TF60 SN Tech Guide

INDEX

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Introduction.......................................................................................................Application Chart...............................................................................................Pressure Testing.................................................................................................Internal Wiring Harness.....................................................................................Wiring Diagram.................................................................................................Solenoid Operation and Testing.........................................................................Case Passage Identification................................................................................Clutch Assemblies.............................................................................................Sprag Rotation...................................................................................................Fluid Specification.............................................................................................ATSG Bulletins..................................................................................................Data Block Information.....................................................................................Solenoid Amp Chart...........................................................................................Clutch Adapt Re-Set...........................................................................................Codes.................................................................................................................Valve Body.........................................................................................................Valve Body Mapping.........................................................................................Hydraulic Schematics........................................................................................

3 7 8 12 16 18 23 27 32 33 35 48 50 53 57 60 71 86

Copyright © ATSG 2009

TF60-SN09G/09M

09K - Overseas

AUTOMATIC TRANSMISSION SERVICE GROUP18635 S.W. 107 AVENUE

CUTLER BAY, FLORIDA 33157(305) 670-4161

IntroductionThe 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.

AUTOMATIC TRANSMISSION SERVICE GROUP18635 SW 107TH AVENUE

CUTLER BAY, FLORIDA 33157(305) 670-4161

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.

JIM DIALSENIOR CONSULTANT

ED KRUSETECHNICAL CONSULTANT

WAYNE COLONNAPRESIDENT

GERALD CAMPBELLTECHNICAL CONSULTANT

DALE ENGLAND TECHNICAL CONSULTANT

GREGORY LIPNICKTECHNICAL CONSULTANT

JERRY GOTTECHNICAL CONSULTANT

JON GLATSTEINTECHNICAL CONSULTANT

DAVID CHALKERTECHNICAL CONSULTANT

GREG CATANZAROTECHNICAL CONSULTANT

CLAY WICKHAMTECHNICAL CONSULTANT

ROLAND ALVAREZTECHNICAL CONSULTANT

The information and part numbers contained in this booklet havebeen carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

Copyright © ATSG 2010

PETER LUBANTECHNICAL SUPERVISOR

2nd PrintingNovember 2010

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 A2 2006-On 2.0L 09G (TF-60SN)AUDI A4 2006-On 2.0L 09G (TF-60SN)AUDI TT 2003-04 1.8L 09G (TF-60SN)BMW Mini Clubman 2008-On 1.6L 09G (TF-60SN)BMW Mini Cooper 2002-On 1.6L 09G (TF-60SN)SEAT Altea 2004-On 09G (TF-60SN)SEAT Leon 2005-On "1.4, 1.6, 2.0L" 09G (TF-60SN)SEAT Toledo 2004-On "1.6, 1.9, 2.0L" 09G (TF-60SN)VW Beetle 2005-On "1.8, 1.9, 2.0, 2.5L" 09G (TF-60SN)VW Eos 2007-On "2.0, 3.2L" 09G (TF-60SN)VW Jetta 2005-On "1.9, 2.0, 2.5L" 09G (TF-60SN)VW Passat 2006-On 2.0L 09G (TF-60SN)VW Tiguan 2008-On "1.4, 2.0L" 09G (TF-60SN)VW Touran (Non US) 2003-On "1.6, 1.9, 2.0L" 09G (TF-60SN)VW Passat 2006-On 3.6L 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.

TF60-SNPRELIMINARY INFORMATION

3AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

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.

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

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.

Selector Lever

The appearance of the selector lever may vary for different vehicles however, the operation and the functionremains 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.

Thumb Paddles

Lock Button


Downshift Button (E439)

Upshift Button (E438)

- +

ATSG

4 AUTOMATIC TRANSMISSION SERVICE GROUP



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.

- Upshift prevention or downshift prevention.

Dynamic Shifting Program (DSP)

This automatic transmission has the latest generation Dynamic Shifting Program DSP.

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.




40

50

60

60

40

20

0

70

50

30

10

9050 130 0

1/21/1

PRNDS

Emergency Mode

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

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.

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

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.

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).

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

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”.

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.

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.

TCC - OFF

RegulatedTCC Apply

Fully AppliedTCC

En

gin

e L

oad

Vehicle Speed



K3 K1 B1 F1 B2 K2

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

CLUTCH APPLICATION CHARTComponent

Gear1st Gear2nd Gear3rd Gear

4th Gear5th Gear

6th GearRev Gear

K1X

K2 K3

X

B1

X

X

B2X* X

F1

XXX X

XX

X

X X


Application Chart

Figure 17AUTOMATIC TRANSMISSION SERVICE GROUP


Copyright © 2010 ATSG

K1 K2 Lube B2 TCC Release


Pressure Taps

Figure 28 AUTOMATIC TRANSMISSION SERVICE GROUP



2400. 7540

2024330a

K3


Pressure Taps




B1


Pressure Taps




Lube


Pressure Taps




GA

U6

A0

68

94

DC

B6

A0

90

64

FBX

6A

08

57

4

ABY6

A0

94

12

CC

P6

A0

92

14

CC

P6

A0

92

12

917

3T5

EO

Wiring Harnessfrom 8 terminalCase Connector

(ISS, OSS & TFT)

Wiring Harnessfrom 14 terminalCase Connector(All Solenoids)

OSS BlueClip Connector

(G195)

ISS WhiteClip Connector

(G182)

TransmissionFluid Temp. Sensor

(G93)

ISS G182The 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 G195The 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 G93Transmission 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.


Internal Harness




GA

U6

A0

68

94

DC

B6

A0

90

64

FBX

6A

08

57

4

ABY6

A0

94

12

CC

P6

A0

92

14

CC

P6

A0

92

12

917

3T5

EO

N89(#2 Sol.)

N88(#1 Sol.)

N90(#3 Sol.)

N91(#4 Sol.)

N92(#5 Sol.)

N93(#6 Sol.)

N282(#9 Sol.)

N283(#10 Sol.)

Hydraulic Pressure Senders G193 and G194The 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 N89Solenoid 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 N283Solenoid 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


Solenoid Identification

Figure 7

Hydraulic Pressure

Sender # 2 (G194)

Hydraulic Pressure

Sender # 1 (G193)




1

13

11

9

7

5

3

2

4

6

8

10

12

14

Solenoid

Number (Name)

Positive Meter Lead

Terminal # (Wire Color)

Solenoid # 1 (N88)

Solenoid # 2 (N89)

Solenoid # 3 (N90)

Solenoid # 4 (N91)

Solenoid # 5 (N92)

Solenoid # 6 (N93)

Solenoid # 9 (N282)

Solenoid # 10 (N283)

1 (White)

2 (Black)

7 (Lt. Blue)

11 (Lt. Green)

3 (Yellow)

13 (Green)

5 (Red)

9 (White)

Negative Meter Lead


Case Ground

Case Ground

8 (Lt. Green)

12 (Brown)

4 (Purple)

14 (Grey)

6 (Blue)

10 (Black)

Resistance

( Ohms)Ù

10.0 - 16.0

10.0 - 16.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

View looking into the 14 terminal transmission case connector

The internal wire colors are provided in the chart above.


Solenoid Case Connector




1

7

5

3

2

4

6

8


Sensor

ID (Name)

Positive Meter Lead


TFT (G93)

ISS (G182)

OSS (G195)

PS1 (G193)

PS2 (G194)

1 (Orange)

3 (White)

5 (Tan)

7 (N/A)**

8 (N/A)**

Negative Meter Lead


2 (Orange)

4 (Red)

6 (Blue)

Case Ground

Case Ground

Resistance

( Ohms)Ù

37.0 - 51.0 K @ -30º C

5.0 - 8.0 K @ 10º C

3.0 - 5.0 K @ 25º C

230 - 265 @ 110º C

100 - 120 @ 145º C

Ù

Ù

Ù

Ù

Ù

5.0 M *Ù

5.0 M *Ù

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.


