a larger volume of pressure lost which can cause the harsh applications.

CORRECTION: Refer to Figure 41 and replace the bonded K3 balance piston. Note: At the time of this printing, there are "No" aftermarket replacement pistons available and the dealer only sell parts for this transmission as an assembly.

K3 CLUTCH CROSS-SECTIONAL VIEW Pump K3 Clutch Drum

K3 Clutch Apply Piston K3 Clutch Balance Piston K3 Clutch Balance Piston Controlled leak

Stator Support

K3 Clutch Piston Feed

K3 Clutch Balance Piston Feed (Lube circuit) Copyright © 2010 ATSG

Figure 38


45

Technical Service Information K3 CLUTCH "OFF" Pump K3 Clutch Drum


Stator Support



Figure 44

K3 CLUTCH "ON" Pump K3 Clutch Drum


Stator Support



Figure 40

46


Technical Service Information K3 CLUTCH DRUM EXPLODED VIEW

K3 BALANCE PISTON

K3 CLUTCH ASSEMBLY

K3 RETURN SPRING

K3 CLUTCH PISTON

K3 CLUTCH DRUM


Figure 41


47

Technical Service Information VW/AUDI TF60-SN/09-G 09-M DESCRIPTION OF DATA BLOCKS CONTROL MODULE SELECTION 02 Auto Trans GROUP SELECTION 08 Measured Blocks

Data Block 001

Engine Speed

Trans RPM G182 (Input)

Trans RPM G195 (Output)

xxxx

xxxx

xxxx

Driving Mode

Park = 0 Reverse = R Neutral = 0 Drive = 1H-6H 3M-6M (Tcc) Trans RPM G182 (Input)

002

xxxx

G182 (Input) Voltage 1.440v

Trans RPM G195 (Output)

G195 (Output) Voltage

xxxx

1.440v

.50v-1.440v Accelerator Driving Manner Pedal Position%

003

0-100%

.50v-1.440v VSS km/h xxxx Park = 0 Reverse = R Neutral = 0 Drive = 1H-6H 3M-6M (Tcc)

DS= Drive TT= Manual

Accelerator Selector Lever Pedal Position%

004

Driving Mode

Declination Recognition

Driving Mode

0-100% P-R-D S or Manual

Level DW (downhill) UP (uphill)

Park = 0 Reverse = R Neutral = 0 Drive = 1H-6H 3M-6M (Tcc)

*Note= There are many duplications of information listed in the data blocks this is to aid the technician when monitoring specific groups Copyright © 2010 ATSG

Figure 42

48


Technical Service Information MEASURED BLOCKS CONTINUED 08 Measured Blocks

Data Block 005

Hill Driving Factor

Throttle Valve Factor

0.0%

0.0%

Accelerator Throttle Dynamic Pedal Position% Index 0-100% Changes based on snap of Throttle

006

ATF Temp G93

Specified Current (TCC) Solenoid Valve 4 (N91)

Lock-up Clutch Slip

Lock-up Clutch Slip

84.0°C

.200A

xxxx

xxxx

Solenoid Valve 5 (N92)




.100A Fully "Off" .980A Fully "On" See Note*




(LP) Solenoid Valve 6 (N93)

(TC) Solenoid Valve 4 (N91)

Solenoid Valve 1 Solenoid Valve 2

Battery Voltage

00000000

13.6V

007

008 .200A to .940A Based on engine load

009

.200A to 1.0A Based on load and PCM TCC strategy

Brake Pedal Switch

Kick-down Switch

00000000

00000010

00000000=Off 00000011=On

May be model dependant no state change

N89 N88

00000000 0= Off 1= On 11- for M1 10- for Tcc On

Selector Lever

00000000 P-R-N-D Manual

*Note= Amperage changes during shift transitions

Figure 43

49

Multifunction Switch


P=00001001 R=00001100 N=00000101 D=00000110 S=00001111 Copyright © 2010 ATSG

Technical Service Information MEASURED BLOCKS CONTINUED 08 Measured Blocks

Data Block 010

011

ATF Temp G93

ATF Temp Voltage

Trans Condition

Voltage Supply

94.0°C

.60V

Blank

13.50V

Brake Switch Condition (F47)

Locking SL

Speed

Selector Lever

0.0km/h

OFF or ON P/N =Locked Press Brake = --

Selector Lever

Tiptronic Recognition

P-R-N-D Manual

P-R-N-D= Blank Manual= M

Selector Lever

Multifunction Switch

P-R-N-D Manual Driving Mode

012

013

P=00001001 R=00001100 N=00000101 D=00000110 S=00001111

Accelerator Pedal Position%

014

Park = 0 Reverse = R Neutral = 0 Drive = 1H-6H 3M-6M (Tcc) Tiptronic Tiptronic Recognition Recognition 00000000

00000000 P-R-N-D Manual

0-100%

Transferrable Torque 100.0%

P-R-N-D= Blank Manual= M UP Button =UP DN Button = Down

D=00000000 M=00001000 UP=00011000 DN=00001100

Idle Switch Condition

APP Condition 00000000

N/A Off Idle=00000000 At Idle=00000001


Figure 44

50


Technical Service Information SOLENOID APPLICATION CHART RANGE

GEAR

SOLENOID Reverse Neutral

Park

Drive Manual 2H 1H 1H

3H 3M

4H 4M

5H 5H

6H 6M

SV5-N92 (K1)

.100A

.980A

.980A .100A .100A .100A .100A .100A .980A .980A

SV9-N282 (K2)

.100A

.980A

.980A .980A .980A .980A .980A .100A .100A .100A

SV3-N90 (K3)

.980A

.100A

.980A .980A .980A .980A .100A .980A .100A .980A

SV10-N283 (B1) .980A

.980A

.980A .980A .980A .100A .980A .980A .980A .100A

SV6-N93 (LP) SV4-N91 (TC-PWM)

.980A

.980A

.200A

.200A

.980A .980A .740A .860A .980A .980A .740A .740A .200A .200A .200A .200A .200A .200A .200A .200A .990A .990A .990A .990A

SV2-N89

0

0

0

0

1

0

SV1-N88

0

0

0

0

1

0

3H=0 4H=0 5H=0 6H=0 3M=1 4M=1 5M=1 6M=1

0*-1

0*-1

0*-1

0*-1

Description of terms: .100A= Very Low amperage Solenoid OFF .980A= Very High amperage Solenoid ON

SV1&2-N88&89 0 =OFF 1=ON 0*-1= OFF or ON During shift transitions

3H = 3rd Gear TCC OFF 3M = 3rd Gear TCC ON (This applies to gears 3-6)

Special Notes: 1. Solenoid Valves 3,5,9 and 10 are Normally Applied which applies the component they are in charge of when they are Off. They are Energized (On) to turn the component they are in charge of Off. These Solenoids are also Modulated to control the apply and release rates. Consult the Clutch Application Chart below and compare the amperage to Clutch/Brake app. Example: Solenoid Valve 10 (N283) is pulsed Off during the 1H-2H transition and the Amperage will drop from .980A in 1H to .690A to .300A to .100A when the shift is finally completed into 2H to control the apply rate and shift feel of the B1 Brake. 2. Solenoid Valve 6 -N93 is modulated based on engine load. Low line pressure will indicate an amperage of 1.0 to .980A. Amperage will drop to increase line pressure. 3. Solenoid Valve 4-N91 is modulated to control Torque Converter Apply rate, but is dependant on Solenoid Valve 2-N89 to apply the TCC. There will be situations where during Manual shifts in Tiptronic mode, SV4-N91 amperage will indicate .500 to .700 and the TCC will be Off as Solenoid Valve 2-N89 is "0" which indicates Off.

CLUTCH APPLICATION CHART Gear 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear Rev Gear

K1 X X X X

K2

Component K3 B1

B2 X*

F1 X

X X X X X

X

X X X * The B2 clutch is applied in Tiptronic Mode 1st gear only for engine braking.


