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AW 6 Speed FWD
Presented by Bob Warnke
ATRA Powertrain Expo 2009
© Sonnax 2009
AW 6 SPEED FWD
1 ©Sonnax Industries ATRA EXPO 2009
AW 6 Speed FWD Table of Contents
Topic Page/s
Features, Powerflow, Hydraulic Control and Adjustments
2-9
Exploded view, Vacuum test locations on TF-81SC (Ford/Mazda)
10-16
Exploded view, Vacuum test locations on AF-40 (Volvo, Opel, Saab)
17-26
Exploded view, Vacuum test locations on TF-60SN (VW 09G)
27-34
Pressure Testing
35-40
Common Complaints, Cause, Correction on AW6-FWD
41-50
Codes and Relearn Procedure
51, 52
AW 6 SPEED FWD
2 ©Sonnax Industries ATRA EXPO 2009
AW6 FWD & RWD TECHNICAL FEATURES
• AW55-50 was designed in ‘98 and went into production in ‘99. Torque capacity of
330 N.m. • AW/TF-60 was designed in ‘02 along with the rear wheel drive unit, the TR-60SN.
Both units use similar power flow & control. TF-60 went into production in the ‘03 Beetle (09G) with torque capacity of 280N.m. The later 09K has 400N.m. and 09M has a 450 N.m. torque capacity.
• Skip shift scheduling controls 4 clutches simultaneously. The units have the ability and programming for 2-4; 4-6 upshifts and 6-2, 2-1; 5-3, 3-1, 4-2 and 2-1 downshifts. This is accomplished by designing a compact hydraulic circuit that remains pre-charged. • Each clutch apply or release is controlled by one solenoid and valve circuit. • The control pressure curve of each circuit is affected by the adjustment screw on
the end of the bore opposite the solenoid. That feature is combined with fast adapts and CAN feedback.
• Software has been reduced by 45% over 5 speed and parts by 27% with a gain
of 5% fuel economy. • TF-80SC utilizes a brake band, TF-60SN uses a B1 clutch. The oil transfer
grooves in the band drum are critical to the timing for apply and to reduce heat. The double wrapped band has special oil grooves to reduce heat.
• Temperature sensor is extremely critical to proper shift strategy and adaption! TCM
has 3 distinct temperature modes of operation. 1. TCC apply & normal clutch apply release strategy. 2. Stage 1: 127°C (260°F) shifts become later and TCC remains applied longer. 3. Stage 2: Engine torque reduction.
AW 6 SPEED FWD
3 ©Sonnax Industries ATRA EXPO 2009
SO
LEN
OID
PO
WE
RFL
OW
A
W6
FWD
R
AN
GE
S
OLE
NO
ID
CLU
TCH
B
RA
KE
O
.W.C .
FOR
D/V
OLV
O/P
SA
S
SC
S
LC1
SS
D
SLC
2 S
SE
S
LC3
SS
F S
LB1
SS
A
S1
SS
B
S2
C-1
C
-2
C-3
B
-1
BA
ND
B
-2
CLU
TCH
F-
1
V.W
. N
92#5
N
282#
9 N
90#3
N
283#
10
N88
N
89
K-1
K
-2
K-3
B
-1
Clu
tch
B-2
C
LUTC
H
F-1
P
X X
X X
R
X X
X
X
X
N
X X
X X
Neu
tral C
ontro
l X
X
X
X
X
D S
1ST
X
X
X Z
Z X
Z
X
2ND
X X
X
X
3RD
X
X C
y C
y X
X
4TH
X
X C
y C
y X
X
5TH
X
X C
y C
y
X X
6TH
X
X
C
y C
y
X
X
S
SC
& S
SE
sol
enoi
ds h
ave
resi
dual
clu
tch
pres
sure
feed
ing
back
to th
e op
posi
ng c
lutc
h co
ntro
l val
e
Sol
enoi
d fo
r Clu
tch
C-1
C
-2
C-3
B
-1
RE
SIS
TAN
CE
-OH
MS
4.
0-8.
0 4.
0-8.
0 4.
0-8.
0 4.
0-8.
0 10
-16
10-1
6 Li
near
sol
enoi
ds o
pera
te a
t 300
Hz.
Sol
enoi
d Fl
ow
N.O
N
.O.
N.O
. N
.O.
N.C
N
.C
N91
/TC
C/S
LU is
N.C
.; N
93/E
PC
/SLT
is N
.O
X
=ON
=
OFF
Z =
ON
DU
RIN
G E
NG
INE
BR
AK
ING
C
y=C
YCLE
D
AW 6 SPEED FWD
4 ©Sonnax Industries ATRA EXPO 2009
K3 K1 F
B2 K2 B1
AF-40 - B1 is a Band
TF-60SN - B1 is a Clutch
K2 Case
sleeve
• Clutch piston travel is critical and set by selective flange/snap rings. • Split band has a print mark between the straps near the anchor. If the print mark is
worn away, band should be replaced. The C3 clutch drum onto which the B1 band applies, has a special surface finish and should not be altered. The B1 band should be pre-soaked with the correct fluid for 2 hours.
• Faced clutch plates have a print mark. OE suggests if the print mark is not legible the friction plate should be replaced and a new pre-soaked friction installed.
AW 6 SPEED FWD
5 ©Sonnax Industries ATRA EXPO 2009
Servo Actuating: • Reduces gear shift lag by prim-
ing circuit. • Uses temperature & pressure
to adjust. • Accurately times end of piston
stroke.