TFT and RPM Sensor Case Connector

Open

Open




OSS

TFT Sensor

Tiptronic Switch

CAN Communication

PowerSupplyRelay

Fuse

Fuse

Battery

N90

N89

N88

38 SP+

50 SP-

NIN+

NIN-

45 TFT +

8 TFT -

48

46 CAN-H

34 CAN-L

27 IGN

3 B+

1 GND

41S1

15S2

30S3+

18S3 -

5S4 +

43S4 -

3S5 +

4S5 -

31S6 +

17S6 -

16S9 +

32S9 -

4S10 +

44S10 -

TCMJ217

N91

N92

N93

N282

N283

1

2

7

8

11

12

3

4

13

14

5

6

9

10

2

Gear LeverPosition Sensor

47

36

22

10

1

9

5

7

218

Data BUS On Board Diag. Interface

5

6

51

39

3

4ISS

1

2

24 Press. Sw. 1

25 Press. Sw. 28

7Some Models

28 IGN

8 Terminal Trans. Case Conn.

14 Terminal Trans. Case Conn.

Typical VW Wiring




View looking into the TCM (J217)

View looking into the 52 pin J217 connector

1 2 3 4 5 6 7 8 9 10 11 12 13 14

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

29 30 31 3227 28 33 34 35 36 37 38 39 40

41 42 43 44 45 46 47 48 49 50 51 52

Solenoid

Number (Name)

Positive Meter Lead


Solenoid # 1 (N88)

Solenoid # 2 (N89)

Solenoid # 3 (N90)

Solenoid # 4 (N91)

Solenoid # 5 (N92)

Solenoid # 6 (N93)

Solenoid # 9 (N282)


TFT (G93)

ISS (G182)

OSS (G195)

PS1 (G193)

PS2 (G194)

41 (Black/Violet)

15 (Black/Grey)

30 (Yellow/Violet)

5 (Green/Violet)

42 (White/Violet)

31 (Grey)

16 (Brown/Violet)

4 (Blue/Green)

45 (Violet)

51 (White)

38 (White)

24 (Violet/Grey)

25 (Green/Grey)

Negative Meter Lead


1or2 (Brown)

1or2 (Brown)

18 (Yellow/Green)

43 (Yellow/Blue)

6 (Violet/Green)

17 (Green/Grey)

32 (Blue)

44 (Violet/Yellow)

8 (Violet/White)

39 (Brown)

50 (Green)

1or2 (Brown)

1or2 (Brown)

Resistance

(W Ohms)

10.0 - 16.0

10.0 - 16.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

See chart P.12

5.0M

5.0M

Open

Open

External harness wire colors are provided in the chart above and may vary depending on year, makeand model of vehicle.


TCM J215 Connector




50

C4

50

C4.032”

X

N90 - N92 - N93 - N282 - N283Solenoid Operation

X

Solenoid Off Solenoid On

X


Solenoid Details

Figure 12




38

GA

U6

A0

69

84

2D

X


X

X

X

X

X

.032”

N91Solenoid Operation


Solenoid Feed


Solenoid Details

Figure 13




1 2+

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

OFF

RPM

RPMCOMmAA

V

V

mVW

W

VmAA

mAA

5.6 W

12-21 W Bulb

OFF

ON

Valve should stroke

50

C4

50

C4


5.0 - 5.6 W

Figure 14




OFF

RPM

RPMCOMmAA

V

V

mVW

W

VmAA

mAA

5.6 W

12-21 W Bulb

OFF

ON

Valve should stroke

38 GAU6A069842D

38 GAU6A069842D


Bench Testing the SLU Solenoid(N91) 5.0 - 5.6 W

1 2+

Figure 15





OFF

RPM

RPMCOMmAA

V

V

mVW

W

VmAA

mAA

12.7 W

Bench Testing S88 and S89

11 - 15 W

X

OFF

ON

Solenoid should open

In

Out

Ex

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


Figure 16



To Cooler from VB (1)

TCC Apply

TCC Release

Pump Inlet Pump Outlet

B1 K1 K3

B2 K2


Blocked by Pump

Differential LubeFrom VB (1)

Front Planet Lube (1)

K1 Pressure TapTCC Release Pressure Tap Lube

TCC Apply

TCC Release

B1K1

K3FrontPlanetLube(3)

To B1 Pressure Tap

Pump InletPump Outlet

Cooler Return To VB (5)

Through Pump


Through Pump


Through Pump

Passage I.D.

Figure 17

Case passage ID with the heat exchanger attached to thetransmission




7

Converter Case Cover

Transmission Case Cover

TransCooler

To Cooler From VB (2)

To Cooler From VB (3)

Pipe To Cooler From VB (4)

Cooler In From VB (5)

Cooler ReturnTo VB (1)Through

Pump


Through Pump

Cooler Return PipeTo VB (2)

Through Pump


Through Pump


Through Pump



To B1 Pressure Tap

Front PlanetLube (2)

K3

K1

B1

Pump OutletPump InletBlockedby Pump

TCC Release

TCC Apply


Passage I.D.

Figure 18




To External Cooler from VB (1)

TCC Apply

TCC Release

Pump Inlet Pump Outlet

B1 K1 K3

B2 K2


Blocked by Pump


Front Planet Lube (1)

K1 Pressure TapTCC Release Pressure Tap Lube

TCC Apply

TCC Release

B1K1

K3FrontPlanetLube(3)

To B1 Pressure Tap

Pump InletPump Outlet

To External Cooler Through Pump (6)


Through Pump

External Cooler Return

To VB (2)

Passage I.D.

Figure 19

Case passage ID with the heat exchanger (cooler) separatefrom thetransmission

Cooler Lube Filter




7

Converter Case Cover

Transmission Case Cover

To External Cooler From VB (2)

To External Cooler From VB (3)

Pipe To External Cooler From VB (4)

To external cooler (5)

To external Cooler Through Pump (7)

To external Cooler From Pump (8)



To B1 Pressure Tap

Front PlanetLube (2)

K3

K1

B1

Pump OutletPump InletBlockedby Pump

TCC Release

TCC Apply


Passage I.D.

Figure 20

To external Cooler From Pump (9)

External Cooler Return

To VB (1)




K1 Clutch Drum Assembly


Figure 21






Figure 22






Figure 23




B1 Clutch Brake Assembly


2.9mm (0.113”)

3

2.4mm (0.95”)

Cushion Plate(Sits like a cone )

This end face pump. The piston to applythis clutch is in the pump. There is nosnap ring as the caged piston return

spring assembly sits between the pistonand the cushion plate retaining the assembly.

Bottom Plate is steppedwith stepped side down


Figure 24







23.6mm (0.142”)

3.1mm (0.122”)

Piston sits in the bottomof the case

Figure 25




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 )


Sprag Rotation

Figure 26




VW Technical Data

Manufacturer AISIN Co., LTD. Japan

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

Control Hydraulic control module (Valve Body) in oil sump with an externalelectronic control module.

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

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

Intermediate drivefor code lettersGSY/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 lowerstransmission gear ratio and increases driving dynamics.


Figure 27




Check and Fill Plug

Fluid LevelStand Pipe

Fluid Level

Figure 28




GA

U6

A0

68

94

DC

B6

A0

90

64

FBX

6A

08

57

4

ABY6

A0

94

12

CC

P6

A0

92

14

CC

P6

A0

92

12

917

3T5

EO

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.

Solenoid N88 and N89 were accidently cross connected.

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.

TF60-SNNO 4th, 5th, 6th OR REVERSE

Complaint:

Cause:

Correction:

N89Black Wire

(#2 Sol.)