Figure 45


51


Additional Solenoid Details N88 Solenoid (#1 Solenoid) The N88 Solenoid is an On/Off solenoid and is On and Open in gears 4th through 6th. If this solenoid fails Closed (in the Off state), 4th through 6th will not be available. N89 Solenoid (# 2 Solenoid) The N89 Solenoid is also an On/Off solenoid and is On and Open to apply the converter clutch. When both the N88 and N89 solenoids are energized at the same time, the B2 brake clutch is applied in Tiptroni 1st Gear (Manual Low). If the N89 Solenoid fails in the Closed (in the off state) there will be no converter clutch apply and no engine breaking in Tiptronic 1st gear (manual Low). N90 Solenoid (# 3 Solenoid) The N90 Solenoid is a normally applied pulse/width modulated solenoid controlling the apply of the K3 Clutch. When this solenoid is fully off, the K3 clutch is fully applied. If this solenoid fails in the off (Normally Applied) position, 3rd, 5th and Reverse shifts may be firm. N91 Solenoid (#4 Solenoid) The N91 Solenoid is a normally applied pulse/width modulated solenoid controlling the apply and release of the Converter Clutch. When this solenoid is fully off, the converter clutch is fully released. If this solenoid fails in the off (Normally Applied) position, there will be no converter clutch application. Solenoid N92 (#5 Solenoid) The N92 Solenoid is a normally applied pulse/width modulated solenoid controlling the apply of the K1 Clutch. When this solenoid is fully off, the K1 clutch is fully applied. If this solenoid fails in the off (Normally Applied) position, 1st through 4th shifts may be firm. Solenoid N93 (#6 Solenoid) The N92 Solenoid is a normally applied pulse/width modulated solenoid controlling the main line pressure. When this solenoid is fully off maximum line pressure is observed. If this solenoid fails in the off (Normally Applied), all shifting may be harder. Solenoid N282 (#9 Solenoid) The N282 Solenoid is a normally applied pulse/width modulated solenoid controlling the apply of the K2 Clutch. When this solenoid is fully off, the K2 clutch is fully applied. If this solenoid fails in the off (Normally Applied) position, 4th, 5th and 6th shifts may be firm. Solenoid N283 (#10 Solenoid) The N283 Solenoid is a normally applied pulse/width modulated solenoid controlling the apply of the B1 Clutch. When this solenoid is fully off, the B1 clutch is fully applied. If this solenoid fails in the off (Normally Applied) position, 2nd and 6th shifts may be firm. Figure 46

52


Technical Service Information VW 09A & 09G 2-3 FLARE -HARSH 3-4 DOUBLE BUMP 2-3 / DOWNSHIFT CLUNKS COMPLAINT:

After overhaul, vehicles equipped with the 09A (JF506E) may exhibit a 2-3 flare and a harsh application into 4th. On vehicles equipped with the 09G (TF60-SN) the complaint may be, a double bump on the 2-3 and or downshift clunks.

CAUSE:

The cause may be that the clutch adaptives were not reset.

CORRECTION: Using a capable scan tool go into the engine side and reset all the adapts. The following steps will show how to reset the adaptives thru the lap top based Vag Com Diagnostic System. It will be necessary to take a 15 shift cycle road test after performing this reset to fine tune the adapts. Note: Early model 09A require a capable scan tool to reset adapts. You can not drive them out! ATSG Highly recommends resetting adapts on all the above mentioned vehicles.

Step 1 This is the first screen that will appear after the vehicle is plugged into the Lap-top. Press Select to select control module

x

VCDS: Main Screen

VCDS Release 805.1 Select Control Module

Auto-Scan

Control Module Finder

Select an Individual Control Module such as Engine, ABS, Airbag, etc.

An automatic scan of all controllers for Fault Codes.

Scans an address range for ISO9141 compliant control modules.

Select

Auto-Scan

Control Module Finder

OBD-ll Functions

Applications

Program Options

Generic OBD2 Mode. Retrieve and clear faults and freeze frame, obtain live data.

Features consisting of several basic commands, like transport mode.

Select Comm Port. Set Debug and Protocol Options, etc.

Applications

OBD-ll

Options

Exit

About


Figure 47


53

Technical Service Information Step 2- Select 01-Engine

x

VCDS Release 805.1: Select Control Module

VCDS

Select Control Module Common

Drivetrain

Chassis

Comfort/Conv.

Electronics 1

Electronics 2

01-Engine

02-Auto Trans

03-ABS Brakes

08-Auto HVAC

09-Cent. Elect.

15-Airbags

16-Steering Wheel

17-Instruments

18-Aux .Heat

19-CAN Gateway

22-AWD

25-Immobilizer

35-Centr. Locks

37-Navigation

45-Inter. Monitor

45-Central Conv.

55-Xenon Range

56-Radio

Direct Entry Address Word (01-7F):

Go Back

Go!

Step 3- Select Adaption - 10

x

VCDS Release 805.1: 01-Engine,Open Controller

VCDS

Comm Status IC=1 TE=0 RE=0

Open Controller

Protocol:KW1 281 Controller Info VAG Number:

XXX XXX XXX XX

Soft. Coding:

XXXXX

Component:

XX XX XXX

Shop #.

X

XXXX

XXX XXXXX

XXXXXXXXXXXXXXXX XXXXXXXXXXXX

Extra: Extra: Basic Functions

Advanced Functions Refer to Service Manual!

These are "Safe"

Fault Codes-02

Readiness- 15

Login - 11

Coding - 07

Measured Blocks-08

Advanced ID - 1A

Basic Settings - 04

Adaption - 10

Single Reading-09

Adv. Meas. blocks

Output Tests - 03

Security Access-16

Close Controller, Go Back - 06


54

Figure 48


Technical Service Information Step 4- 00 will show up in the Channel window. Press the Read button

x


VCDS


Open Controller

Protocol:KW1 281 Controller Info

VCDS Release 805.1: 01-Engine, Adaptation

VAG Number:

XXX XXX XXX XX

Soft. Coding:

XXXXX

Component:

XX XX XXX

X

XXXX

x

XXX XXXXX

Shop #.

XXXXXXXXXXXXXXXX XXXXXXXXXXXX

Extra: Extra: Channel Up Basic Functions 00 These are Dn "Safe" Stored value

Fault Codes-02

Advanced Functions Add to Log Refer to Service Manual!

Read

Readiness- 15

New value Measured Blocks-08 UpAdvanced ID - 1A

Single Reading-09 Test value

Dn Adv. Meas. blocks

Login - 11

Coding - 07

Basic Settings - 04

Adaption - 10

Output Tests - 03

Security Access-16

Close Controller, Go Back - 06 Save

Test

Done, Go Back

Step 5- 000 will show up in the New and test value windows. Channel 00 resets ALL Factory DefaultsPress Save

x


VCDS


Open Controller



XXX XXX XXX XX

VAG Number: Soft. Coding:

Note: SAVE Extra:

Component:

XX XX XXX

X

XXXX

x

XXXXX XXX XXXXX Shop #. Ch. 00 Resets All Factory Defaults XXXXXXXXXXXXXXXX XXXXXXXXXXXX

Extra: Channel Up Basic Functions 00 These are Dn "Safe" Stored value Fault Codes-02 ---

Advanced Functions Add to Log Refer to Service Manual!

Read

Readiness- 15

Login - 11

Coding - 07

New value Measured Blocks-08 UpAdvanced ID - 1A 000

Basic Settings - 04

Adaption - 10


Output Tests - 03

Security Access-16


000

Test


Done, Go Back


Figure 49


55

Technical Service Information Step 6- Press Yes to save All Factory Defaults

x


VCDS


Open Controller



XXX XXX XXX XX

VAG Number:

XX XX XXX

Component:

X

XXXX

x

XXXXX XXX XXXXX Shop #. Ch. 00 Resets All Factory Defaults XXXXXXXXXXXXXXXX XXXXXXXXXXXX

Soft. Coding:

Note: SAVE Extra: Extra:

x

VCDS: ADP Save Conf. Channel Up Basic Functions Advanced Functions Add to Log Read 00 These are "Safe" Refer to Service Manual! Save Value: 0 Dn To Channel: 00 Stored value Fault Codes-02 Readiness- 15 With WSC: 00066 Login - 11 Coding - 07 --Are You SURE? New value Basic Settings - 04 Adaption - 10 Measured Blocks-08 UpAdvanced ID - 1A 000 Yes No

?



Output Tests - 03

Security Access-16

000

Test


Done, Go Back

Note: It will be necessary to perform a 15 shift cycle road test after Factory Defaults are reset. This will fine tune the adapts. Copyright © 2010 ATSG

Figure 50

56


Technical Service Information VOLKSWAGEN "VAG" DIAGNOSTIC TROUBLE CODES DTC 00258 00260

DESCRIPTION N88-SV1 Shift Solenoid 1, Circuit Error (Open or Short) N89-SV2 Shift Solenoid 2, Circuit Error (Open or Short)

00262 00264 00266 00268

N90- SV3 K3 Control Solenoid Circuit Error (Open or Short) N91-SV4 Torque Converter Clutch PWM Solenoid, Circuit Error (Open or Short)

00293 00300

Transaxle Range (TR) switch F125, circuit malfunction (Implausible signal) Transmission Fluid Temp, (G93) circuit malfunction (Open or Short)

00348

N282-SV9, K2 Control Solenoid Circuit Error (Open or Short)

00349 00364 00453 00529

N283-SV10, B1 Control Solenoid Circuit Error (Open or Short) System Voltage to Low Function restriction because of excess Trans Fluid Temp. TCM to ECM Error, No Engine Speed Signal G28

00541 00777

ATF temp to high Throttle Position Sensor, No Signal CAN bus connection interupted

01045 01166 01192

Tiptronic Switch F189 implausible signal Engine Torque signal no signal from ECM Torque Converter Clutch mechanical fault (slip)

01236

Selector Lever Lock Solenoid, Circuit Error N110 (Open or Short)

01312 01314

Drive Train Data Bus Fault, No Communication Engine Control Module, DTC present

01316 01679 01680

ABS Module, No Communication, or ignition switched on with TCM unplugged Speed signal from ABS Front Left wheel implausible Speed signal from ABS Front Right wheel implausible