Torque Phase: • CAN & adaptive strategy timing
apply & release of exhausting clutch.
Inertia Phase:
• After initial apply, RPM vs. torque vs. slippage is monitored. Pressure is adjusted to eliminate the slip at the end of the shift.
Skip Shift: • Four elements controlled • Controls the apply & release
to reduce overlap without bind or flare.
SLIP SHIFT 6-3
UPSHIFT
UPSHIFT
SLIP SHIFT 6-3
AW 6 SPEED FWD
6 ©Sonnax Industries ATRA EXPO 2009
A balance area opposes clutch apply pistons. These are fed from lubrication oil. The valve body damper/accumulators pre-charge all circuits.
A:
Piston Hydraulic Pressure Chamber
B:
Centrifugal Hydraulic Pressure Control
Chamber
C-1 = 1.2 to 1.4mm 2.8-3.5mm
C-2 = .045 to .065mm 2.5-3.2mm
C-3 = 0.6 to 0.8mm 2.8-3.5mm
B-2 = 1.2 to 1.4mm 47-53mm
Clutch Piston Stroke (use selective flanges)
AW 6 SPEED FWD
7 ©Sonnax Industries ATRA EXPO 2009
Adjuster: By sealing this with Loctite or
cutting o-ring groove. Both the vacuum test and clutch
control improve.
Vacuum Test Example 3”=Poor 7”=Poor
12”=Normal 11”=Normal 14-18” =Post repair 14-18”=Post repair
Refer to vacuum test locations on all covers.
AW 6 SPEED FWD
8 ©Sonnax Industries ATRA EXPO 2009
(3) a
lignm
ent h
oles
EXA
MP
LE:
C
-3 a
djus
ter:
Tur
n sc
rew
out
-w
ard
to in
crea
se C
-3 c
lutc
h pr
essu
re.
1/
4 tu
rn is
abo
ut 4
psi
. di
ffere
nce.
W
ould
sug
gest
1/2
turn
firs
t at
tem
pt.
Hill
hol
d, N
-D, 4
-5, 5
-4
3-4,
4-3
Rev
s.
2-3,
4-5
3-
2, 5
-4
3-4
4-3,
6-5,
6-3
1-2,
3-2
5-
6, 6
-5
Line
rise
& s
hift
qual
ity
TCC
sol
enoi
d
Incr
easi
ng c
lutc
h pr
essu
re w
ill re
duce
slip
dur
ing
upsh
ift.
Incr
easi
ng p
ress
ure
will
slo
w c
lutc
h ex
haus
t dur
ing
rele
ase.
FOR
D-M
AZD
A P
ICTU
RED
HE
RE
(U
se o
ther
Illu
stra
tions
and
app
licat
ion
char
t on
pg. 3
to m
atch
AW
6 D
esig
n)
You
Can
Alte
r Driv
e-ab
ility
by a
djus
ting
clut
ch p
ress
ure
cont
rol o
n A
LL A
W6!
Rem
embe
r! C
lutc
h ov
erla
p re
quire
s tim
ing
or a
djus
tmen
t of t
he a
pply
and
/or t
he re
leas
ing
clut
ches
. A
lway
s m
easu
re th
e ad
just
er o
r not
e th
e tu
rns
to re
gain
OE
, if r
equi
red.
SS
C
SS
D
SS
E S
SF
AW 6 SPEED FWD
9 ©Sonnax Industries ATRA EXPO 2009
Tips Regarding Clutch Control Adjustment 09G
When adjusted properly: • Hill hold will not allow vehicle to roll back nor move forward with foot off accelerator. • Smooth engagement into Fwd-Revs. Not more than 1.5 second delay or double
bump into reverse. To Isolate proper drive-ability & shift quality: • Suggest graphing engine RPM & transmission ISS #182. When correct, they follow
each other with slight delay/lower ISS. • Flare & harsh shifts show up on graphs as spikes or square wave shift transitions. • Drive monitoring TCC slip RPM. Verify TCC stages: off, on, modulated slip mode. • When K-3 is too far out of adjustment, a cut-loose will occur on 2-3 or harsh 3-2
downshifts. It is likely the B-1 will have to be adjusted at the same time. • Drive and adjust in city driving conditions first. Once acceptable, drive it harder with
elevated upshifts and coast down. Testing on hydraulic test stand. • Strongly suggest the solenoid cover with control valves be tested independent of
the rest of the valve body. • Compare OE duty % and clutch control output, then adjust your rebuild to match.
AW 6 SPEED FWD
10 ©Sonnax Industries ATRA EXPO 2009
IDENTIFICATION OF VALVE BODY CORES
AF/AWF-21; TF-81SC; AW6A-EL FORD LINCOLN
Year Vehicle Engine Year Vehicle Engine 05-07 Five Hundred 3.0L 07-09 MKX, MKZ 3.5L
06-09 Fusion 3.0L 06-07 Zephyr 3.0L
LAND ROVER MERCURY 07 Freelander II 1.8/2.5L 06-09 Milan 3.0L
07 LR2 3.2L 05-07 Montego 3.0L
07-08 CX7 2.3L
07-08 CX9 3.5L
06-07 6S 3.0L
MAZDA
Side mount valve body & pan.
AW 6 SPEED FWD
11 ©Sonnax Industries ATRA EXPO 2009
Ford
/Maz
da-F
ront
Cov
er
TCC
SSE
SSF
PC
A
SS
D
SS
C
C3
Clu
tch
Con
trol
B1
Ban
d C
ontro
l
Mai
n P
ress
ure
Reg
.