N88White Wire

(#1 Sol.)

Figure 29




VW/AUDI09M/09M TF60-SN

NO REVERSE NEUTRALS IN THIRD

COMPLAINT:

CAUSE:

CORRECTION:

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.

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.

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.



GA

U6

A0

68

94

DC

B6

A0

90

64

FBX

6A

08

57

4

ABY6

A0

94

12

CC

P6

A0

92

14

CC

P6

A0

92

12

9173

T5

EO

N89(#2 Sol.)

N88(#1 Sol.)

N90(#3 Sol.)

N91(#4 Sol.)

N92(#5 Sol.)

N93(#6 Sol.)

N282(#9 Sol.)

N283(#10 Sol.)

SOLENOID LOCATIONS


SOLENOID & CLUTCH APPLICATION CHARTComponent

Gear

1st Gear2nd Gear3rd Gear

4th Gear5th Gear

6th GearRev Gear

K1 K2 K3 B1 B2

On

F1Pressure Control Solenoids

N92S-5

N282S-9

N90S-3

N283S-10

N93S-6

N91S-4

On*

OnOn

OnOn

On

OnOnOnOnOn

OnOnOn

PWM

PWM

PWM

PWM

PWM

PWM

PWM

PWM

PWM

PWM

PWM

PWMOffOffOffOffOnOnOn Off OnOn

On On OnOn On OffOn Off OnOff On On

OnOffOffOff On Off




GA

U6

A0

68

94

DC

B6

A0

90

64

FBX

6A

08

57

4

ABY6

A0

94

12

CC

P6

A0

92

14

CC

P6

A0

92

12

9173

T5

EO


(ISS, OSS & TFT)



(G195)


(G182)


(G93)

Figure 32

GA

U6

A0

68

94

DC

B6

A0

90

64

FBX

6A

08

57

4

ABY6

A0

94

12

CC

P6

A0

92

14

CC

P6

A0

92

12

9173

T5

EO


(ISS, OSS & TFT)



(G195)


(G182)


(G93)

INCORRECTInternal Harness

Routing

Figure 31

CORRECTInternal Harness

Routing

Solenoid #9(N282)

Solenoid #3(N90)

Solenoid #9(N282)

Solenoid #3(N90)

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.

09M models route the upper and lowerharnesses from the

right side of thevalve body with a

hold down bracket.




1

13

11

9

7

5

3

2

4

6

8

10

12

14

Solenoid

Number (Name)

Positive Meter Lead


Solenoid # 1 (N88)

Solenoid # 2 (N89)

Solenoid # 3 (N90)

Solenoid # 4 (N91)

Solenoid # 5 (N92)

Solenoid # 6 (N93)

Solenoid # 9 (N282)


1 (White)

2 (Black)

7 (Lt. Blue)

11 (Lt. Green)

3 (Yellow)

13 (Green)

5 (Red)

9 (White)

Negative Meter Lead


Case Ground

Case Ground

8 (Lt. Green)

12 (Brown)

4 (Purple)

14 (Grey)

6 (Blue)

10 (Black)

Resistance

(WOhms)

10.0 - 16.0

10.0 - 16.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0

4.0 - 8.0


14 TERMINAL CASE CONNECTOR AND INTERNAL HARNESS I.D.




Figure 34

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.

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.

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.

TF60-SN

K2 CLUTCHSTEEL SEALING

RING SLEEVE

COMPLAINT:

CAUSE:

CORRECTION:

SLIPPING 3-4 OR NEUTRAL 3-4




An apparent loss of lubrication fluid causing premature failure of the transmission’s drivetrain immediately after a main case or valve body exchange.

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.

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

TF60-SNLOSS OF LUBRICATION

Complaint:

Cause:

Correction:

AUTOMATIC TRANSMISSION SERVICE GROUP


41

TransCooler

Cooler In

Cooler Return


Figure 35

To external heatexchanger (Cooler)(cooler line pockets

are in the main case)

External heatexchanger

(Cooler) return

Converter housing case half with heat exchanger.

Converter housing case half without heat exchanger.



42


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


Heat exchanger(Cooler) Return

Figure 36

Main case half for a heat exchangermounted on the converter housing.

Main spacer plate to case for a case whichhas an attached heat exchanger

Heat exchanger(Cooler) Return

into the valve bodyfor lubrication

distribution



43


To Remote Heat Exchanger(Cooler)


External HeatExchanger

(Cooler) Return

Figure 37

Cooler Lube Filter

Main case half for a remote heat exchanger.

Remote heat exchanger

(Cooler) Returninto the valve body

for lubricationdistribution

Main spacer plate to case for a case whichhas a remote heat exchanger



44


K3 CLUTCH CROSS-SECTIONAL VIEW

K3 Clutch Drum

K3 Clutch Apply Piston

K3 ClutchBalance Piston


Feed (Lube circuit)K3 Clutch

Piston Feed

K3 ClutchBalance PistonControlled leak

Pump

Stator Support

VW/AUDI09M/09M TF60-SN

HARSH REVERSE THIRD &FIFTH GEAR

COMPLAINT:

CAUSE:

CORRECTION:

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.

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.

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.

Figure 38



45


K3 CLUTCH "OFF"

K3 Clutch Drum

K3 ClutchApply Piston



Feed (Lube circuit)K3 ClutchPiston Feed


Pump

Stator Support

K3 Clutch Drum

K3 ClutchApply Piston



Feed (Lube circuit)K3 ClutchPiston Feed


Pump

Stator Support

K3 CLUTCH "ON"

Figure 40

Figure 44



46



Figure 41

K3 CLUTCH DRUM EXPLODED VIEW

K3 CLUTCHDRUM

K3 CLUTCHPISTON

K3 RETURNSPRING

K3 BALANCEPISTON K3 CLUTCH

ASSEMBLY



47


TF60-SN/09-G 09-MDESCRIPTION OF DATA BLOCKS

VW/AUDI

CONTROL MODULE SELECTION

02 Auto Trans

GROUP SELECTION

08 Measured Blocks

001

Engine Speed

xxxx

Trans RPMG182 (Input)

xxxx

Trans RPMG195 (Output)

xxxx

Driving Mode

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

002 xxxx

G182 (Input)Voltage

1.440v

Trans RPMG195 (Output)

xxxx

DataBlock

Trans RPMG182 (Input)

G195 (Output)Voltage

1.440v

003

AcceleratorPedal Position%

0-100%

VSSkm/h

xxxx

Driving Manner

DS= DriveTT= Manual


Driving Mode

004


0-100%

DeclinationRecognitionSelector Lever

P-R-DS or Manual


Driving Mode

LevelDW (downhill)UP (uphill)

*Note= There are many duplications of information listed in the data blocksthis is to aid the technician when monitoring specific groups

.50v-1.440v .50v-1.440v

Figure 42



48


MEASURED BLOCKS CONTINUED

08 Measured Blocks

005

Hill DrivingFactor

0.0%

Throttle ValveFactor

006 84.0°C

Specified Current(TCC) Solenoid Valve 4 (N91)

.200A

Lock-upClutch Slip

xxxx

DataBlock

ATF TempG93

007

.100A Fully "Off"

.980A Fully "On"See Note*

008

Solenoid Valve 1Solenoid Valve 2 Battery Voltage

0.0%

Throttle DynamicIndex

Changesbased onsnap ofThrottle


0-100%

Lock-upClutch Slip

xxxx

Solenoid Valve 5 (N92)


.100A Fully "Off"



.100A Fully "Off"



.100A Fully "Off"


(LP) Solenoid Valve 6 (N93)

.200A to .940ABased on

engine load

(TC) Solenoid Valve 4 (N91)