01681

Speed signal from ABS Rear Left wheel implausible

01682 01683 65535

Speed signal from ABS Rear Right wheel implausible Wheel speed signals/vehicle speed implausible Control Module Faulty, (TCM)

N92-SV5, K1 Control Solenoid Circuit Error (Open or Short) N93-SV6 Pressure Control Solenoid, Circuit Error (Open or Short)


Figure 51


57

Technical Service Information VOLKSWAGEN "VAG" to obd11 DIAGNOSTIC TROUBLE CODES vag 16988

obd11 P0604

DESCRIPTION TCM faulty

16989 16997

P0605 P0613

17084

P0700

TCM faulty TCM faulty TCM faulty

17089 17090 17095

P0705 P0706 P0711

Multifunction Trans Range sensor F125 electrical fault Multifunction Trans Range sensor F125 implausible signal Trans Fluid Temp G93 fault in electrical circuit

17096 17097 17099

P0712 P0713 P0715

Trans Fluid Temp G93 signal too low Trans Fluid Temp G93 signal too high Input Speed sensor G182 circuit fault

17100

P0716

Input Speed sensor G182 Implausible signal

17101 17105

P0717 P0721

Input Speed sensor G182 no signal Output Speed sensor G195 circuit fault

17109

P0725

Engine Speed sensor G28 circuit fault from ECM

17113 17114 17115

P0729 P0730 P0731

Clutch of indicated gear is faulty (wrong ratio, slip) Clutch of indicated gear is faulty (wrong ratio, slip) 1st Gear (wrong ratio, slip)

17116

P0732

2nd Gear (wrong ratio, slip)

17117 17118 17119

P0733 P0734 P0735

3rd Gear (wrong ratio, slip) 4th Gear (wrong ratio, slip) 5th Gear (wrong ratio, slip)

17132 17135 17136

P0748 P0751 P0752

N91-SV4 Torque Converter Clutch PWM Solenoid, Circuit (Open or Short) N88-SV1 Shift Solenoid 1, Circuit Error (Open or Short to ground) N88-SV1 Shift Solenoid 1, Circuit Error (Short to Battery voltage)

17137

P0753

N88-SV1 Shift Solenoid 1, Electrical Circuit fault

17140 17141 17182

P0756 P0757 P0798

N89-SV2 Shift Solenoid 2, Circuit Error (Open or Short to ground) N89-SV2 Shift Solenoid 2, Circuit Error (Short to Battery voltage)

17195 17224 17225 17226 17299 17230 17231

P0811 P0840 P0841 P0842 P0845 P0846 P0847

Heavy Clutch Slip Trans pressure sensor 1 G193 mechanical fault (model dependant) Trans pressure sensor 1 G193 open or short/implausible (model dependant) Trans pressure sensor 1 G193 short to ground (model dependant) Trans pressure sensor 2 G194 mechanical fault (model dependant) Trans pressure sensor 2 G194 open or short/implausible (model dependant) Trans pressure sensor 2 G194 short to ground (model dependant) Figure 52 Copyright © 2010 ATSG

58

N93-SV6 Pressure control Circuit Error (Open or Short)


Technical Service Information VOLKSWAGEN "VAG" to obd11 DIAGNOSTIC TROUBLE CODES vag 18010

obd11 P1602

DESCRIPTION Voltage supply too low

18255 18554

P1847 P2122

DTC in ABS problem Throttle position sensor signal too low G79

19146

P2714

N91-SV4 Torque Converter Clutch PWM Solenoid, Circuit (Open or Short)

19147 19148

P2715 P2716

N91-SV4 Torque Converter Clutch PWM Solenoid, Circuit (short to B+) N91-SV4 Torque Converter Clutch PWM Solenoid, electrical circuit fault

19155 19156

P2723 P2724

N92-SV5 K1 Clutch control Solenoid, Circuit (Open or Short) N92-SV5 K1 Clutch control Solenoid, Circuit (short to B+)

19157

P2725

N92-SV5 K1 Clutch control Solenoid, electrical circuit fault

19164 19165

P2732 P2733

N93-SV6 Pressure control Solenoid, Circuit (Open or Short) N93-SV6 Pressure control Solenoid, Circuit (short to B+)

19166

P2734

N93-SV6 Pressure control Solenoid, electrical circuit fault Copyright © 2010 ATSG

Figure 53


59

Technical Service Information "09G" VALVE BODY EXPLODED VIEW 243

244 243

243

245

240

246 247 1 T

241 242

248

00 3C A 7C

70 91

70

8

249

1

7C

A

00 3C

70

4

T1

3B B

00

0 40

5B

6 70 01 3A X

5B

3A Y

01

37

250

5C

252

4A

U

00 3C

10

0

251

70 91

240 241 242 243 244 245 246 247 248 249 250 251 252 254 300

LOWER V.B. TO ACCUMULATOR HOUSING 2 BOLT (70 MM LENGTH). LOWER V.B. TO UPPER V.B. BOLT (39.5 MM LENGTH). LOWER V.B. TO UPPER V.B. BOLT (28 MM LENGTH). ACCUMULATOR-1 HOUSING TO UPPER V.B. (64 MM LENGTH)(3 REQ). ACCUMULATOR-1 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ). ACCUMULATOR-2 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ). ACCUMULATOR-2 HOUSING TO UPPER V.B. (64 MM LENGTH)(2 REQ). ACCUMULATOR-1 HOUSING ASSEMBLY. ACCUMULATOR-1 ASSEMBLY SPACER PLATE. ACCUMULATOR-2 HOUSING ASSEMBLY. ACCUMULATOR-2 ASSEMBLY SPACER PLATE. UPPER V.B. TO LOWER V.B. BOLTS (21 MM LENGTH)(10 REQUIRED). UPPER VALVE BODY ASSEMBLY. LOWER VALVE BODY ASSEMBLY. MAIN VALVE BODY SPACER PLATE.

300

254


Figure 54

60


Technical Service Information "09G" LOWER VALVE BODY ASSEMBLY, EXPLODED VIEW 274 275

273 275

276

272 271 262 261 A 7C

3C

00

70

8

260 70 00

4

277

Y 5B

6 70 5B

3A X

01

258

3A

01

37

1

7C

3C A

259

269

257 B

3B

00

40

0

267 268

70 91

5C 0 10 00 U 4A

254

266

263

3C

256

270

265

T1

264

255

278 279

255 283 254

284 285

280 281

284

286

289

282

290 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275

LOWER VALVE BODY ASSEMBLY. PRESSURE SWITCH ASSEMBLY (2 REQUIRED). N91, PWM CONVERTER CLUTCH SOLENOID. N93, PWM LINE PRESSURE CONTROL SOLENOID. N92, PWM K1 CLUTCH CONTROL SOLENOID. N282, PWM K2 CLUTCH CONTROL SOLENOID. N283, PWM B1 CLUTCH CONTROL SOLENOID. N90, PWM K3 CLUTCH CONTROL SOLENOID. PWM SOLENOID RETAINING PINS (6 REQUIRED) K1 CLUTCH REGULATOR VALVE. K1 CLUTCH REGULATOR VALVE SPRING. K2 CLUTCH REGULATOR VALVE. K2 CLUTCH REGULATOR VALVE SPRING. B1 CLUTCH REGULATOR VALVE. B1 CLUTCH REGULATOR VALVE SPRING. K3 CLUTCH REGULATOR VALVE. K3 CLUTCH REGULATOR VALVE SPRING. N91 AND N93 SOLENOID PIN RETAINING BRACKET. SOLENOID PIN RETAING BRACKET BOLT. TRANSAXLE FLUID TEMPERATURE SENSOR RETAINING BRACKET. TFT SENSOR RETAINING BRACKET BOLT. SOLENOID PIN RETAINING BRACKET BOLTS (2 REQUIRED).

287

291

288 292

276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292

N92, N282, N283, N90 SOLENOID PIN RETAINING BRACKET. MANUAL VALVE. PRIMARY PRESSURE REGULATOR VALVE. PRIMARY PRESSURE REGULATOR VALVE SPRING. PRIMARY PRESSURE REGULATOR BOOST VALVE. PRIMARY PRESSURE REGULATOR BOOST VALVE SLEEVE. PRIMARY REGULATOR BOOST SLEEVE RETAINER. N88, ON/OFF SOLENOID. SOLENOID RETAINING BOLT (2 REQUIRED). N89, ON/OFF SOLENOID. SECONDARY PRESSURE REGULATOR VALVE. SECONDARY PRESSURE REGULATOR SPRING. SECONDARY PRESSURE REGULATOR BORE PLUG. SECONDARY PRESSURE REGULATOR BORE PLUG RETAINER. SOLENOID MODULATING VALVE A FOR N88, N89, N90, N282, N283. SOLENOID MODULATING VALVE A SPRING. SOLENOID MODULATING VALVE A SPRING RETAINER.


