6-Speed Automatic Transmission09G/09M Design and Function

Self-Study ProgramCourse Number 851503

Volkswagen of America, Inc.Service TrainingPrinted in U.S.A.Printed 04/05Course Number 851503

2005 Volkswagen of America, Inc.

All rights reserved. Information containedin this manual is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at anytime without notice. No part of this documentmay be reproduced, stored in a retrievalsystem, or transmitted in any form or by anymeans, electronic, mechanical, photocopying,recording or otherwise, nor may these materials be modified or reposted to other sites without the prior expressed writtenpermission of the publisher.

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Always check Technical Bulletins and the latest electronic service repair information that may supersede any information included in this booklet.

Trademarks: All brand names and product names used in this manual are trade names, service marks, trademarks, or registered trademarks; and are the property of their respective owners.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-Speed Automatic Transmission 09G/09M

Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Selector Lever Positions and Operation, Selector Lever Design in2004 Golf, Selector Lever Design in 2004 Eurovan, Ignition KeyRemoval Lock in 2004 Golf, Ignition Key Removal Lock in 2004Eurovan

Transmission Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Transmission Section 09G, Transmission Section 09G - Schematic,Planetary Gear/Shifting Elements, Torque Converter, TorqueConverter Lock-Up Clutch, ATF Supply/Lubrication, Section -Automatic Transmission, Park Lock, Hydraulic Control, Torque Flow

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Example: 2004 Golf

Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Transmission Control Module (TCM) J217, Dynamic ShiftingProgram DSP, Sport Mode S, Emergency Running Mode,Towing, Starter Interlock, Back-up Light, Sensors, Actuators,Solenoid Valves, Electrical Pressure Control Valves, 2004 GolfFunctional Diagram, 2004 EuroVan Functional Diagram, 2004 GolfCAN Databus Connections

Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Diagnostic

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Special Tools

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Terms

Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Table of Contents

Page

i

New!

Important/Note!The Self-Study Program provides you with informationregarding designs and functions.

The Self-Study Program is not a Repair Manual!

For maintenance and repair work, always refer to thecurrent technical literature.

ii

1

6-Speed Automatic Transmission09G/09M

The Japanese automatic transmissionmanufacturer AISIN Co., LTD is thedeveloper and manufacturer of the 09Gtransmission. Volkswagen engineersdeveloped the transmission in conjunctionwith Aisin and adapted it to Volkswagenvehicles.

The 09G/09M 6-speed automatictransmission is installed in the followingVolkswagen vehicles:

The size of the torque converter

The torque converter characteristiccurve of the torque boost (conversionfactor or conversion boost)

The selector lever

The ignition key removal lock

Introduction

Designation

09G

09G

09M

184 lbs-ft (250 Nm)

184 lbs-ft (250 Nm)

332 lbs-ft (450 Nm)

2005 Jetta/New Beetle

2006 Passat

2006 Passat

Maximum Torque Transfer Vehicles

The transmission is adapted for use withdifferent engines and vehicles by varying:

The number of disc pairs for clutchesand brakes

The adaptation of the ATF pressure onthe clutches and brakes

The configuration of gear pairs,planetary gear sets (e. g. four instead ofthree planetary gears), shafts andbearings

The reinforcement of housingcomponents

The ratio of the final drive and theintermediate drive

The transmission sets new standards fordynamics and efficiency in the diagonallyinstalled, conventional stepped automatictransmission segment through:

Low weight

High overall transmission ratio spread

Compact dimensions of thetransmission

High speed of shifting

High level of shifting comfort

The same manufacturer makes the 6-speedautomatic transmission in the VolkswagenTouareg designated 09D. Both automatictransmissions from AISIN use a Lepelletierarrangement.

The advantage of this Lepelletierarrangement is its simple, space-saving andlightweight design. It combines a simpleplanetary gear set with a subsequentRavigneaux arrangement. This makes sixspeeds possible with only five shiftingelements.

Introduction

2

ATF Cooler

Multi-function Switch

Electrical Connections

3

Technical Data

Depending on engine type, overall ratio is configured as 5+E transmission or as 6-speedtransmission.

For the 5+E transmission, the highest speed is reached in 5th gear. The 6th gear reducesengine speed, improves driving comfort and reduces fuel consumption:

For the 6-speed transmission configuration, the highest speed is reached in 6th gear. The 6thgear lowers transmission gear ratio and increases driving dynamics.

Introduction

Manufacturer

Transmission type

Control

Torque performance

Final drive GSY

Final drive GJZ

ATF specification

Filling amount

Weight

Length

Spread

G 052 025 A2

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

Approx. 182 lbs (82.5 kg)

Approx. 13.8 in (350 mm)

6.05

Intermediate drivefor code lettersGSY/GJZ

Electro-hydraulically controlled 6-speed planetary gear(stepped automatic transmission) with hydrodynamic torqueconverter and traction controlled torque converter lock-up clutchfor front wheel drive and transverse installation

Hydraulic control module in oil sump with external electroniccontrol module

Dynamic Shifting Program DSP with separate Sport program inPosition S and the Tiptronic shifting program for manual gearchange (optional with Tiptronic steering wheel)

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

No. of teeth 52/49 = 1.061

No. of teeth 61/15 = 4.067

No. of teeth 58/15 = 3.867

AISIN Co., LTD. Japan

The appearance of the selector lever may differ for different vehicles. The operation and thefunction is the same, however, for all vehicles with this automatic transmission.

Steering wheel paddles are available as options and can also differ in appearance forindividual vehicles.

Selector Lever Positions andOperation

P - ParkBefore the selector lever can be moved outof this position, the ignition must beswitched on and the foot brake must bepressed.Additionally, the locking button on theselector lever must be pressed.

R - ReverseTo shift into this gear, the locking buttonmust be pressed.

N - NeutralThe transmission is in idle in this position.If the selector lever is in this position for along time and the vehicle is driven at lessthan 3 mph (5 km/h), the foot brake must bepressed again to leave this position.

D - DriveIn this driving position, the forward gears areshifted automatically.

S - SportThe locking button must be pressed to shiftinto the selection range S. The controlmodule selects gears automaticallyaccording to a sporty characteristic curve.

+ and -The Tiptronic functions are performed in theright selector lever gate and at the steeringwheel paddles.

Selector Lever

4

Locking Button

Steering Wheel Paddles

Selector Lever Park Position Lock Switch F319

Tiptronic Switch F189

Shift Lock Solenoid N110

5

Selector Lever Design in 2005 Jetta

The selector lever activates the Multi-Function Transmission Range (TR) SwitchF125 via the selector lever linkage.Mechanical movement of the linkage isconverted by the Multi-Function TransmissionRange (TR) Switch F125 into electricalsignals corresponding to the selector leverposition. The electrical signals are sent overanalog wires to the Transmission ControlModule (TCM) J217.

Selector Lever Park Position Lock SwitchF319

If the selector lever is in the P position,the switch sends the signal selector leverin position P to the Steering ColumnElectronic Systems Control Module J527. Thecontrol module requires this signal to controlthe ignition key removal lock.

Shift Lock Solenoid N110

The Shift Lock Solenoid N110 is controlled bythe Transmission Control Module (TCM) J217.

Tiptronic Switch F189

The switch recognizes the Tiptronic gate aswell as Tip + and Tip -. The signal travels overan analog wire to the Transmission ControlModule (TCM) J217.

Selector Lever

Ignition Switch Key Lock Solenoid N376

Ignition Lock

Ignition Key Removal Lock in 2005Jetta

The ignition key removal lock prevents theignition key from being turned back into theremoval position when the par