.200A to 1.0ABased on

load and PCMTCC strategy

00000000

00000000

N89 N88

0= Off1= On

11- for M110- for Tcc On

13.6V

009

Brake PedalSwitch

00000000

Kick-downSwitch Selector Lever

Multifunction Switch

00000000=Off00000011=On

00000010

May be modeldependant

no state change

P-R-N-DManual

00000000

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

*Note= Amperage changes during shift transitions S=00001111

Figure 43



49


MEASURED BLOCKS CONTINUED

08 Measured Blocks

010 94.0°C .60V

Trans Condition

Blank

DataBlock

ATF TempG93

011 OFF or ON

012

TransferrableTorque

VoltageSupply

13.50V

Brake SwitchCondition (F47)

LockingSL

P/N =LockedPress Brake = --

TiptronicRecognition

P-R-N-D= BlankManual= M

100.0%

ATF TempVoltage

Speed

0.0km/h

Selector Lever

P-R-N-DManual

Selector Lever

P-R-N-DManual


Driving Mode

013 00000000

Selector Lever

P-R-N-DManual

Multifunction Switch

00000000

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


P-R-N-D= BlankManual= M

UP Button =UPDN Button = Down

014

APPCondition

00000000

Idle SwitchCondition


0-100% N/A

Off Idle=00000000At Idle=00000001

S=00001111


D=00000000M=00001000

UP=00011000DN=00001100

Figure 44



50


SOLENOID APPLICATION CHART

SOLENOIDGEARRANGE

Park Reverse NeutralDrive1H

Manual1H 2H

3H 4H 5H6M3M 4M 5H6H

SV5-N92 (K1)

SV9-N282 (K2)

SV3-N90 (K3)

SV10-N283 (B1)

SV6-N93 (LP)

SV4-N91 (TC-PWM)

SV2-N89

SV1-N88

.100A

.100A

.980A

.980A

.980A

.200A

0

0

.980A

.980A

.100A

.980A

.980A

.200A

0

0

.980A

.980A

.980A

.980A

.980A

.200A

0

0

.200A

.100A

.980A

.980A

.980A

.980A

.200A

.100A

.980A

.980A

.980A

.740A

10

0

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

1

.980A

.980A

.100A

.860A

.200A

0

0

.980A

.100A

.980A

.980A

.990A

.200A

3H=03M=1

0*-1

.100A

.980A

.980A

.980A

.990A

.200A

4H=04M=1

.100A .100A

.980A

.100A

.740A .740A

.100A

.980A

.990A

.200A

5H=05M=1

.990A

.200A

6H=06M=1


CLUTCH APPLICATION CHARTComponent

Gear1st Gear2nd Gear3rd Gear

4th Gear5th Gear

6th GearRev Gear

K1X

K2 K3

X

B1

X

X

B2X* X

F1

XXX X

XX

X

X X

Description of terms: .100A= Very Low amperage

Solenoid OFF

.980A= Very High amperageSolenoid ON

SV1&2-N88&89 0 =OFF1=ON

0*-1= OFF or ONDuring 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.

0*-1 0*-1 0*-1

Figure 45



51


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

Additional Solenoid Details



52

VCDSRelease 805.1

VCDS: Main Screen

Select Control Module Auto-Scan Control Module Finder

Program OptionsApplicationsOBD-ll Functions

Select Auto-Scan Control Module Finder

OptionsApplicationsOBD-ll

About Exit

Features consisting of severalbasic commands, like transportmode.

Select Comm Port. Set Debug andProtocol Options, etc.

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

Select an Individual Control Modulesuch as Engine, ABS, Airbag, etc.

An automatic scan of all controllersfor Fault Codes.

Scans an address range forISO9141 compliant control modules.

x

VW 09A & 09G2-3 FLARE -HARSH 3-4

DOUBLE BUMP 2-3 / DOWNSHIFT CLUNKS

COMPLAINT:

CAUSE:

CORRECTION:

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.

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

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 1This is the first screen that will appear after the vehicle is

plugged into the Lap-top. Press Select to select control module

Figure 47



53


Fault Codes-02

Measured Blocks-08

Single Reading-09

Comm Status

IC=1 TE=0 RE=0

Protocol:KW1 281

Controller Info

VAG Number:

Soft. Coding:

Extra:

Extra:

Component:

Shop #.

Readiness- 15 Login - 11 Coding - 07

Adaption - 10Basic Settings - 04

Output Tests - 03

VCDSOpen Controller

Basic Functions

These are "Safe" Refer to Service Manual!

Advanced Functions

Advanced ID - 1A

Adv. Meas. blocks Security Access-16

Close Controller, Go Back - 06

XXX XXX XXX XX

XXXXX XXX XXXXX

XX XX XXX X XXXX

XXXXXXXXXXXXXXXX XXXXXXXXXXXX

xVCDS Release 805.1: 01-Engine,Open Controller

VCDSSelect Control Module

VCDS Release 805.1: Select Control Module x

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

Common Drivetrain Chassis Comfort/Conv. Electronics 1 Electronics 2

Go BackGo!Direct EntryAddress Word (01-7F):

Step 2- Select 01-Engine

Step 3- Select Adaption - 10



54


Fault Codes-02

Measured Blocks-08

Single Reading-09

Comm Status

IC=1 TE=0 RE=0

Protocol:KW1 281

Controller Info

VAG Number:

Soft. Coding:

Extra:

Extra:

Component:

Shop #.



Output Tests - 03

VCDSOpen Controller

Basic Functions


Advanced Functions

Advanced ID - 1A



XXX XXX XXX XX

XXXXX XXX XXXXX

XX XX XXX X XXXX



Channel

00

Stored value

New value

Test value

ReadUp

Dn

Up

Dn

Test Save Done, Go Back

Add to Log

xVCDS Release 805.1: 01-Engine, Adaptation

Fault Codes-02

Measured Blocks-08

Single Reading-09

Comm Status

IC=1 TE=0 RE=0

Protocol:KW1 281

Controller Info

VAG Number:

Soft. Coding:

Extra:

Extra:

Component:

Shop #.



Output Tests - 03

VCDSOpen Controller

Basic Functions


Advanced Functions

Advanced ID - 1A



XXX XXX XXX XX

XXXXX XXX XXXXX

XX XX XXX X XXXX



Channel

00

Stored value

New value

Test value

ReadUp

Dn

Up

Dn


Add to Log


---

000

000

Note: SAVE Ch. 00 Resets All Factory Defaults

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

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

Figure 49



55


Fault Codes-02

Measured Blocks-08

Single Reading-09

Comm Status

IC=1 TE=0 RE=0

Protocol:KW1 281

Controller Info

VAG Number:

Soft. Coding:

Extra:

Extra:

Component:

Shop #.



Output Tests - 03

VCDSOpen Controller

Basic Functions


Advanced Functions

Advanced ID - 1A



XXX XXX XXX XX

XXXXX XXX XXXXX

XX XX XXX X XXXX



Channel

00

Stored value

New value

Test value

ReadUp

Dn

Up

Dn


Add to Log


---

000

000

Note: SAVE Ch. 00 Resets All Factory Defaults

Yes

Save Value: 0To Channel: 00With WSC: 00066

Are You SURE?

No

?

xVCDS: ADP Save Conf.