Figure 55


61

Technical Service Information "09G" LOWER VALVE BODY SMALL PARTS, EXPLODED VIEW

70 91

252

300

298

ENLARGED VIEW

297

299 301 302 254

295 296

293 294

303 304

252 254 293 294 295 296 297 298 299

UPPER VALVE BODY ASSEMBLY. LOWER VALVE BODY ASSEMBLY. CHECK VALVE 2: LUBE (.392" DIAMETER). CHECK VALVE 2 SPRING. CHECK VALVE 3: FWD ENG./K1/K2 REG VALVE FEED (.313" DIAMETER). CHECK VALVE 3 SPRING. PLASTIC CHECK VALVE 1: K2 CHECK VALVE 4: FWD ENG. ACCUM. EXHAUST (.392" DIAMETER). CHECK VALVE 4 SPRING.

300 301 302 303 304

MAIN VALVE BODY SPACER PLATE. CHECK VALVE 5: B2 ORIFICE CONTROL- REVERSE (.313" DIAMETER). CHECK VALVE 5 SPRING. CHECK VALVE 1: LUBE & COOLER (.392" DIAMETER). CHECK VALVE 1 SPRING.

Figure 56

62



Technical Service Information LOWER VALVE BODY CHECK VALVE AND VALVE SPRING SPECS

264. K1 Regulator Valve Spring


No. Coils-10 Overall Length-.710" Outside Diameter- .325" Coil Diameter- .035" Color- Lt. Pink

No. Coils-11 Overall Length-.740" Outside Diameter- .260" Coil Diameter- .040" Color- White

268. B1 Regulator Valve Spring


No. Coils-9 Overall Length-.745" Outside Diameter- .252" Coil Diameter- .038" Color- Red

No. Coils-10 Overall Length-.815" Outside Diameter- .325" Coil Diameter- .040” Color- none

287. Secondary Pressure Regulator Valve Spring

291. Solenoid Modulator Valve A Spring

No. Coils-9 Overall Length-1.440" Outside Diameter- .524" Coil Diameter- .045" Color- Pink

No. Coils-13 Overall Length-1.500" Outside Diameter- .424" Coil Diameter- .045" Color- White

No. Coils-10 Overall Length-1.000" Outside Diameter- .315" Coil Diameter- .040” Color- White

294. Check Valve 2 Spring


279. Primary Pressure Regulator Valve Spring

No. Coils-8 Overall Length-.560" Outside Diameter- .250" Coil Diameter- .040" Color- Lt. Blue

No. Coils-10 Overall Length-.380" Outside Diameter- .163" Coil Diameter- .016” Color- Red


299. Check Valve 4 Spring No. Coils-8 Overall Length-640" Outside Diameter- .640" Coil Diameter- .035" Color- Red/Orange


No. Coils-10 Overall Length-.380" Outside Diameter- .163" Coil Diameter- .016” Color- Red

No. Coils-12 Overall Length-.595" Outside Diameter- .250" Coil Diameter- .025” Color- White Copyright © 2010 ATSG

Figure 57


63

Technical Service Information "09G" UPPER VALVE BODY ASSEMBLY, EXPLODED VIEW

300

319 316

312

317 318 313 309

314 310

308

311

315

320

307 306

321 305

327 331

252 344 252 300 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327

335

340

UPPER VALVE BODY ASSEMBLY. MAIN VALVE BODY SPACER PLATE. TCC SWITCH VALVE. TCC SWITCH VALVE SPRING. TCC SWITCH VALVE SPRING RETAINER. PRESSURE MODIFIER VALVE BORE PLUG RETAINER. PRESSURE MODIFIER VALVE STEEL BORE PLUG. PRESSURE MODIFIER VALVE SPRING. PRESSURE MODIFIER VALVE. K3 RELAY VALVE BORE PLUG RETAINER. K3 RELAY VALVE STEEL BORE PLUG. K3 RELAY VALVE. K3 RELAY VALVE SPRING. B2 RELAY VALVE (M1) SPRING RETAINER. B2 RELAY VALVE (M1) SPRING. Br YELAY VALVE (M1). SCREEN FOR MODULATING VALVES A & B. RELAY VALVE PLUG. RELAY VALVE. RELAY VALVE SPRING. RELAY VALVE SPRING RETAINER. B1 SWITCH VALVE BORE PLUG RETAINER. B1 SWITCH VALVE BORE PLUG. B1 SWITCH VALVE. B1 SWITCH VALVE SPRING.

330

341 345

324 325

332

336

347

323

334

339 343

322 326

338

333

329 328

342 346 328 329 330 331 332 333 334 335 336 338 339 340 341 342 343 344 345 346 347

4-5 TIMING VALVE BORE PLUG RETAINER. 4-5 TIMING VALVE STEEL BORE PLUG. 4-5 TIMING VALVE. 4-5 TIMING VALVE SPRING. K2 RELAY VALVE RETAINER. K2 RELAY VALVE BORE PLUG. K2 RELAY VALVE. K2 RELAY VALVE SPRING. K1 RELAY VALVE RETAINER. K1 RELAY VALVE BORE PLUG. K1 RELAY VALVE. K1 RELAY VALVE SPRING. B2 SWITCH VALVE BORE PLUG RETAINER. B2 SWITCH VALVE STEEL BORE PLUG. B2 SWITCH VALVE. B2 SWITCH VALVE SPRING. B2 SWITCH VALVE TIPTRONIC M1 BORE PLUG RETAINER. B2 SWITCH VALVE TIPTRONIC M1 BORE PLUG. B2 TIPTRONIC M1 VALVE.


Figure 58

64


Technical Service Information "09G" UPPER VALVE BODY SMALL PARTS, EXPLODED VIEW ENLARGED VIEW

354

252 (ACCUMULATOR SIDE)

70 91

300

351 350 319 ENLARGED VIEW

352

353

349 348

252 (MAIN SPACER SIDE)

252 300 319 348 349 350 351 352 353 354

UPPER VALVE BODY ASSEMBLY. MAIN VALVE BODY SPACER PLATE (MODEL SENSITIVE). PLASTIC FILTER FOR SOLENOID MODULATING VALVES A & B. PLASTIC VALVE CHECK VALVE 2: SECONDARY PR VALVE. PLASTIC CHECK VALVE 4: K1 CHECK BALL 1, 5.3 MM (.210") DIAMETER. CHECK VALVE 6: MANUAL VALVE (.392" DIAMETER). CHECK VALVE 6 SPRING. PLASTIC CHECK VALVE 3: B. PLASTIC CHECK VALVE 5: K3.


Figure 59


65

Technical Service Information UPPER VALVE BODY VALVE SPRING SPECS

310. Pressure Modifier Valve Spring

306. TCC Switch Valve Spring No. Coils-9 Overall Length-1.160" Outside Diameter- .275" Coil Diameter- .022" Color- Lt. Green

322. Relay Valve Spring No. Coils-12 Overall Length-1.135" Outside Diameter- .290" Coil Diameter- .029" Color- White

No. Coils-9 Overall Length-1.010" Outside Diameter- .325" Coil Diameter- .027" Color- Lt. Blue

327. B1 Switch Valve Spring

315. K3 Relay Valve Spring No. Coils-13 Overall Length-1.135" Outside Diameter- .252" Coil Diameter- .027” Color- Red

331. 4-5 Timing Valve Spring


340. K1 Relay Valve Spring

No. Coils-13 Overall Length-1.135" Outside Diameter- .252" Coil Diameter- .027” Color- Red

No. Coils-12 Overall Length-1.135" Outside Diameter- .290" Coil Diameter- .029” Color- White

335. K2 Relay Valve Spring No. Coils-11 Overall Length-1.060" Outside Diameter- .273" Coil Diameter- .025” Color- Red

344. B2 Switch Valve Spring


No. Coils-9 Overall Length-1.010" Outside Diameter- .325" Coil Diameter- .027” Color- Lt. Blue

Figure 60

66

317. B2 Relay (M1) Valve Spring



Technical Service Information "09G" ACCUMULATOR BODY 1, EXPLODED VIEW 368 368 395 386

243

385 381 377

388

382

380

389

391

394

390

393

384

392

383

378 376

387 379

243

244 399

1 T

244

398 397

244 244 247 243 244 247 248 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407

ACCUM. BODY 1 HOUSING TO UPPER V.B. (64 MM LENGTH)(3 REQ). ACCUM. BODY 1 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ). ACCUM. BODY 1 HOUSING ASSEMBLY. ACCUM. BODY 1 SPACER PLATE. K3 CONTROL VALVE BORE PLUG RETAINER. K3 CONTROL VALVE BORE PLUG. K3 CONTROL VALVE. K3 CONTROL VALVE SPRING. 3-4 TRANSITION VALVE BORE PLUG RETAINER. 3-4 TRANSITION VALVE BORE PLUG. 3-4 TRANSITION VALVE. 3-4 TRANSITION VALVE SPRING. B1 CLUTCH ACCUMULATOR PISTON. B1 CLUTCH ACCUMULATOR PISTON OUTER SPRING. B1 CLUTCH ACCUMULATOR PISTON INNER SPRING. K3 CLUTCH ACCUMULATOR PISTON. K3 CLUTCH ACCUMULATOR PISTON OUTER SPRING. K3 CLUTCH ACCUMULATOR PISTON INNER SPRING. K1 CLUTCH ACCUMULATOR PISTON. K1 CLUTCH ACCUMULATOR PISTON SPRING. K2 CLUTCH ACCUMULATOR PISTON. K2 CLUTCH ACCUMULATOR PISTON OUTER SPRING. K2 CLUTCH ACCUMULATOR PISTON INNER SPRING. ACCUMULATOR PISTON AND SPRING RETAINER PLATE. B1/K3 3-WAY CHECK VALVE BORE PLUG RETAINER. B1/K3 3-WAY CHECK VALVE BORE PLUG. B1/K3 3-WAY CHECK VALVE (.250" STEEL BALL). B1/K3 3-WAY CHECK VALVE SEAT. B1 RELAY VALVE BORE PLUG RETAINER. B1 RELAY VALVE BORE PLUG. B1 RELAY VALVE. B1 RELAY VALVE SPRING. CHECK VALVE 11: MAIN LINE PRESSURE LIMIT VALVE. CHECK VALVE 11 SPRING. CHECK VALVE 10: REGULATED EXHAUST (.392" DIAMETER). CHECK VALVE10 SPRING.