1 B
oost
Ass
embl
y
C1
Clu
tch
Con
trol
B1
Ban
d A
ccum
ulat
or
C2
Clu
tch
Con
trol
2 1
3
AW 6 SPEED FWD
12 ©Sonnax Industries ATRA EXPO 2009
Ford
/Maz
da M
iddl
e C
astin
g -F
ront
Sid
e 7
4 V
acuu
m m
arks
at v
alve
s, n
ote
test
ed fr
om
circ
uit o
n op
posi
te s
ide
of c
astin
g.
B1/
C3
cont
rol Lo
ckup
Rel
ay
B1/C
3 R
elay
12
B1/
C3
Shi
ft R
estri
ct
B1/
C3
Sw
itch
8 5
6
C1
Shi
ft
B2/
C2
Sw
itch
C2
Rel
ay C
3 Si
gnal
B1
Sig
nal
Seco
ndar
y Pr
ess
Reg
.
Sequ
ence
Cut
back
15
14
13
11
10
3
4
5
6
7
8
9
AW 6 SPEED FWD
13 ©Sonnax Industries ATRA EXPO 2009
Ford
/Maz
da R
ear C
over
, Fro
nt S
ide
10
11
9
12
L/U
Con
trol
L/U
Con
trol P
lung
er
Ass
embl
y
Sole
noid
Mod
ulat
or #
1
C1
Rel
ay
C2
Tim
ing
Sole
noid
Mod
ulat
or #
2
Engi
ne B
rake
En
gage
men
t
20
21
18
19
17
16
AW 6 SPEED FWD
14 ©Sonnax Industries ATRA EXPO 2009
FORD/MAZDA
AW 6 SPEED FWD
15 ©Sonnax Industries ATRA EXPO 2009
FORD AW6 SPRING I.D. Bore # Identification Color Wire dia. Spring OD Free Length
SOLENOID/FRONT COVER 1 Main Pressure regulator Plain .047” .541” 1.472” SSD-C2 Plain .032” .253” .740” SSC-C1 Pink .032” .324” .762” SSE-C3 Plain .032” .253” .740” SSF-B1 Blue .030” .253” .675” Accumulator inner Lt. blue .061” .430” 1.089” Accumulator outer Plain .082” .631 1.085” Relief. 0.392 diameter White .023” .249” .593” Relief.314 dia. x2 Orange .014” .161” .368”
MIDDLE CASTING 3 C1 Shift Lt. brown .026” .252” 1.126” 4 B2/C2 Switch White .028” .297” 1.131” 5 C2 Relay Pink .024” .275” 1.071” 6 C3 Signal Lt. brown .026” .252” 1.126” 7 B1 Signal Pink .024” .275” 1.075” 8 Secondary regulator Plain .039” .413” 1.582” 9 Sequence White .026” .325” 1.038”
10 Cut back White .026” .325” 1.038” 11 B1-C3 Switch Pink .024” .275” 1.074” 12 B1-C3 Check ball 13 B1-C3 Relay Pink .024” .275” 1.074” 14 Lock-up Relay Lt green .020” .275” 1.054” 15 B1-C3 Control Lt brown .026” .252” 1.126”
REAR CASTING 16 Engine brake 17 Solenoid modulator 2 Plain .052” .389” 1.207” 18 C2 Timing White .028” .295” 1.130” 19 C1 Relay Pink .024” .271” 1.075” 20 Lock-up Control Plain .026” .382” .781” 21 Solenoid modulator 1 Plain .050” .389” 1.207
(4 lower accumulator)
Accumulator diameter .627” Red .040” .308” .921” Red .061” .479” .923”
Accumulator diameter .627” Red .040” .308” .921” Red .061” .479” .923”
Accumulator diameter .785” Lt. blue .062” .430” 1.090” Plain .080” .630” 1.088”
Accumulator diameter .785” Lt. blue .062” .430” 1.090” Plain .080” .630” 1.088”
Large accumulator end diameter .942” Plain .0772” 3.045”
Upper Accumulator dia.785” Plain .080” .635” 1.085” Blue .060” .428” 1.085”
Lower Accumulator diameter .785”
Green .053” .416” 1.056” Green .076” .618” 1.045”
(Inch x 25.4=mm)
AW 6 SPEED FWD
16 ©Sonnax Industries ATRA EXPO 2009
VALVE RELIEF CUP & SPRING REFERENCE
Valve #
Relief Cups & Springs Specification
Valve #
Relief Cups & Springs Specification
1 .392”O.D. White
.247” O.D. .022”wire
.597” free length 10.5 coils
7
Opposite side
TEE relief No color
.370” O.D. .050” wire
.427” free length 3.2 coils
2 .312” O.D. Orange
.161” O.D. .015” wire
.371” free length 8.5 coils
8
Opposite side
.392” O.D. No color
.203” O.D. .018” wire
.448” free length 9 coils
3 .312” O.D. Orange
.161” O.D. .015” wire
.371” free length 8.5 coils
9 .393” O.D. White
.247” O.D. .022” wire
.597” free length 10.5 coils
4 .392” O.D. White
.246” O.D. .025” wire
.600 free length 10.5 coils
10 .393” O.D. White
.247” O.D. .022” wire
.597” free length 10.5 coils
5 .392 O.D. Light Blue .250” O.D. .040” wire
.548” free length 6.0 coils
11 .312” O.D. Orange
.162” O.D. .014” wire
.365” free length 8.5 coils
6 .392” O.D. Orange
.250” O.D. .034” wire
.620” free length 7 coils
12 .393” O.D. White
.247” O.D. .022” wire
.597” free length 10.5 coils
TF-81SC FORD/MAZDA
AW 6 SPEED FWD
17 ©Sonnax Industries ATRA EXPO 2009
IDENTIFICATION OF VALVE BODY CORES
AF40/AM6; AW TF-80SC VOLVO CITROEN
Year Vehicle Engine Year Vehicle Engine 07-09 XC90 3.2L 06-07 C4
06-09 XC90 4.4L 06 on C5 1.8/2.0L 2.2dsl
08-09 XC70 3.2L 05-07 C6
09 XC60 3.0L 05-07 C8
07-09 580 3.2L 02 on Synergie Transit
07-09 580 4.4L OPEL
SAAB 06-07 Vectra C 2.2/3.2L
06-07 9-3 2.0/2.8L 05-07 Zafira 2.2L
06-07 Axtra G 2.0/2.2L
PEUGEOT 06-07 607 2.2/2.9L FIAT
07 407 06-07 Croma
06-07 307 1.7/2.2L
AW 6 SPEED FWD
18 ©Sonnax Industries ATRA EXPO 2009
TF-80SC; AF-40/AM6
33
31
32
30 SLT
SLC1
SLC2
S1-S2
TCC
SLC3
SLB1
29
Ports in middle check control valve to solenoid. Outside ports check control valve to adjuster. Don’t be surprised at 5” or less on a vacuum test!