Step 6- Press Yes to save All Factory Defaults

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

Figure 50



56


Figure 51

DTC

N88-SV1 Shift Solenoid 1, Circuit Error (Open or Short)

N89-SV2 Shift Solenoid 2, Circuit Error (Open or Short)

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

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

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

Transmission Fluid Temp, (G93) circuit malfunction (Open or Short)

TCM to ECM Error, No Engine Speed Signal G28

Tiptronic Switch F189 implausible signal

Drive Train Data Bus Fault, No Communication

Torque Converter Clutch mechanical fault (slip)

Engine Control Module, DTC present

Throttle Position Sensor, No Signal CAN bus connection interupted

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

Control Module Faulty, (TCM)

00258

00260

00264

00266

00268

00300

01045

01192

00777

01236

01312

01314

65535

VOLKSWAGEN "VAG" DIAGNOSTIC TROUBLE CODES

DESCRIPTION

N90- SV3 K3 Control Solenoid Circuit Error (Open or Short)00262

Transaxle Range (TR) switch F125, circuit malfunction (Implausible signal)00293

N282-SV9, K2 Control Solenoid Circuit Error (Open or Short)00348

N283-SV10, B1 Control Solenoid Circuit Error (Open or Short)00349

System Voltage to Low 00364

Function restriction because of excess Trans Fluid Temp. 00453

00529

00541 ATF temp to high

Engine Torque signal no signal from ECM01166

ABS Module, No Communication, or ignition switched on with TCM unplugged01316

Speed signal from ABS Front Left wheel implausible01679

Speed signal from ABS Front Right wheel implausible01680

Speed signal from ABS Rear Left wheel implausible01681

Speed signal from ABS Rear Right wheel implausible01682

Wheel speed signals/vehicle speed implausible01683



57

Copyright © 2010 ATSGFigure 52

vag

TCM faulty16988

VOLKSWAGEN "VAG" to obd11 DIAGNOSTIC TROUBLE CODES

DESCRIPTIONobd11

P0604

TCM faulty

TCM faulty

TCM faulty

16989 P0605

16997 P0613

17084 P0700

Multifunction Trans Range sensor F125 electrical fault17089 P0705

Multifunction Trans Range sensor F125 implausible signal17090 P0706

Trans Fluid Temp G93 fault in electrical circuit17095 P0711

Trans Fluid Temp G93 signal too low17096 P0712

Trans Fluid Temp G93 signal too high17097 P0713

Input Speed sensor G182 circuit fault17099 P0715

Input Speed sensor G182 Implausible signal17100 P0716

Input Speed sensor G182 no signal17101 P0717

Output Speed sensor G195 circuit fault17105 P0721

Engine Speed sensor G28 circuit fault from ECM17109 P0725

Clutch of indicated gear is faulty (wrong ratio, slip)17113 P0729

Clutch of indicated gear is faulty (wrong ratio, slip)17114 P0730

1st Gear (wrong ratio, slip)17115 P0731

2nd Gear (wrong ratio, slip)17116 P0732

3rd Gear (wrong ratio, slip)17117 P0733

4th Gear (wrong ratio, slip)17118 P0734

5th Gear (wrong ratio, slip)17119 P0735

17132 P0748 N91-SV4 Torque Converter Clutch PWM Solenoid, Circuit (Open or Short)

17135 P0751 N88-SV1 Shift Solenoid 1, Circuit Error (Open or Short to ground)

17136 P0752 N88-SV1 Shift Solenoid 1, Circuit Error (Short to Battery voltage)

17137 P0753 N88-SV1 Shift Solenoid 1, Electrical Circuit fault

17140 P0756 N89-SV2 Shift Solenoid 2, Circuit Error (Open or Short to ground)

17141 P0757 N89-SV2 Shift Solenoid 2, Circuit Error ( )Short to Battery voltage

17182 P0798 N93-SV6 Pressure control Circuit Error (Open or Short)

17195 P0811 Heavy Clutch Slip

17224 P0840 Trans pressure sensor 1 G193 mechanical fault (model dependant)

17225 P0841 Trans pressure sensor 1 G193 open or short/implausible (model dependant)

17226 P0842 Trans pressure sensor 1 G193 short to ground (model dependant)

17299 P0845 Trans pressure sensor 2 G194 mechanical fault (model dependant)

17230 P0846 Trans pressure sensor 2 G194 open or short/implausible (model dependant)

17231 P0847 Trans pressure sensor 2 G194 short to ground (model dependant)



58


Figure 53

vag

Voltage supply too low18010

VOLKSWAGEN "VAG" to obd11 DIAGNOSTIC TROUBLE CODES

DESCRIPTIONobd11

P1602

DTC in ABS problem

Throttle position sensor signal too low G79

18255 P1847

18554 P2122

19146 P2714 N91-SV4 Torque Converter Clutch PWM Solenoid, Circuit (Open or Short)

19147 P2715 N91-SV4 Torque Converter Clutch PWM Solenoid, Circuit (short to B+)

19148 P2716 N91-SV4 Torque Converter Clutch PWM Solenoid, electrical circuit fault

19155 P2723 N92-SV5 K1 Clutch control Solenoid, Circuit (Open or Short)

19156 P2724 N92-SV5 K1 Clutch control Solenoid, Circuit (short to B+)

19157 P2725 N92-SV5 K1 Clutch control Solenoid electrical circuit fault,

19164 P2732 N93-SV6 Pressure control Solenoid, Circuit (Open or Short)

19165 P2733 N93-SV6 Pressure control Solenoid, Circuit (short to B+)

19166 P2734 N93-SV6 Pressure control Solenoid electrical circuit fault,



59

91709170

T1T1

9170T17CA3C00708

7CA3C00704

5BY3A01371

5BX3A01706

5CB3B00400

4AU3C00100

"09G" VALVE BODY EXPLODED VIEW

240

241

242

243

243

247

248

252

300

254

243244

246

249

250

251

245

240 LOWER V.B. TO ACCUMULATOR HOUSING 2 BOLT (70 MM LENGTH). 241 LOWER V.B. TO UPPER V.B. BOLT (39.5 MM LENGTH). 242 LOWER V.B. TO UPPER V.B. BOLT (28 MM LENGTH). 243 ACCUMULATOR-1 HOUSING TO UPPER V.B. (64 MM LENGTH)(3 REQ). 244 ACCUMULATOR-1 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ). 245 ACCUMULATOR-2 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ). 246 ACCUMULATOR-2 HOUSING TO UPPER V.B. (64 MM LENGTH)(2 REQ). 247 ACCUMULATOR-1 HOUSING ASSEMBLY. 248 ACCUMULATOR-1 ASSEMBLY SPACER PLATE. 249 ACCUMULATOR-2 HOUSING ASSEMBLY. 250 ACCUMULATOR-2 ASSEMBLY SPACER PLATE. 251 UPPER V.B. TO LOWER V.B. BOLTS (21 MM LENGTH)(10 REQUIRED). 252 UPPER VALVE BODY ASSEMBLY. 254 LOWER VALVE BODY ASSEMBLY. 300 MAIN VALVE BODY SPACER PLATE.




60

Figure 54

9170T1

7CA3C00708

7CA3C00704

5BY3A01371

5BX3A01706

5CB3B00400

4AU3C00100

254 LOWER VALVE BODY ASSEMBLY. 255 PRESSURE SWITCH ASSEMBLY (2 REQUIRED). 256 N91, PWM CONVERTER CLUTCH SOLENOID. 257 N93, PWM LINE PRESSURE CONTROL SOLENOID. 258 N92, PWM K1 CLUTCH CONTROL SOLENOID. 259 N282, PWM K2 CLUTCH CONTROL SOLENOID. 260 N283, PWM B1 CLUTCH CONTROL SOLENOID. 261 N90, PWM K3 CLUTCH CONTROL SOLENOID. 262 PWM SOLENOID RETAINING PINS (6 REQUIRED) 263 K1 CLUTCH REGULATOR VALVE. 264 K1 CLUTCH REGULATOR VALVE SPRING. 265 K2 CLUTCH REGULATOR VALVE. 266 K2 CLUTCH REGULATOR VALVE SPRING. 267 B1 CLUTCH REGULATOR VALVE. 268 B1 CLUTCH REGULATOR VALVE SPRING. 269 K3 CLUTCH REGULATOR VALVE. 270 K3 CLUTCH REGULATOR VALVE SPRING. 271 N91 AND N93 SOLENOID PIN RETAINING BRACKET. 272 SOLENOID PIN RETAING BRACKET BOLT. 273 TRANSAXLE FLUID TEMPERATURE SENSOR RETAINING BRACKET. 274 TFT SENSOR RETAINING BRACKET BOLT. 275 SOLENOID PIN RETAINING BRACKET BOLTS (2 REQUIRED).