403 402

396 401 400

248

248 404 405

406 407

247


Figure 61


67

Technical Service Information ACCUMULATOR BODY 1 CHECK VALVE, VALVE AND ACCUMULATOR SPRING SPECS

379. K3 Control Valve Spring No. Coils-10 Overall Length-1.080" Outside Diameter- .278" Coil Diameter- .027" Color- Pink

385. B1 Accum. Outer Spring

383. 3-4 Transition Valve Spring No. Coils-13 Overall Length-1.135" Outside Diameter- .252" Coil Diameter- .027" Color- None

386. B1 Accum. Inner Spring

No. Coils-6 Overall Length-1.000" Outside Diameter- .620" Coil Diameter- .080" Color- Green

No. Coils-6 Overall Length-1.050" Outside Diameter- .620" Coil Diameter- .080” Color- Green

393. K2 Accum. Outer Spring

No. Coils-6 Overall Length-1.060" Outside Diameter- .620" Coil Diameter- .080" Color- Green

No. Coils-11 Overall Length-1.054" Outside Diameter- .278" Coil Diameter- .027” Color- Pink


No. Coils-9 Overall Length-1.038" Outside Diameter- .400" Coil Diameter- .065” Color- Pink


403. B1 Relay Valve Spring


405. Check Valve 11 Spring No. Coils-4 Overall Length-.425" Outside Diameter- .370" Coil Diameter- .055" Color- Pink or none

389. K3 Accum. Inner Spring No. Coils-9 Overall Length-1.070" Outside Diameter- .412" Coil Diameter- .055” Color- Green

389. K2 Accum. Inner Spring No. Coils-9 Overall Length-1.060" Outside Diameter- .412" Coil Diameter- .055” Color- Green

407. Check Valve 10 Spring No. Coils-12 Overall Length-.595" Outside Diameter- .250" Coil Diameter- .025” Color- White Copyright © 2010 ATSG

Figure 62

68


Technical Service Information "09G" ACCUMULATOR BODY 2, EXPLODED VIEW 368 367 366 245 365 246 245

364

245 245

246 249 363 362 245 246 249 250 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375

ACCUM. BODY 2 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ). ACCUM. BODY 2 HOUSING TO UPPER V.B. (64 MM LENGTH)(2 REQ). ACCUM. BODY 2 HOUSING ASSEMBLY. ACCUM. BODY 2 SPACER PLATE. TCC APPLY CONTROL VALVE SLEEVE RETAINER. TCC APPLY CONTROL VALVE SLEEVE. TCC APPLY CONTROL VALVE. TCC APPLY CONTROL VALVE SPRING. TCC APPLY CONTROL VALVE. SOLENOID MODULATOR VALVE B BORE PLUG RETAINER. SOLENOID MODULATOR VALVE B BORE PLUG. SOLENOID MODULATOR VALVE B FOR N91, N92, N93. SOLENOID MODULATOR VALVE B SPRING. N93 LINE PRESSURE ACCUMULATOR PISTON. N93 LINE PRESSURE ACCUMULATOR PISTON OUTER SPRING. N93 LINE PRESSURE ACCUMULATOR PISTON INNER SPRING. N93 LINE PRESSURE ACCUMULATOR SPRING RETAINER PLATE. N93 ACCUMULATOR RETAINER BOLTS (11 MM LENGTH). CHECK BALL 2, 5.3 MM (.210") DIAMETER. PRESSURE CONTROL SOLENOID (N93) LIMIT CHECK VALVE 7. PRESSURE CONTROL SOLENOID (N93) LIMIT CHECK VALVE 7 SPRING. CHECK VALVE 8: REGULATED EXHAUST. CHECK VALVE 8 SPRING. COOLER PRESSURE LIMIT CHECK VALVE 9 (.392" DIAMETER). COOLER PRESSURE LIMIT CHECK VALVE 9 SPRING.

361 250

360

359 358 357

356 250

355

370 369

371

372 373

374 375 249


Figure 63


69

Technical Service Information ACCUMULATOR BODY 2 CHECK VALVE, VALVE AND ACCUMULATOR SPRING SPECS

363. Solenoid Modulator Valve B Spring

358. TCC Apply Control Valve Spring No. Coils-9 Overall Length-1.200" Outside Diameter- .380" Coil Diameter- .025" Color- None

No. Coils-10 Overall Length-1.000" Outside Diameter- .322" Coil Diameter- .041” Color- None

365. N93Accum. Outer Spring

386. N93 Accum. Inner Spring

No. Coils-6 Overall Length-1.064” Outside Diameter- .620" Coil Diameter- .080" Color- Green

371. Check Valve 7 Spring No. Coils-7 Overall Length-.800" Outside Diameter- .335" Coil Diameter- .030" Color- Dk. Green


373. Check Valve 8 Spring No. Coils-12 Overall Length-.595" Outside Diameter- .250" Coil Diameter- .025” Color- White

375. Check Valve 9 Spring No. Coils-12 Overall Length-.595" Outside Diameter- .250" Coil Diameter- .025” Color- White Copyright © 2010 ATSG

Figure 64

70


Technical Service Information VALVE BODY MAPPING 09G PARTIAL HYDRAULIC SCHEMATIC FOR B1 RELAY VALVE

B1 Relay Valve 101L

120L 107L 115L

ACCUMULATOR BODY 1 (SAME ON ALL CASTINGS) 100L SERIES

110L

120L 122L 125L

101L

HOW TO USE THIS MANUAL

107L

115L

114L

110L

All castings and spacer plates have been numbered so they Can be identified in an oil diagram. Example: Circuit 110L passage is located in the #1 Accumulator Body, lower side (100L Series). This passage can now be located in the partial oil circuit diagram shown above. Spacer plate orifice sizes and locations are also identified in the oil circuit diagram labeled Valve Body Mapping.

116L

102L

113L

106L

105L 124L

117L 111L

112L 118L 119L 109L 104L

103L 123L

108L

121L 100L


Figure 65


71


ACCUMULATOR BODY 1 UPPER SIDE 100U Series 1 T

ACCUMULATOR BODY 2 UPPER SIDE 300U Series

ACCUMULATOR BODY 1 LOWER SIDE 100L Series


ACCUMULATOR BODY 1 SPACER PLATE 200 Series LOWER VALVE BODY UPPER SIDE 5000U Series

UPPER SPACER PLATE 2 400 Series

70 91

LOWER SPACER PLATE 6000 Series

LOWER VALVE BODY LOWER SIDE 5000L Series

UPPER VALVE BODY UPPER SIDE 7000U Series

UPPER VALVE BODY LOWER SIDE 7000L Series


Figure 66

72



7000L

7012L 7014L

9173

7015L

7013L

7007L

7008L

7009L

7001L

7005L

7002L

7003L

7004L

7010L

7006L

7011L

UPPER VALVE BODY LOWER SIDE 7000L Series

T5


Figure 67


73

7056U

7086U

7040U


Figure 68

7053U

7062U

7074U

7076U

7073U

7084U 7072U

7049U

7071U

7009U

7070U

7069U

7055U

7068U

7065U

7067U

7044U

7048U

7011U

7033U

7059U

7058U

7064U

7057U

7055U

7045U

7034U

7082U

7010U

7052U

7039U

7081U

7030U

7038U

7035U

7028U

7085U

7036U 7006U 7041U

7031U

7016U

7026U

7037U

7013U

7022U

7021U

7015U

7017U

7002U

7051U 7007U 7008U 7042U

7061U

7050U

7047U

7063U 7043U

7046U

7012U

7032U

7018U

7005U

U

7080U

7079U

7066U

7075U

7019U

7003U

7000U

27

7004U

7077U

7078U

7020U

7054U

7001U

U

74 7029U

7023U

7025U

U

60

70

24

4U

Check Valve 5 B2 Orifice Control (Rev)

70

70

Check Valve 1 Lube & Cooler

70 1

7083U

Technical Service Information UPPER VALVE BODY UPPER SIDE 7000U Series Check Valve 2 Lube