AW 6 SPEED FWD
19 ©Sonnax Industries ATRA EXPO 2009
4
3
2
1
TF80SC; AF-40/AM6
AW 6 SPEED FWD
20 ©Sonnax Industries ATRA EXPO 2009
TF-80SC; AF-40/AM6
AW 6 SPEED FWD
21 ©Sonnax Industries ATRA EXPO 2009
5
8
6
7
.392 TEE pink .350” O.D. .042” wire
.680” free length 4.5 coils
.392” cup white .246” O.D. .024” wire
.595” free length 10.5 coils
.312” cup red .160” O.D. .015” WIRE
.374” free length 9 coils
TF-80SC; AF-40/AM6 9
AW 6 SPEED FWD
22 ©Sonnax Industries ATRA EXPO 2009
Acc
umul
ator
2
red
sprin
gs
.392
” cup
O
rang
e .2
48” O
.D.
.036
” wire
.6
15 fr
ee
leng
th
7 co
ils
.392
” cup
whi
te
.246
” O.D
. .0
24” w
ire
.595
” fre
e le
ngth
10
.5 c
oils
Acc
umul
ator
2
red
sprin
gs
.392
” cup
whi
te
.246
” O.D
. .0
24” w
ire
.595
” fre
e le
ngth
10
.5 c
oils
TF-80SC; AF-40/AM6
AW 6 SPEED FWD
23 ©Sonnax Industries ATRA EXPO 2009
18A
17
16
15
13
14A
12
11
A=Accumulators. Can be vacuum tested through the cover as well.
19A
No
20
21
22A
23
24
25
TF-80SC ; AF-40/AM6
AW 6 SPEED FWD
24 ©Sonnax Industries ATRA EXPO 2009
.312
” cup
red
.161
” O.D
. .0
16” w
ire
.363
” fre
e le
ngth
.468
” cup
whi
te
.275
” O.D
. .0
18” w
ire
.655
” fre
e le
ngth
26
27
TF-80SC; AF-40/AM6
AW 6 SPEED FWD
25 ©Sonnax Industries ATRA EXPO 2009
TF-80SC; AF-40/AM6
AW 6 SPEED FWD
26 ©Sonnax Industries ATRA EXPO 2009
VOLVO AW 6 SPEED SPRING I.D. Bore # Identification Color Wire dia Spring OD Free Length
MIDDLE CASTING 1 Main pressure regulator Plain .050” .551” 1.495” 2 Sequence valve Lg. blue .028” .326” 1.021” 3 B2/C2 Switch White .030” .299” 1.127” 4 C1 Shift Red .028” .254” 1.100” 5 B1/C3 Control Orange .028” .255” 1.131” 6 B1/C3 Relay Pink .026” .278” 1.055” 7 B1/C3 Check ball 8 B1/C3 Switch Valve Pink .026” .281” 1.075” 9 Manual Valve
REAR BODY WITH 1 ACCUMULATOR 26 Accumulator C1 Plain .087” .771” 3.051” 27 Lock-up control Plain .028” .382” .800”
TOP COVER WITH SOLENOIDS 29 Cut back Lt. blue .028” .322” 1.015” 30 SLB1-B1 Control Plain .034” .258” .739” 31 SLC2-C2 Control Blue .032” .258” .663” 32 SLC3-C3 Control Plain ..034” .258” .739” 33 SLC1-C1 Control Pink .034” .327” .752”
REAR CASTING WITH ACCUMULATORS & END PLATES 11 C2 Relay Pink .026” .283” 1.064” 12 C2 Timing White .029” .298” 1.132” 13 B1 Signal Pink .026” .280” 1.071”
14 Accumulator Outer Plain .083” .633” 1.094” Accumulator Inner White .063” .433” 1.089”
15 Engine brake engagement No spring 16 Accumulator 17 Secondary Regulator Plain .041” .416” 1.595” 18 Accumulator Inner Plain .083” .633” 1.094” 19 Accumulator Outer White .063” .433” 1.089” 20 Solenoid Modulator Plain .052” .393” 1.195” 21 Relay Valve Pink .027” .279” 1.069”
22 Accumulator Outer Green .079” .618” 1.040” Accumulator Inner Green .055” .414” 1.068”
23 Shift Valve Orange .029” .254” 1.130” 24 Solenoid modulator Plain .052” .393” 1.200” 25 TCC Lock up relay Lt. green .023” .273” 1.025”
Note: Valve terminology may differ!