276 N92, N282, N283, N90 SOLENOID PIN RETAINING BRACKET. 277 MANUAL VALVE. 278 PRIMARY PRESSURE REGULATOR VALVE. 279 PRIMARY PRESSURE REGULATOR VALVE SPRING. 280 PRIMARY PRESSURE REGULATOR BOOST VALVE. 281 PRIMARY PRESSURE REGULATOR BOOST VALVE SLEEVE. 282 PRIMARY REGULATOR BOOST SLEEVE RETAINER. 283 N88, ON/OFF SOLENOID. 284 SOLENOID RETAINING BOLT (2 REQUIRED). 285 N89, ON/OFF SOLENOID. 286 SECONDARY PRESSURE REGULATOR VALVE. 287 SECONDARY PRESSURE REGULATOR SPRING. 288 SECONDARY PRESSURE REGULATOR BORE PLUG. 289 SECONDARY PRESSURE REGULATOR BORE PLUG RETAINER. 290 SOLENOID MODULATING VALVE A FOR N88, N89, N90, N282, N283. 291 SOLENOID MODULATING VALVE A SPRING. 292 SOLENOID MODULATING VALVE A SPRING RETAINER.

"09G" LOWER VALVE BODY ASSEMBLY, EXPLODED VIEW

255

254

254256

257

258

259

260

261

262

263

265267

269

264

266268

270

271

272

273

274

275

276

277

278

279

280

281

282

283

285

286

290

291

292

287

288

289

284

284

275

255




61

Figure 55

91709170

ENLARGED VIEW

252 UPPER VALVE BODY ASSEMBLY. 254 LOWER VALVE BODY ASSEMBLY. 293 CHECK VALVE 2: LUBE (.392" DIAMETER). 294 CHECK VALVE 2 SPRING. 295 CHECK VALVE 3: FWD ENG./K1/K2 REG VALVE FEED (.313" DIAMETER). 296 CHECK VALVE 3 SPRING. 297 PLASTIC CHECK VALVE 1: K2 298 CHECK VALVE 4: FWD ENG. ACCUM. EXHAUST (.392" DIAMETER). 299 CHECK VALVE 4 SPRING.

300 MAIN VALVE BODY SPACER PLATE. 301 CHECK VALVE 5: B2 ORIFICE CONTROL- REVERSE (.313" DIAMETER). 302 CHECK VALVE 5 SPRING. 303 CHECK VALVE 1: LUBE & COOLER (.392" DIAMETER). 304 CHECK VALVE 1 SPRING.

254

293

294

295

296

297

300

252

301

302

303

304

298

299

"09G" LOWER VALVE BODY SMALL PARTS, EXPLODED VIEW




62

Figure 56

LOWER VALVE BODY CHECK VALVE AND VALVE SPRING SPECS

264. K1 RegulatorValve Spring

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


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

268. B1 RegulatorValve Spring

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


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

279. Primary PressureRegulator Valve Spring

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

294. Check Valve 2Spring

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


No. Coils-8Overall Length-640"Outside Diameter- .640"Coil Diameter- .035"Color- Red/Orange


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


287. Secondary PressureRegulator Valve Spring

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

291. Solenoid ModulatorValve A Spring

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


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


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



63

Figure 57

328 4-5 TIMING VALVE BORE PLUG RETAINER. 329 4-5 TIMING VALVE STEEL BORE PLUG. 330 4-5 TIMING VALVE. 331 4-5 TIMING VALVE SPRING. 332 K2 RELAY VALVE RETAINER. 333 K2 RELAY VALVE BORE PLUG. 334 K2 RELAY VALVE. 335 K2 RELAY VALVE SPRING. 336 K1 RELAY VALVE RETAINER. 338 K1 RELAY VALVE BORE PLUG. 339 K1 RELAY VALVE. 340 K1 RELAY VALVE SPRING. 341 B2 SWITCH VALVE BORE PLUG RETAINER. 342 B2 SWITCH VALVE STEEL BORE PLUG. 343 B2 SWITCH VALVE. 344 B2 SWITCH VALVE SPRING. 345 B2 SWITCH VALVE TIPTRONIC M1 BORE PLUG RETAINER. 346 B2 SWITCH VALVE TIPTRONIC M1 BORE PLUG. 347 B2 TIPTRONIC M1 VALVE.

252 UPPER VALVE BODY ASSEMBLY. 300 MAIN VALVE BODY SPACER PLATE. 305 TCC SWITCH VALVE. 306 TCC SWITCH VALVE SPRING. 307 TCC SWITCH VALVE SPRING RETAINER. 308 PRESSURE MODIFIER VALVE BORE PLUG RETAINER. 309 PRESSURE MODIFIER VALVE STEEL BORE PLUG. 310 PRESSURE MODIFIER VALVE SPRING. 311 PRESSURE MODIFIER VALVE. 312 K3 RELAY VALVE BORE PLUG RETAINER. 313 K3 RELAY VALVE STEEL BORE PLUG. 314 K3 RELAY VALVE. 315 K3 RELAY VALVE SPRING. 316 B2 RELAY VALVE (M1) SPRING RETAINER. 317 B2 RELAY VALVE (M1) SPRING. 318 Br YELAY VALVE (M1). 319 SCREEN FOR MODULATING VALVES A & B. 320 RELAY VALVE PLUG. 321 RELAY VALVE. 322 RELAY VALVE SPRING. 323 RELAY VALVE SPRING RETAINER. 324 B1 SWITCH VALVE BORE PLUG RETAINER. 325 B1 SWITCH VALVE BORE PLUG. 326 B1 SWITCH VALVE. 327 B1 SWITCH VALVE SPRING.

252

305

306

307

313

316

317

318

319

320

321

322

326

327

335

339

340

347343

344 334

331

330

323

324

328333

336

338341

342345

346

332329

325

314

315

312

308

309

310

311

300

"09G" UPPER VALVE BODY ASSEMBLY, EXPLODED VIEW




64Figure 58

319

91709170

ENLARGED VIEW

ENLARGED VIEW

252 UPPER VALVE BODY ASSEMBLY. 300 MAIN VALVE BODY SPACER PLATE (MODEL SENSITIVE). 319 PLASTIC FILTER FOR SOLENOID MODULATING VALVES A & B. 348 PLASTIC VALVE CHECK VALVE 2: SECONDARY PR VALVE. 349 PLASTIC CHECK VALVE 4: K1 350 CHECK BALL 1, 5.3 MM (.210") DIAMETER. 351 CHECK VALVE 6: MANUAL VALVE (.392" DIAMETER). 352 CHECK VALVE 6 SPRING. 353 PLASTIC CHECK VALVE 3: B. 354 PLASTIC CHECK VALVE 5: K3.