Check Valve 3 FWD Eng. Accum. & Reg. Valve Line Feed (K1 & K2)

Plastic Check Valve 1 (K2)

Check Valve 4 FWD Eng. Accum. Exhaust


Technical Service Information LOWER SPACER PLATE 6000 Series

X

6044

6039

6024

6043

6065

X

6140

6063 6062

6045

6057

6040

6041

X

6047 6078

6021

6056

6077

6052

6061 6064 6070

6025 6149

6049

X 6050

6023

6048

X

6054

6046

6053 6009 6008 6007

X

X

6042

X

X

6051

6071 6150

6033

6029

X

6010

6028 6072

6066

X

6011

6026

X

6022

6055

6000

6003

6031

X

6085

6030

6004

6073 6105

6012

X

X

6027

6104

6067

6006

X

X

6110 6106

6038

6148

6082

6139 6087 6138

X X 6100

6086 6107

6097

6089 6058

6014

X

6018

6088

6013

6101

6015 6123

6080

6108

6113

X

6079

X 6059

6019 6075

6093

6119

6118

X

6094 6090

6076

6125

6016 6069 6127 6126 6095

X

6144

6111

6122

6060

6084

X

6141

6034

X

6020

X 6128

6147 6109

6145

X

6114

6120

6146

6142 6143

6124

X

6001

X

6102

6112

6068

6092

6032

X

6017

6098 6099

X

6103

6074

X

X

6002

6081

6005

6121 6155

6129 6091

X

6153

X

6083

6133

6115

X

6154 6096 6136

6134 6135

6130

6151

X

6035 6036

X

6116 6152

6137

6037

6117

X

6132

6131

X Copyright © 2010 ATSG

Figure 69


75

L

5054L

5081L

5088L

5079L


Figure 70 5030L

5074L

5046L

5087L

5056L

Covered

5039L

5049L

5063L

5086L

5044L

5089L

5047L

5059L

5083L

5035L

5000L 5014L

5026L

5009L

5057L

5027L

L 42

5032L

5028L

5025L

5017L 5022L

5010L 5023L 5016L 5020L

5024L

5002L

5003L

5091L

5021L

5041L

50

5036L

5031L

5001L

5084L

5090L

5 12 013 L L

7L

50

503

5061L

5033L

5019L

5052L

5038L

5043L

5007L

5055L

5018L

5060L

5064L

5029L

5069L

5005L

5011L

LOWER VALVE BODY LOWER SIDE 5000L Series

5015L

5092L

5066L

5058L

Covered

5050L

5045L

5067L

5062L

5071L

5073L

5008L

5053L

5078L 5085L

5077L

5076L

5094L

5040L

5065L

5080L

5082L

51

50

76 5072L

Plastic Check Valve 4 (K1)

5075L

5070L

5006L

Plastic Check Valve 3 (B1)

5034L

Technical Service Information Solenoid Modulator Valve A & B Screen

Plastic Check Valve 2 (Secondary Reg.)

5004L

5048L

Check Ball 1

Check Valve 6 (MV)

5093L


50

10

U

5005U

5009U

5012U

5004U 5000U 5016U

5014U 5013U

5019U

5011U 5022U

5050U

5018U

5051U

5015U 5016U 5001U

5008U

5007U

5006U

5020U

5030U

5033U

5044U

Covered

Covered

5027U

5049U 5002U

5031U

5028U

5035U

5042U

5039U

AUTOMATIC TRANSMISSION SERVICE GROUP 5052U

5048U

5025U 5032U

5034U

5024U

5043U 5021U 5003U 5041U 5026U

5023U

50 36 U

5047U

5046U

5038U

5045U

5040U

5053U

5029U

5037U

5017U

Technical Service Information LOWER VALVE BODY UPPER SIDE 5000U Series Plastic Check Valve 5 (K3)

T1

Figure 71


77

Technical Service Information ACCUMULATOR BODY 2 SPACER PLATE 400 Series

414 419

420 413

412

418

421 415

408 411 417

416

X

409

401

405 402 422 407

403

400

406 404 410


Figure 72

78


Technical Service Information ACCUMULATOR BODY 2 LOWER SIDE 300L Series Check Valve 7 N93 (LP) Limit Check Valve 8 Regulated Exhaust

Check Ball 2

310L 314L 313L

308L 309L

312L

305L

311L

Check Valve 9 Cooler

306L 303L 304L

301L 300L 315L

302L 307L


Figure 73


79

Technical Service Information ACCUMULATOR BODY 2 UPPER SIDE 300U Series

302U 300U

303U 304U

301U


Figure 74

80


Technical Service Information ACCUMULATOR BODY 1 SPACER PLATE 200 Series

231 229

228

232

201 215

220 222

203

211 223

221

210

208 202

207

235

219 217

214 218

204

209

226 227

233 234

205

212

206 216 225

224 213

230 200


Figure 75


81

Technical Service Information Check Valve 10 Regulated Exhaust


120L 122L 125L

101L

107L

115L

Check Valve 11 (LP Limit)

114L

110L

116L

102L

113L

106L

105L 124L

117L 111L

112L 118L 119L 109L 104L

103L 123L

108L

121L 100L


Figure 76

82


Technical Service Information ACCUMULATOR BODY 1 UPPER SIDE 100U Series


Figure 77


83

Technical Service Information BOTTOM CASE TO VALVE BODY BC Series

BC1

BC2

BC17

BC6

BC3 BC4 BC5

BC16

BC7

BC15 BC14 BC13

BC12

BC11 BC10

BC9

BC8

BC18


Figure 78

84


Technical Service Information PUMP TO CASE P Series

P9 P8

P7 P10 P11

P6 P5 P4

P3

P2

P1


Figure 79


85

K3 Accum

K1 Accum

K2 Accum

B2 Accum

BC3

B1 312L

103L

TCC Apply Control Valve Solenoid Mod. Valve B

307L X 301U Front lube

Pump

P1 Suction

P10 P10 Apply Rel.

Diff. lube

P2 Line

X 300U

Rear lube

301L

BC6

BC7 BC13 BC10

5048U

BC14

BC15 BC16

104L 109L 119L 118L 112L

5084L 5090L

5066L

5091L

BC5

K3

121L

K3/B1 3 Way Check Valve

104L 119L

101L

123L 103L

120L 107L

111L

5058L 315L

B1 Relay Valve

100L

5035L

5092L

3-4 Transition Valve

K3 Control Valve

B2 Switch Valve

5026U

300L

306L BC2

X 302U X 303U X 304U

304L 303L

BC1

B2 Relay Valve (M1)

108L

BC4

116L

** 5043U

305L

K1

114L

115L

110L

105L

110L

113L

5057L

421 418

TCC Switch Valve

5028L

B2 Switch Valve (M1)

5016U

5013U 5014U

5006U 5019L 6047 6054

6045 6044

7024U

5024L

5012U 5025L 6046

Rel. Tap BC 5005U 12 5016L 6050 6051 6049 6048

7023U

7027U

5016U 5091L 5014U 5032L

416 415

228 222

213 214 215 216 217

201

209

210 211

218

124L

122L

231 219 221 226 223 224 225 206 207 208 227 230 (.025) 232

233

234 (.025)

Relay Valve

102L 220

235 5053U 5093L

5039U 5076L

B1 Switch Valve

K2 Relay Valve 5011L

5018L

5059L 5047L 5089L

5063L 5056L 5055L

5044L

5043L

7032U

K3 Relay Valve **

5049U 5045U 5027U

5053L

5027U 5046U 5047U

5077L

203 202

5085L 5033U

5045L

**

5078L

5031U

212 BC11

B2

5041U P-Ckv-3 5085L

5052U

5092L **

5062L

5070L 5068L

5034U **

5054L 5082L

5027U

5080L 5078L

5037U

5065L

5046L

BC9 5027U

5044U

K2

5087L 5058L

2

**

5056L

5029U

5021U

5056L

5028U

5015U

5026U 5029L 5010U 5021L 6053 6057 6058 6059 6060 5030L

7026U

5051U

Blocked

311L

5019U

6042 6043

7025U

205

P-Ckv-5

K1 Relay Valve

5016U 5042L 6061

5041L

5023L 5011U

200 204

5050U 5091L

Solenoid Mod. Valve A

5022L 5017L 5020L 5016L

5007U

229

117L

403 5022U 5041L

5008U 5009U

419

106L

CKV11

408 417

314L

420 (.025)

4-5 Timing Valve

404

125L

313L Ck Ball 2

422 (.035) 400 401 402 411 412 413

CKV10

CKV9

410 409 405 406 407

309L CKV8

308L

302L

7033U 5052L 6093 6094

6005 6004 (.075)