AW 6 SPEED FWD
27 ©Sonnax Industries ATRA EXPO 2009
IDENTIFICATION OF VALVE BODY CORES
TF-60SN, 09G, 09M, 09K V.W. AUDI
Year Vehicle Engine Year Vehicle Engine 07 Eos 2.5L 03-06 A3 2.0/3.2L
06-07 Golf 1.9L dsl 06-07 A4 2.0/3.2L
06-07 Golf 2.5L 04-06 Avant, S4 4.2L
06 GTI 2.0L 03-06 TT 1.8/3.0L
05-06 Jetta 1.9L dsl
05-06 Jetta 2.5L SEAT 03-07 Multi-van 2.5/3.2L 06-07 Altea
03 Beetle 1.8/1.9L 06-07 Leon
06-07 Passat 2.0/3.6L 05-07 Toledo
06-07 Polo
05-07 Touran BMW 04 Transporter 06-07 Mini’s 1.6L
Pressure switches used until ‘04.
There are external & case mounted cooler
designs!
The separator plate must match the type of cooler. A7/A6 plate code is case mounted.
F0 is external cooler.
AW 6 SPEED FWD
28 ©Sonnax Industries ATRA EXPO 2009
primary pressure regulator –1
2-secondary pressure regulator
3 G 193
N88
N 89
G 194
N 91 TCC N 93
EPC
7 N 90 K3
6 N 283
B1
5 N 282
K2
4 N 92 K1
8
TF-60SN
Align. pin
Align. pin
Control valve index: Min. .187”-4.74mm Max. .220”-5.58mm From end of casting
Use 2 alignment pins of.238” diameter
AW 6 SPEED FWD
29 ©Sonnax Industries ATRA EXPO 2009
.293” cup red; .160” O.D. .015” wire; .374” free length
.392” cup orange; .249” O.D.; .035 wire;
.694” free length; 6.5 coils
.392” cup white; .246” O.D.; .024” wire;
.595” free length
.312” cup red; .160” O.D.; .015” wire;
.374” free length .392” cup orange; .249” O.D.; .035” wire; .624” free length;
6.5 coils
Relief is not in all TF60 units. No hole in plate=no relief.
Key: Vacuum test location
TF-60SN
AW 6 SPEED FWD
30 ©Sonnax Industries ATRA EXPO 2009
9 10 11 12 13 14 15
19 18 17 16
Rubber check ball .210-.218”
.375” cup white .246” O.D. .024” wire
.589” free length 11 coils
TF-60SN
AW 6 SPEED FWD
31 ©Sonnax Industries ATRA EXPO 2009
26 27
25
24
23 22
21
20
4 Accumulator pistons on back side. .392” TEE no color; .374” O.D.;
.050” wire; .428” free length
3 coils Line relief at B1/C3 control valve.
25
24
20
21
.392” cup white; .245” O.D. .024” wire
.598” free length 10.5 coils
TF-60SN
AW 6 SPEED FWD
32 ©Sonnax Industries ATRA EXPO 2009
.392” cup white .245” O.D. .024” wire
.598” free length
Rubber
.392” TEE green .334” O.D. .030” wire
.793” free length
30
28
29
AW 6 SPEED FWD
33 ©Sonnax Industries ATRA EXPO 2009
Plate ID and
cooler hole area
Main separator plates vary. A6/A7 (pictured above) are used with case mounted cooler FO code has external cooler.
AW 6 SPEED FWD
34 ©Sonnax Industries ATRA EXPO 2009
09G AW6 SPRING I.D. Bore
# Identification Color Wire dia. Spring OD Free Length
SOLENOID/FRONT COVER 1 Primary Regulator Pink .043” .519” 1.450” 2 Secondary Regulator White .046” .410” 1.485” 3 Solenoid Modulator #2 No color .040” .315” 1.00” 4 N-90 K3 Control Pink .036” .325” .800” 5 N-283 B1 Control White .034” .256” .740 6 N-282 K2 Control Dark Red .034” .250” .746” 7 N-92 K1 Control Dark Green .040” .326” .805” 8 Manual Valve
MIDDLE CASTING 9 B2-C2 Switch White .028” .290” 1.140” 10 B1-C3 Switch Pink .024” .270” 1.080” 11 C1 Shift Brown .026” .250” 1.135” 12 B1 Signal Pink .024” .275” 1.075” 13 C1 Relay Pink .024” .275” 1.075” 14 B2 Switch Lt. Green .026” .322” 1.010” 15 Engine Brake No Spring 16 Lock up Relay Lt. Green .022” .275” 1.010” 17 Cut back Lt. Green .026” .322” 1.010” 18 C2 Signal Brown .026” .250” 1.135” 19 C2 Timing White .028” .290” 1.135”
UPPER/FRONT 4 ACCUMULATOR PISTON BODY 20 Check ball 21 B1 Signal Pink .024” .278” 1.085” 22 K3 Accumulator No/Lt. Green .076/.053” .621/.412” 1.050/1.055” 23 B2 Accumulator Lt. Green/Pink .089/.060” .620/.400” 1.0/1.036” 24 B1-C3 Relay Pink .024” .278” 1.073” 25 B1-C3 Control Brown .026” .248” 1.146” 26 K1 Accumulator No color .076” .620” 1.055” 27 K2 Accumulator No color .076/.055” .620/.410”. 1.055/1.046”
UPPER/REAR TCC CONTROL BODY
28 Solenoid modulator Lt. Brown 29 TCC Control Dk. Green 30 Line Pressure Accumulator -
Sm diameter Lg. diameter
No paint No paint
.053” .077”
.412” .618”
1.058” 1.045”
Note: Valve terminology may differ! (Inch x 25.4=mm)
AW 6 SPEED FWD
35 ©Sonnax Industries ATRA EXPO 2009
TC Release on Ford/Mazda
C1
C3
C2
B2 on AF-40, lube on TS80
B2
AF-40 B1
AF-40 TC Re-lease
Pressure Tap Location Ford/Mazda Type Similar in location to AF-40
Cooler return
AW 6 SPEED FWD
36 ©Sonnax Industries ATRA EXPO 2009
PRESSURE TAP IDENTIFICATION 09G
K3
K1
K2 Lube B2 TCC Release
B1
AW 6 SPEED FWD
37 ©Sonnax Industries ATRA EXPO 2009
TYP
ICA
L C
-1 C
LUTC
H P
RE
SS
UR
E (T
ypic
al o
f all
FWD
AW
6)
P, N
19-2
0 C
-1 e
ngag
es
PA
RK
TO
DR
IVE
Poi
nt o
f E
ngag
emen
t, 1.