348

349

350

351

352353

354

252 (ACCUMULATOR SIDE)

252(MAIN SPACER SIDE)

300

"09G" UPPER VALVE BODY SMALL PARTS, EXPLODED VIEW




65

Figure 59

UPPER VALVE BODY VALVE SPRING SPECS

306. TCC SwitchValve Spring

No. Coils-9Overall Length-1.160"Outside Diameter- .275"Coil Diameter- .022"Color- Lt. Green

310. Pressure ModifierValve Spring

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

315. K3 RelayValve Spring

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

317. B2 Relay (M1)Valve Spring

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

322. Relay ValveSpring

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



344. B2 SwitchValve Spring

No. Coils-9Overall Length-1.010"Outside Diameter- .325"Coil Diameter- .027”Color- Lt. Blue Copyright © 2010 ATSG

327. B1 SwitchValve Spring


331. 4-5 TimingValve Spring






66

Figure 60

T1T1

376

243

384

387

388

389

390

391

392

393

394

395

396

400

401

402

403

404

405406

407

397398

399

368368

385

386

243

244

244

244

244

380

381

382

383

377

247

248

248

247

378

379

"09G" ACCUMULATOR BODY 1, EXPLODED VIEW

243 ACCUM. BODY 1 HOUSING TO UPPER V.B. (64 MM LENGTH)(3 REQ). 244 ACCUM. BODY 1 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ). 247 ACCUM. BODY 1 HOUSING ASSEMBLY. 248 ACCUM. BODY 1 SPACER PLATE. 376 K3 CONTROL VALVE BORE PLUG RETAINER. 377 K3 CONTROL VALVE BORE PLUG. 378 K3 CONTROL VALVE. 379 K3 CONTROL VALVE SPRING. 380 3-4 TRANSITION VALVE BORE PLUG RETAINER. 381 3-4 TRANSITION VALVE BORE PLUG. 382 3-4 TRANSITION VALVE. 383 3-4 TRANSITION VALVE SPRING. 384 B1 CLUTCH ACCUMULATOR PISTON. 385 B1 CLUTCH ACCUMULATOR PISTON OUTER SPRING. 386 B1 CLUTCH ACCUMULATOR PISTON INNER SPRING. 387 K3 CLUTCH ACCUMULATOR PISTON. 388 K3 CLUTCH ACCUMULATOR PISTON OUTER SPRING. 389 K3 CLUTCH ACCUMULATOR PISTON INNER SPRING. 390 K1 CLUTCH ACCUMULATOR PISTON. 391 K1 CLUTCH ACCUMULATOR PISTON SPRING. 392 K2 CLUTCH ACCUMULATOR PISTON. 393 K2 CLUTCH ACCUMULATOR PISTON OUTER SPRING. 394 K2 CLUTCH ACCUMULATOR PISTON INNER SPRING. 395 ACCUMULATOR PISTON AND SPRING RETAINER PLATE. 396 B1/K3 3-WAY CHECK VALVE BORE PLUG RETAINER. 397 B1/K3 3-WAY CHECK VALVE BORE PLUG. 398 B1/K3 3-WAY CHECK VALVE (.250" STEEL BALL). 399 B1/K3 3-WAY CHECK VALVE SEAT. 400 B1 RELAY VALVE BORE PLUG RETAINER. 401 B1 RELAY VALVE BORE PLUG. 402 B1 RELAY VALVE. 403 B1 RELAY VALVE SPRING. 404 CHECK VALVE 11: MAIN LINE PRESSURE LIMIT VALVE. 405 CHECK VALVE 11 SPRING. 406 CHECK VALVE 10: REGULATED EXHAUST (.392" DIAMETER). 407 CHECK VALVE10 SPRING.




67

Figure 61

ACCUMULATOR BODY 1 CHECK VALVE, VALVE AND ACCUMULATOR SPRING SPECS

379. K3 ControlValve Spring


383. 3-4 TransitionValve Spring

No. Coils-13Overall Length-1.135"Outside Diameter- .252"Coil Diameter- .027"Color- None

403. B1 RelayValve Spring

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

385. B1 Accum.Outer Spring

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


386. Inner Spring

B1 Accum.

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

388. K3Outer Spring

Accum.

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

389. Inner Spring

K3 Accum.


391. K1 Accum.Outer Spring

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

393. K2Outer Spring

Accum.


389. Inner Spring

K2 Accum.



No. Coils-4Overall Length-.425"Outside Diameter- .370"Coil Diameter- .055"Color- Pink or none





68

Figure 62

249

250

369

370

371372

373 374

375

246

246

249

250

355

356

357358

359360

361362

363

364

365

366

367

368

245

245

245

245

"09G" ACCUMULATOR BODY 2, EXPLODED VIEW

245 ACCUM. BODY 2 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ). 246 ACCUM. BODY 2 HOUSING TO UPPER V.B. (64 MM LENGTH)(2 REQ). 249 ACCUM. BODY 2 HOUSING ASSEMBLY. 250 ACCUM. BODY 2 SPACER PLATE. 355 TCC APPLY CONTROL VALVE SLEEVE RETAINER. 356 TCC APPLY CONTROL VALVE SLEEVE. 357 TCC APPLY CONTROL VALVE. 358 TCC APPLY CONTROL VALVE SPRING. 359 TCC APPLY CONTROL VALVE. 360 SOLENOID MODULATOR VALVE B BORE PLUG RETAINER. 361 SOLENOID MODULATOR VALVE B BORE PLUG. 362 SOLENOID MODULATOR VALVE B FOR N91, N92, N93. 363 SOLENOID MODULATOR VALVE B SPRING. 364 N93 LINE PRESSURE ACCUMULATOR PISTON. 365 N93 LINE PRESSURE ACCUMULATOR PISTON OUTER SPRING. 366 N93 LINE PRESSURE ACCUMULATOR PISTON INNER SPRING. 367 N93 LINE PRESSURE ACCUMULATOR SPRING RETAINER PLATE. 368 N93 ACCUMULATOR RETAINER BOLTS (11 MM LENGTH). 369 CHECK BALL 2, 5.3 MM (.210") DIAMETER. 370 PRESSURE CONTROL SOLENOID (N93) LIMIT CHECK VALVE 7. 371 PRESSURE CONTROL SOLENOID (N93) LIMIT CHECK VALVE 7 SPRING. 372 CHECK VALVE 8: REGULATED EXHAUST. 373 CHECK VALVE 8 SPRING. 374 COOLER PRESSURE LIMIT CHECK VALVE 9 (.392" DIAMETER). 375 COOLER PRESSURE LIMIT CHECK VALVE 9 SPRING.




69

Figure 63

ACCUMULATOR BODY 2 CHECK VALVE, VALVE AND ACCUMULATOR SPRING SPECS

358. TCC Apply ControlValve Spring

No. Coils-9Overall Length-1.200"Outside Diameter- .380"Coil Diameter- .025"Color- None

363. Solenoid ModulatorValve B Spring

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

365. N93Accum.Outer Spring

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


386. N93Inner Spring

Accum.



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







70

Figure 64


VALVE BODY MAPPING 09GPARTIAL HYDRAULIC

SCHEMATIC FORB1 RELAY VALVE



103L

100L

102L

101L

125L

120L 122L

114L

107L

115L

116L

113L

105L

110L

124L

111L

117L

106L

112L

118L

123L119L

109L

104L

108L

121L

101L

107L

110L

115L

120L

B1 RelayValve

ACCUMULATOR BODY 1(SAME ON ALL CASTINGS)

100L SERIES

HOW TO USE THIS MANUAL

All castings and spacer plates have been numbered so theyCan be identified in an oil diagram. Example: Circuit 110Lpassage is located in the #1 Accumulator Body, lower side

(100L Series). This passage can now be located in the partialoil circuit diagram shown above. Spacer plate orifice sizes and locations are also identified in the oil circuit diagram

labeled Valve Body Mapping.