6078 6041 6040 6039 6038 6037 6036 6035 6034 6033 6032 6031 6030 (.032) 7021U

7000L

7019U 7018U 7017U

7020U

5001U

5002L 6055 5026L 6007 6052 (.038) 6066 6067 6068 6069

5013U

5033L

5086L

5034L

5035U

5083L

6150 6149 6146 6145 6143 6144 6142 6147 6141 6137 6138 6139 6140

5010L

5071L 6065 6122 6112 6106 6077 (.038) 6025 6024 6023 6021

7002U TFT 7016U

7039U

7001L

7085U

7083U

7082U

7084U

7080U

5004U

5014U

P-Ckv-4 5047L

5023U 5024U

5049L 5050L 5009L 5048L 5027L 6082 6022 6086 6056 (.038) 6081 6085 6088 6089 6090 6091 6092 6148 6087 (0.38)

7081U

7052U

5025U

5007L

6098 6080 5051L K1 Tap (.038) 6079 (.050) 6097 6099

5003U

5008L 6018 6019 6020 6100 6101

5061L 5060L 5064L 5072L 5030U 5033U 5036U 5038U 5067L 5069L 5073L 5075L 6105 6118 6119 6123 6125 6127 6095 6083 6103 6102 6104 (.050) 6110 6111 6107 6108 6109 6113 6114 6115 6084 6116 6117 (.050) (.025) 6120 6121 6124 (.025) (.050) (.050) 6126 6155 6128 6151

BC8 7059U P-Ckv-1

7053U

5040U

5042U 5088L

7060U

7061U

7063U

7062U

7065U

7066U

7075U

CKV 6

5000U 5001L 6006

5081L 5079L

6134 6130 6131 6132 6133 (.050) 6135 6136 6129 6154

6096 X

7056U

CKV 5

6002 6003

5012L 6027 6029 6028 (.050) 6026

CKV 4

6001 7001U

CKV2

6000 7000U

P-Ckv-2 5013L

CKV 3

5014L

CKV1

5015L 5000L

BC18 7054U

7079U

Forward Engagement Control Accumulator Copyright © 2010 ATSG

Solenoid Application N91 TCC Solenoid (NV) N93 Line Pressure Solenoid (NA)

K1 Reg. Valve

B1 Reg. Valve

K2 Reg. Valve

K3 Reg. Valve

7003U X 7002L

7030U

7051U

7064U 7057U

7061U 7050U

7004L 5020U 5037L

5038L

5039L

6072 6073 6074 6075 6076

5002U

7022U 5005L

5006L 6016 6015 6014

5036L

7031U

7015U

6013 6070 6071 6012 6011 6010 6017

7006U

6008

7015U

7036U

7009U

7042U

7041U

7035U 6062 6063 (.038) (.038) 6064

FILTER

SUMP

X 7005L

310L

414

NC

N88

N89 Secondary Reg. Valve

X 7013L

7068U

7073U 7055U

Solenoid Mod "A" pressure

Suction/P.R. Exhaust TCC Release

X 7015L

Solenoid Mod "B" pressure

7045U

N-93/Line Pressure Control

7067U

Secondary Reg. pressure

NA

X 7007L

7034U

7012U

NA

X 7012L

7048U

7049U

7011U

7010U

NA

X 7014L

NA

7077U

7011U 7004U

NA

N91 TCC

N93 LP

N92 K1

N282 K2

N283 B1

N90 K3 7040U

Primary Reg. Valve

Cooler/Lube Circuit

7072U

X 7006L

1

5031L

Off Off

TCC Apply

7038U

5017U

NC

7046U

7037U 7013U

NV 7006U

X 7009L

X 7010L

X 7011L

7005U

7008U

CKV 7

7044U

LOW

N89 Solenoid (NC)

7076U

7029U

6009 (.038)

7014U

7028U 7043U

7055U

X 7008L

7047U

7004L 7007U

HIGH

N282 K2 Clutch Solenoid (NA)

7074U

7078U

5003L

X 7003L

N283 B1 Brake Solenoid (NA) N88 Solenoid (NC)

7070U 7069U 7055U

7002U

5004L

5018U

HIGH

Legend

6153 6152

7086U

Manual Valve

Mod LOW


Line Pressure

7058U

LOW


5094L Ck Ball 1

7071U 7017U

Solenoid DUTY /State

= Connected circuit ** = Blocked by spacer plate

"09G” RANGE "Park"

N93 Accum.

K3 Accum.

K1 Accum.

K2 Accum.

B1 Tap

B1 Accum.

BC3

B1

K3 Tap BC5

TCC Apply Control Valve Solenoid Mod. Valve B X Front lube

Release

X

Pump

K3


K1 Tap

B2 Switch Valve

B1 Relay Valve

X


(.025)

9

X Apply

Diff. lube

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV11 CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

** X

B2 Switch Valve (M1) (.038)

(.038)

TCC Switch Valve

4-5 Timing Valve

K2 Relay Valve

K1 Relay Valve

(.025)

CKV8

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

**

Forward Engagement Accumulator

CKV4


(.050)

CKV5

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K1 Reg Valve

N93 Line Pressure Solenoid (NA)

K3 Reg Valve

K2 Reg Valve

Solenoid Application N91 TCC Solenoid (NV)

(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1

HIGH

N283 B1 Brake Solenoid (NA)

HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Suction/P.R. Exhaust X

TCC Release TCC Apply Solenoid Mod "A" pressure


X

X


(.038)

(.038)

X

X

N-93/Line Pressure Control X

X

Cooler/Lube Circuit

(.038)

Secondary Reg. pressure X

= Connected circuit (.038)

Sump Filter

NC

NC

N88 OFF

N89 OFF

CKV7

(.038)

X

NV

NA

NA

NA

NA

** = Blocked by spacer plate

NA

X

N91 TCC LOW

N93 LP MOD

N92 K1 HIGH

N282 K2 HIGH

N283 B1 HIGH

"09G”

N90 K3 HIGH

Manual Valve

Mod HIGH


Legend

X

LOW


Line Pressure

X


RANGE "Park"

K3 Accum.

N93 Accum.

K1 Accum.

K2 Accum.

B1 Tap

B1 Accum.

BC3

B1

K3 Tap BC5


Release

X

K3


K1 Tap

B2 Switch Valve

B1 Relay Valve

X


(.025)

X Apply

Diff. lube

Pump

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV11 CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

CKV8

K2 Relay Valve **

X


(.038)

TCC Switch Valve

4-5 Timing Valve

(.025)

K1 Relay Valve

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

**


CKV4


(.050)

CKV5

K3 Reg Valve

K1 Reg Valve

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K2 Reg Valve


(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1

Mod


HIGH


HIGH


HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Legend

X




X

X


(.038)

(.038)

X

X


X

Cooler/Lube Circuit

(.038)



Sump Filter

NC

NC

N88 OFF

N89 OFF

CKV7

(.038)

X

NA

NV

NA

NA

NA


NA

X

N91 TCC LOW

N93 LP MOD

N92 K1 HIGH

N282 K2 HIGH

N283 B1 HIGH

"09G”

N90 K3 LOW

Manual Valve

LOW


Line Pressure

X


RANGE "Reverse”

N93 Accum.

K1 Accum.

K3 Accum.

K2 Accum.

B1 Tap

B1 Accum.

BC3

B1

K3 Tap BC5


Release

X

K3


K1 Tap

B2 Switch Valve

B1 Relay Valve

X


(.025)

X Apply

Diff. lube

Pump

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV11 CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

CKV8

K2 Relay Valve **

X

11


12

8

(.038)

TCC Switch Valve

4-5 Timing Valve

(.025)

K1 Relay Valve

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

**


CKV4


(.050)

CKV5

K3 Reg Valve

K1 Reg Valve

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K2 Reg Valve


(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1

Mod


HIGH


HIGH


HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Legend

X




X

X


(.038)

(.038)

X

X


X

Cooler/Lube Circuit

(.038)



Sump Filter

NC

NC

N88 OFF

N89 OFF

CKV7

(.038)

X

NA

NV

NA

NA

NA


NA

X

N91 TCC LOW

N93 LP MOD

N92 K1 LOW

N282 K2 HIGH

N283 B1 HIGH

"09G”

N90 K3 HIGH

Manual Valve

LOW


Line Pressure

X


RANGE "Drive" 1st Gear

N93 Accum.

K1 Accum.

K3 Accum.

B1 Accum.

K2 Accum.

B1 Tap BC3

B1

K3 Tap BC5


Release

X

K3


K1 Tap

B2 Switch Valve

B1 Relay Valve

X


(.025)

X Apply

Diff. lube

Pump

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV11 CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

** X


(.038)

TCC Switch Valve

4-5 Timing Valve

K2 Relay Valve

K1 Relay Valve

(.025)

CKV8

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

**


CKV4


(.050)

CKV5

K3 Reg Valve

K1 Reg Valve

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K2 Reg Valve


(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1

Mod


HIGH


HIGH


HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Legend

X




X

X


(.038)

(.038)

X

X


X

Cooler/Lube Circuit

(.038)



Sump Filter

NC

NC

N88 OFF

N89 OFF

CKV7

(.038)

X

NA

NV

NA

NA

NA


NA

X

N91 TCC LOW

N93 LP MOD

N92 K1 LOW

N282 K2 HIGH

N283 B1 LOW

"09G”

N90 K3 HIGH

Manual Valve

LOW


Line Pressure

X


RANGE "Drive" 2nd Gear

K3 Accum.