2 se
cond
s.
Driv
e ac
cele
ratio
n to
1-
2 sh
ift
2-3
SH
IFT
& 3
-4
4-5
5-4,
6-4
4-
3-2
190,
180
ju
st p
rior t
o do
wns
hifts
Am
ount
of l
ine
rise
is to
rque
pro
porti
onat
e.
58-6
1 D
/Idle
225
Stal
l D
rive
AW 6 SPEED FWD
38 ©Sonnax Industries ATRA EXPO 2009
TYP
ICA
L C
-3 C
LUTC
H P
RE
SS
UR
E (A
ll AW
6 FW
D)
PA
RK
P
TO
RE
VS
.75
SE
CO
ND
S
Idle
R
evs.
.
RE
VS
ST
ALL
1ST-
2ND
2-
3, 1
.2 S
EC
ON
DS
3-
4, 1
.2 S
EC
ON
DS
4-
5, 1
.2 S
EC
C-3
pre
ssur
e sp
ikes
to a
ppro
xim
ate
170-
180
on a
ll do
wn
shift
s.
334
max
.
88
AW 6 SPEED FWD
39 ©Sonnax Industries ATRA EXPO 2009
AW6
TYP
ICA
L LU
BE
PR
ES
SU
RE
PA
RK
, RE
V, N
, ID
LE
DR
IVE
EN
GA
GE
1.
5 S
EC
C
OO
L TE
MP
DR
IVE
IDLE
A
T H
WY
S
PE
ED
S H
OT
1-2.
2-3
RIS
E
AT
EA
CH
S
HIF
T
3-4
SH
IFT
NO
RM
AL
5-
8 ps
i TC
C
AP
PLI
ED
AW 6 SPEED FWD
40 ©Sonnax Industries ATRA EXPO 2009
#6-N
93
EP
C L
INE
AR
SO
LEN
OID
(Typ
ical
TF-
60S
N)
PA
RK
-N, R
-N, N
-D
RE
V. S
TALL
TY
PIC
AL
UP
SH
IFT
4TH
CR
UIS
E,
4-5,
5-6
Low
am
pera
ge=
Hig
h pr
essu
re o
r inv
erse
pro
porti
onal
#5 N
92 L
INE
AR
SO
LEN
OID
(Typ
ical
TF-
60S
N)
PA
RK
P
-R
N-D
1,
2, 3
, 4
5-4
FOR
CE
D D
OW
NS
HIF
T 5T
H &
6TH
C
ontro
ls K
-1/C
-1 c
lutc
h.
L
ow A
mp=
Hig
h cl
utch
pre
ssur
e.
AW 6 SPEED FWD
41 ©Sonnax Industries ATRA EXPO 2009
COMMON COMPLAINTS WITH AW 6 SPEED FWD
NOTES:
AW 6 SPEED FWD
42 ©Sonnax Industries ATRA EXPO 2009
Complaint: • Harsh up or downshifts. • TCC slip, fluid overheat • RPM cycling at low speed or coast Cause: • TCC clutch is not releasing or loss of TC modulation control. • Torque converter clutch control valve bore worn and/or secondary regulator valve
bore worn. Diagnostic Procedure: • Monitor converter release pressure to verify the clutch is being controlled. If re-
lease psi remains low (see chart) during up/down shift, the control valve is not stroking. Compare the release pressure to TCC solenoid amperage. For overheated conditions, also monitor cooler flow (see chart).
AW 6 SPEED FWD
43 ©Sonnax Industries ATRA EXPO 2009
Not
e: T
appi
ng re
leas
e pr
essu
re is
a g
ood
met
hod
to v
erify
ope
ratio
n of
#4-
N 9
1 so
leno
id.
T
CC
mod
ulat
es o
ff-on
dur
ing
4-5-
6 ge
ar s
hifts
. Th
is ta
p is
a m
etho
d to
ver
ify T
CC
is a
ffect
ing
shift
qua
lity.
TC
C m
odul
ates
on
afte
r 1-2
shi
ft.
T
CC
cut
off
durin
g Ti
p-Tr
onic
up
& d
owns
hifts
TC
C re
mai
ns o
n du
ring
coas
t dow
n.
If
coo
ler r
elea
se p
ress
ure
is lo
w, c
heck
flui
d le
vel!
AW6
CO
NV
ER
TER
RE
LEA
SE
PR
ES
SU
RE
(Typ
ical
)
STA
RT,
PA
RK,
RE
VS
, N, D
RIV
E ID
LE
RE
VS
. STA
LL
DR
IVE
HA
RD
AC
CE
L.
TCC
AP
PLY
AW 6 SPEED FWD
44 ©Sonnax Industries ATRA EXPO 2009
AW6
CO
NV
ER
TER
RE
LEA
SE
PR
ES
SU
RE
PA
RK
TO
RE
VS
1-
2 U
PS
HIF
T 2-
3 U
PS
HIF
T 3-
4 U
PS
HIF
T 4-
5 S
HIF
T 5-
6 SH
IFT
TO
FULL
TC
C O
N
TC
C s
trate
gy o
f par
tial s
lip b
etw
een
upsh
ifts.
TCC
may
rem
ain
appl
ied
on c
oast
dow
n fo
r eng
ine
brak
ing.
Whe
n co
nver
ter i
s fu
lly a
pplie
d, re
leas
e w
ill b
e –0
-
All
Con
verte
r app
ly &
rele
ase
flow
& p
ress
ure
is c
ontro
lled
by lo
ck-u
p co
ntro
l val
ve a
nd fe
d by
sec
onda
ry re
gula
tor v
alve
,
limiti
ng it
to 1
25 p
si.
AW 6 SPEED FWD
45 ©Sonnax Industries ATRA EXPO 2009
#4-N
91
TCC
LIN
EA
R C
ON
TRO
L S
OLE
NO
ID (T
ypic
al T
F-60
SN
)
PA
RK
, RE
V.,
DR
IVE
1-2
P
OS
T 1-
2 S
HIF
T C
ON
TRO
L S
LIP
FU
LL O
N
DR
OP
DU
RIN
G 2
-3, 3
-4, 4
-5 U
P O
R D
OW
NS
HIF
T
Not
es:
0.2
Am
p =
off
.9/1
.0am
p =
full
on
(E
xam
ple)
; ‘07
TF-
60 J
etta
N
o m
odul
atio
n up
on e
ngag
emen
t int
o P
-R o
r R-D
; can
sta
rt m
odul
atio
n or
con
trol s
trate
gy ju
st a
fter 1
-2 s
hift.
H
ot c
ontin
uous
mod
ulat
ion
durin
g m
aneu
vers
of u
p &
dow
n sh
iftin
g. H
ot c
ontin
uous
mod
ulat
ion
durin
g lif
t thr
ottle
rele
ase.
R
etur
ns to
1.0
Am
p po
st s
hift.
Cut
bac
k to
0.2
(app
roxi
mat
e) in
man
ual T
ip-T
roni
c co
ntro
l shi
fts.
TC
C s
lip v
ery
activ
e at
spe
eds
35-5
0 K
. D
oes
not c
ance
l with
bra
ke p
edal
.
Rem
ains
at 1
.0 A
mp
durin
g co
ast d
own
5, 4
, 3, 2
, 1 fo
r eng
ine
brak
ing.
All
linea
r sol
enoi
ds fo
llow
N 9
1 A
mp
spik
e.
Sug
gest
mon
itor s
lip R
PM w
ith a
mpe
rage
nor
mal
, tra
nsm
issi
on te
mp
is 8
7C a
t 0.7
0 vo
lts.
Max
imum
sta
ll R
PM
, 278
5 in
reve
rse,
bu
t sta
ll te
stin
g is
not
sug
gest
ed.
AW 6 SPEED FWD
46 ©Sonnax Industries ATRA EXPO 2009
AF-
21 ‘0
9 Fu
sion
10K
Coo
l
Hot
Par
k R
ever
se
Idle
R
ever
se
stal
l D
rive
Id
le
Driv
e S
tall
Driv
e 1-
3 TC
C
Can
cel
TCC
Ap
plie
d
Med
. Acc
eler
atio
n
Har
d ac
cele
ratio
n
2.8
TCC
app
lied
on h
ard
ac
cele
ratio
n
Even
t: N
orm
al o
pera
tion
____
____
____
____
____
____
____
____
____
____
____
____
____
____
__
Not
es:
Top
hose
coo
ler r
etur
n___
____
____
____
____
____
____
____
____
____
____
____
____
___
AW 6 SPEED FWD
47 ©Sonnax Industries ATRA EXPO 2009
Complaint: • Flare on 2-3 shift • Harsh engagement • Delay forward or reverse Cause: • Clutch control valves (at solenoid bore) are out of adjustment. Primarily K3/C3 and
or B1. • K3 valve is most active and bore wears quickly. Correction & Diagnosis: Must repair K3/C3 clutch control valve body, then: • Remove oil pan and adjust clutch control valves. Always measure & record the OE
position. • To overcome a flare on 2-3, back out the K3 adjuster which increases apply psi.
You may have to turn in the B1 adjuster to slow down its exhaust rate. Suggest 1/2 to 3/4 turn per test.
• Suggest use of graphing scanner to monitor engine RPM vs. ISS RPM. Should not have spikes in engine RPM during down shift. Engine RPM and ISS #182, sensors should parallel each other. If the engine RPM has spikes at the beginning of shift, clutch pressure is not high/fast enough. If the engine RPM sensor appears to be a square form or dips down during shift, there is a bind up and the opposing clutch (probably B1) may have to be adjusted as well!