N93 Accum.

K1 Accum.

K2 Accum.

B1 Tap

B1 Accum.

BC3

B1

K3 Tap BC5


Release

X

K3


K1 Tap

B2 Switch Valve

B1 Relay Valve

X


(.025)

X Apply

Diff. lube

Pump

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV11 CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

CKV8

K2 Relay Valve **

X


(.038)

TCC Switch Valve

4-5 Timing Valve

(.025)

K1 Relay Valve

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

**


CKV4


(.050)

CKV5

K3 Reg Valve

K1 Reg Valve

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K2 Reg Valve


(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1

Mod


HIGH


HIGH


HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Legend

X




X

X


(.038)

(.038)

X

X


X

Cooler/Lube Circuit

(.038)



Sump Filter

NC

NC

N88 OFF

N89 OFF

CKV7

(.038)

X

NA

NV

NA

NA

NA


NA

X

N91 TCC LOW

N93 LP MOD

N92 K1 LOW

N282 K2 HIGH

N283 B1 HIGH

"09G”

N90 K3 LOW

Manual Valve

LOW


Line Pressure

X


RANGE "Drive" 3rd Gear

N93 Accum.

K2 Accum.

K1 Accum.

K3 Accum.

B1 Tap

B1 Accum.

BC3

B1

K3 Tap BC5


Release

X

K3


K1 Tap

B2 Switch Valve

B1 Relay Valve

X


(.025)

X Apply

Diff. lube

Pump

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV11 CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

CKV8

K2 Relay Valve **

X


(.038)

TCC Switch Valve

4-5 Timing Valve

(.025)

K1 Relay Valve

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

**


CKV4


(.050)

CKV5

K3 Reg Valve

K1 Reg Valve

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K2 Reg Valve

Solenoid Application


N91 TCC Solenoid (NV)

(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1

Mod


HIGH


HIGH


HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Legend Line Pressure

X


X



X

X


(.038)

(.038)

X

X


X

Cooler/Lube Circuit

(.038)



Sump Filter

NC

NC

N88 ON

N89 OFF

CKV7

(.038)

X

NA

NV

NA

NA

NA


NA

X

N91 TCC LOW

N93 LP MOD

N92 K1 LOW

N282 K2 LOW

N283 B1 HIGH

"09G”

N90 K3 HIGH

Manual Valve

LOW


RANGE "Drive" 3-4 Transition

N93 Accum.

K2 Accum.

K1 Accum.

K3 Accum.

B1 Tap

B1 Accum.

BC3

B1

K3 Tap BC5


Release

X

K3


K1 Tap

B2 Switch Valve

B1 Relay Valve

X


(.025)

X Apply

Diff. lube

Pump

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV11 CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

CKV8

K2 Relay Valve **

X


(.038)

TCC Switch Valve

4-5 Timing Valve

(.025)

K1 Relay Valve

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

**


CKV4


(.050)

CKV5

K3 Reg Valve

K1 Reg Valve

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K2 Reg Valve


(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1

Mod


HIGH


HIGH


HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Legend

X




X

X


(.038)

(.038)

X

X


X

Cooler/Lube Circuit

(.038)



Sump Filter

NC

NC

N88 OFF

N89 OFF

CKV7

(.038)

X

NA

NV

NA

NA

NA


NA

X

N91 TCC LOW

N93 LP MOD

N92 K1 LOW

N282 K2 LOW

N283 B1 HIGH

"09G”

N90 K3 HIGH

Manual Valve

LOW


Line Pressure

X


RANGE "Drive" 4th Gear

K3 Accum.

N93 Accum.

K2 Accum.

K1 Accum.

B1 Tap

B1 Accum.

BC3

B1

K3 Tap BC5


Release

X

K3


K1 Tap

B2 Switch Valve

B1 Relay Valve

X


(.025)

X Apply

Diff. lube

Pump

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV11 CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

CKV8

K2 Relay Valve **

X


(.038)

TCC Switch Valve

4-5 Timing Valve

(.025)

K1 Relay Valve

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

2 **


CKV4


(.050)

CKV5

K3 Reg Valve

K1 Reg Valve

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K2 Reg Valve


(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1

Mod


HIGH


HIGH


HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Legend

X




X

X


(.038)

(.038)

X

X


X

Cooler/Lube Circuit

(.038)



Sump Filter

NC

NC

N88 OFF

N89 OFF

CKV7

(.038)

X

NA

NV

NA

NA

NA


NA

X

N91 TCC LOW

N93 LP MOD

N92 K1 HIGH

N282 K2 LOW

N283 B1 HIGH

"09G”

N90 K3 LOW

Manual Valve

LOW


Line Pressure

X



N93 Accum.

K3 Accum.

B1 Accum.

K2 Accum.

K1 Accum.

B1 Tap BC3

B1

K3 Tap BC5


Release

X

K3


K1 Tap

B2 Switch 7 Valve

B1 Relay Valve

X


(.025)

X Apply

Diff. lube

Pump

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV11 CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

CKV8

K2 Relay Valve **

X


(.038)

TCC Switch Valve

4-5 Timing Valve

(.025)

K1 Relay Valve

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

2 **


CKV4


(.050)

CKV5

K3 Reg Valve

K1 Reg Valve

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K2 Reg Valve


(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1

Mod


HIGH


HIGH


HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Legend

X




X

X


(.038)

(.038)

X

X


X

Cooler/Lube Circuit

(.038)



Sump Filter

NC

NC

N88 OFF

N89 OFF

CKV7

(.038)

X

NA

NV

NA

NA

NA


NA

X

N91 TCC LOW

N93 LP MOD

N92 K1 HIGH

N282 K2 LOW

N283 B1 LOW

"09G”

N90 K3 HIGH

Manual Valve

LOW


Line Pressure

X



N93 Accum.

K3 Accum.

B1 Accum.

K2 Accum.

K1 Accum.

B1 Tap BC3

B1

K3 Tap BC5


Release

X

K3


K1 Tap

B2 Switch Valve

B1 Relay Valve

X


(.025)

X Apply

Diff. lube

Pump

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV11 CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

CKV8

K2 Relay Valve **

X


(.038)

TCC Switch Valve

4-5 Timing Valve

(.025)

K1 Relay Valve

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

**


CKV4


(.050)

CKV5

K3 Reg Valve

K1 Reg Valve

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K2 Reg Valve


(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1

Mod


HIGH


HIGH


HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Legend

X




X

X


(.038)

(.038)

X

X


X

Cooler/Lube Circuit

(.038)



Sump Filter

NC

NC

N88 OFF

N89 ON

CKV7

(.038)

X

NA

NV

NA

NA

NA


NA

X

N91 TCC HIGH

N93 LP MOD

N92 K1 HIGH

N282 K2 LOW

N283 B1 LOW

"09G”

N90 K3 HIGH

Manual Valve

LOW


Line Pressure

X


RANGE "Drive" 6th Gear TCC Apply

N93 Accum.

K1 Accum.

K3 Accum.

K2 Accum.

B1 Tap

B1 Accum.

BC3

B1

K3 Tap BC5


Release

X

K3


K1 Tap

B2 Switch Valve

B1 Relay Valve

X


(.025)

X Apply

Diff. lube

Pump

K3 Control Valve

B2 Relay Valve (M1)

X

Rear lube

BC4

K1

(.038) **

Rel. Tap

CKV10

CKV11

CKV9

Relay Valve

x

x

P-Ckv-3

B2 Tap BC11

B2

P-Ckv-5

B1 Switch V.

CKV8

K2 Relay Valve **

X


(.038)

TCC Switch Valve

4-5 Timing Valve

(.025)

K1 Relay Valve

K3 Relay V. **

(.025)

Ck Ball 2

Pressure Mod. Valve

**

**

K2 Tap BC9

K2

**


CKV4


(.050)

CKV5

K3 Reg Valve

K1 Reg Valve

(.038)

Primary Reg. Valve

Secondary Reg V.

(.050)

X

B1 Reg Valve

K2 Reg Valve


(.050)

CKV2

(.050)

CKV6

(.025)

TFT

X

(.025)

P-Ckv-1

(.050)

P-Ckv-4

(.050)

Sol. Mod. V. Screen

CKV3

(.050)

CKV1

(.032)

(.075)

P-Ckv-2

Ck Ball 1


LOW


Mod


HIGH


HIGH


HIGH


HIGH

N88 Solenoid (NC)

Off

N89 Solenoid (NC)

Off

Legend Line Pressure

X


X



X

X


(.038)

(.038)

X

X


X

Cooler/Lube Circuit

(.038)



Sump Filter

NC

NC

N88 ON

N89 ON

CKV7

(.038)

X

NA

NV

NA

NA

NA


NA

X

N91 TCC LOW

N93 LP MOD

N92 K1 LOW

N282 K2 HIGH

N283 B1 HIGH

"09G”

N90 K3 HIGH

Manual Valve

RANGE "Drive" Tiptronic 1st Gear

TF60 SN Tech Guide

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