Note: On the TF-60SN (VW 09G/09K/09M), the Ross-Tech performs well for this diagnosis. (www.Ross-Tech.com)
AW 6 SPEED FWD
48 ©Sonnax Industries ATRA EXPO 2009
Complaint: • Slippage or loss of 3-4, K-2 clutch failure Cause: • TF-60 series commonly have a cross leak under the case sleeve which feeds
the K-2 clutch. Correction: • Replace the sleeve with an aftermarket with improved retention. Complaint: • Loss of lubrication • Transmission temperature codes • Enable of shift mode I or II Cause: • Incorrect valve body and separator plate for case lube design. • Remote heat exchanger and case mounted cooler use different separator plates. Correction: • Install matching parts. To isolate this (prior to road test) check for cooler flow and
release pressure on the lift. Refer to Sonnaflow® charts. Complaint: • (09M, 09G) Harsh reverse, 3rd or 5th. • Bind up on 3-4 or 3-2. Cause: Damaged K-3 clutch balance piston. This piston acts as a return and accumulator counter acting upon the K-3 apply piston. Correction: • Need to replace the K-3 drum assembly unless pistons are available. • Aftermarket pistons are now available with tabs to eliminate the radial piston move-
ment.
AW 6 SPEED FWD
49 ©Sonnax Industries ATRA EXPO 2009
Complaint: • Post overhaul, flare upshifts or bumpy downshifts Cause: • Failure to reset adapts or relearn strategy has not been completed. Correction: • Reset all control modules. • Perform a drive cycle relearn of 15 shift cycles. Complaint: • Fluid discoloration • TCC clutch failure Cause: • Improper fluid will not control TCC clutch slip rate and dissipate heat. Correction: Suggested fluids • T-IV or 1161540 for Volvo • XT-8QAW-Ford • JW53309-Mazda • 9986195-GM • Mobile 1, ESSO or Castrol full synthetic are aftermarket alternatives Complaint: • No reverse, Loss of gear • Low fluid level Cause: • Solenoid wiring may be incorrect. VW Fill adapter: Some VW applications use a plastic fill elbow that enters above the pan and to the left of front. The number on the part is VW AG-JP57344-02. The case could be bored to accept this fill adapter. It would require drilling the case to .517” ID (13.1mm) to a depth of .487” (12.3mm). At the base of the first bore is a stepped transition to a final bore of .412” (10.4mm)
AW 6 SPEED FWD
50 ©Sonnax Industries ATRA EXPO 2009
Complaint, Cause, Correction Issues
Complaint: • Harsh coast downshifts, harsh upshifts. Cause: • TCC control valve bore and sleeve wear. Bore wear reduces the hydraulic control
of release pressure on the converter piston. The piston remains applied during the shift.
Correction: • Service TCC control bore and sleeve. Complaint: • Flare/long upshifts, gear ratio codes, loss of gear. Cause: • Bore wear at a specific clutch control valve. • Solenoid modulator valve bore worn. • Clutch circuit, relay valve sticking. • SL clutch control solenoid defective or contaminated. • Main pressure regulator bore and/or boost sleeve worn. • Incorrect fluid level. Correction: • Inspect and service in order of above. Complaint: • Delayed forward engagement Cause: • Valve body temperature sensor not registering properly. (Will also affect TCC ap-
ply) • Fluid level incorrect’C-1/ K-1 clutch control valve bore worn or defective solenoid. Correction: • Service C-1/K-1 valve and test thermal element.
AW 6 SPEED FWD
51 ©Sonnax Industries ATRA EXPO 2009
PO 602 Control module programming error PO 710 Oil temperature sensor P0 715 Input revolution sensor PO 720 Output revolution sensor PO 729 Gear ratio 6th PO 731 Gear ratio 1st PO 732 Gear ratio 2nd PO 733 Gear ratio 3rd PO 734 Gear ratio 4th PO 735 Gear ratio 5th PO 736 Gear ratio reverse PO 743 SLU Linear solenoid fault PO 748 SLT Linear solenoid fault PO 753 S2 solenoid fault PO 773 S1 solenoid fault PO 780 Unusual shift, (valve stuck) PO 1743 TCC stuck on or off PO 1981 SLC1 Linear solenoid fault PO 1982 SLC2 Linear solenoid fault PO 1983 SLC3 Linear solenoid fault PO 1984 SLB1 Linear solenoid fault
PO U2100 Series– CAN communication errors
Common Codes
AW 6 SPEED FWD
52 ©Sonnax Industries ATRA EXPO 2009
Relearn
Initial Relearn: If transmission or TCM is repaired or replaced, delete the learned data and perform both Neutral and Initial Learning. If the TCM has been overwritten (reflashed), perform relearn process! 1. Warm up ATF to minimum of 66°C (151°F) and maximum of 110C (230°F). 2. Garage shift:
Brake applied, select N for 3 seconds. Then N to D and allow engagement of C1 for 3 seconds. Repeat 5 times for D-Reverse.
3. Gear shift: Drive 25-35% throttle to obtain 6th gear and hold 80 Kmh. Then coast to a stop within a minimum of 60 seconds. Repeat this cycle 10 times.
Note: Spec for maximum N-D engagement is 1.0, N-Rev is 1.5 sec. Neutral Position Relearn: 1. Vehicle running in Park 2. Release & shift to Neutral 3. Verify N is recognized by TCM on dash & scanner. 4. If not recognized, adjust shifter & input Neutral gear with scan tool.