71Figure 65

91709170

T1T1

ACCUMULATOR BODY 1UPPER SIDE100U Series

ACCUMULATOR BODY 1LOWER SIDE

100L Series

ACCUMULATOR BODY 1SPACER PLATE

200 Series

UPPER SPACER PLATE 2400 Series

LOWER VALVE BODY UPPER SIDE5000U Series

LOWER VALVE BODY LOWER SIDE5000L Series

LOWER SPACER PLATE6000 Series

UPPER VALVE BODY UPPER SIDE7000U Series

UPPER VALVE BODY LOWER SIDE7000L Series

ACCUMULATOR BODY 2UPPER SIDE300U Series

ACCUMULATOR BODY 2LOWER SIDE

300L Series




72Figure 66

9173T5

7000L

7002L

7003L

7005L

7006L

7001L

7011L

7010L

7004L

7009L

7007L

7008L

7012L

7013L

7014L

7015L

UPPER VALVE BODY LOWER SIDE7000L Series




73Figure 67

UPPER VALVE BODY UPPER SIDE7000U Series

7001U

7000U

7002U

70

03

U

70

04

U

70

05

U

7006U

70

07

U7

00

8U

70

09

U

7019U

7011U

7012U

70

13

U

7014U

7015U

70

16

U

7017U

7018U

70

10

U

7020U

7021U

7022U

70

23

U

7024U

70

25

U

70

26U

7027U

70

28

U

70

40

U

7044U

7033U

7032U

70

39

U

70

42

U7038U

7063U

7031U

70

30

U

7029U

7036U

70

35

U

7041U

7037U

7034U

7045U

70

46

U

70

47

U

70

48

U7

04

9U

7050U

70

51

U

7052U

7053U

7054U

708

5U

70

81

U

70

59

U

70

58

U

70

64

U

70

57

U

70

55

U

70

71

U

70

70

U

70

69

U

70

55

U

70

68

U

70

65

U

70

67

U7

07

2U

70

73

U

70

76

U

70

74

U7

08

6U

70

56

U

70

79

U

70

80

U

70

77

U

70

75

U

70

82

U

70

78

U

70

66

U

70

83

U

7060U

7043U

7061U

7062U

70

84

U



Check Valve 1Lube & Cooler

Check Valve 2Lube

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

Check Valve 4

FWDEng.

Accum.Exhaust

Plastic Check Valve 1

(K2)

Check Valve 5

B2 OrificeControl(Rev)


74Figure 68

LOWER SPACER PLATE6000 Series

6051

6047

6045

6000

6001

6036

6037

6035

6005

6069

6015

6014

6068

6020

6060 6034

6019 6059

6075

6058

6018

6017

6032

6002

6031

6004

603060556022

6003

6026

6029

6028

6027

6073

6072

6011

6012

6067

6038

6074

6066

6010

6071

60496025

6048

6008

6009

6053

60246039

6043

6042

6046

6054

6044

6050

60406057

6041

6077

60526056

60626063

6061

6070

6065

60236007

6013

60066033

6021

6016

6076

6064

6078

6079

6080

60816082

6083

6084

6085

60866087

60886089

6090

6091

6094

6092

6093

6150

6149 6140

6104

6105

61106106

6138

6097

6107

6102

6103

61456143

6144

6142

6112

6108

6114

6111

6118

61256119

6126 6095 6141

6147

61556129

6154

6096 6136

6135

6134

6137

6133

6130

6115

6151

6116

6152

6131

6132

6117

6128

6146

61486139

6153

6100

6099

6098

61016113

6109

6120

6122

6124

6123

6127

6121



X

X

X

XXX

X XX

X

XX X

X

X

X

X XX

X

XX

X

X

X

X

XX X

X X

XX

XXXX

X

X

X X


75Figure 69

5000L

5014L

5026L

5001L

5017L

50

28

L

5022L

5025L

5019L

5020L

5016L

5023L

5010L

5024L

5002L

5003L

50

21

L5

03

1L

5041L

50

27

L

5042

L

50

32

L

5013

L

5012

L5004L

5033L

50

35

L

5018L

5038L

5007L

5034L

50

05

L

50

30

L5

00

8L

50

39

L

5040L

5015L

5037L

50

36

L

5029L

50

09

L

5011L

5043L

5044L

50

45

L

5046L

5047L

5048L

50

49

L

50

50

L

5052L

5051L

5090L

50

84

L

5057L

50

61

L

50

59

L

50

89

L

50

83

L5

05

5L

5063L

5060L

5056L

50

64

L

50

69

L5

06

2L

50

71

L

50

72

L

5075L

50

70

L

50

77

L5

05

3L

5054L

5081L

50

82

L

50

80

L5078L

50

67

L

50

73

L

5085L

5093L

50

65

L

5088L

5076L

5058L

5066L

5087L

5094L

5079L

5092L

5074L

5086L

Co

ve

red

Co

ve

red

50

06

L

50

91

L

LOWER VALVE BODY LOWER SIDE5000L Series



Check Ball 1

Plastic CheckValve 3

(B1)


(K1)


(Secondary Reg.)

Solenoid Modulator Valve A & B

Screen

Check Valve 6

(MV)


76Figure 70

T1

5026U

5021U

50

02

U

50

23

U

5025U

5000U

5004U

5013U

5014U

50

19

U

5001U

5015U5017U

5012U

5007U

5016U

50

08

U5

00

9U

5006U

50

05

U5010U

5018U

50

11

U5

02

2U

5050U

50

51

U

5016U

50

49

U

5027U

Co

ve

red

Co

ve

red

5044U

5033U

5030U

5036

U

50

28

U

50

31

U 5043U

5020U

5041U

5037U

5003U

5048U

50

52

U

5053U 5

040U

5042U

5029U

5024U

50

39

U

50

47

U

50

46

U

50

38

U

50

45

U

50

35

U

50

34

U

50

32

U

LOWER VALVE BODY UPPER SIDE5000U Series




(K3)


77Figure 71

ACCUMULATOR BODY 2 SPACER PLATE400 Series

404410

406

407

402

405

408

409 417

41

6411

401

415

413412

414

400403

420419

418

X

422



421


78Figure 72

302L

304L

300L

301L

303L

306L

31

2L

308L

311L

309L

310L

305L

314L

313L

307L315L

ACCUMULATOR BODY 2 LOWER SIDE300L Series



Check Ball 2

Check Valve 7

N93 (LP) Limit

Check Valve 8

RegulatedExhaust

Check Valve 9Cooler


79Figure 73

300U

301U

302U

303U

304U

ACCUMULATOR BODY 2 UPPER SIDE300U Series




80Figure 74

200

205

204

202

203

201

213

230

212 225

206

216

224234

233 227

218

226

217

235

209

214

207219

208221

211

222

223210

215220

228

231

232

ACCUMULATOR BODY 1 SPACER PLATE200 Series



229


81Figure 75

103L

100L

102L

101L

125L

120L 122L

114L

107L

115L

116L

113L

105L

110L

124L

111L

117L

106L

112L

118L

123L119L

109L

104L

108L

121L

ACCUMULATOR BODY 1 LOWER SIDE100L Series



Check Valve 10

RegulatedExhaust

Check Valve 11

(LP Limit)


82Figure 76

ACCUMULATOR BODY 1 UPPER SIDE100U Series




83Figure 77

BC1 BC2

BC3 BC4 BC5BC6

BC7

BC8BC9BC10BC11BC12

BC13

BC14

BC15

BC16

BC17

BC18

BOTTOM CASE TO VALVE BODYBC Series




84Figure 78

P1P2P3P4

P5P6

P7

P8

P9

P10

P11

PUMP TO CASEP Series




85Figure 79

208207

B1

K3

K1

B2

K2

Pump

Solenoid Application

N93 Line Pressure Solenoid (NA)

N91 TCC Solenoid (NV)

N92 K1 Clutch Solenoid (NA)

SolenoidDUTY /State

Mod

LOW

LOW


N283 B1 Brake Solenoid (NA)


N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

LOW

HIGH


N91 TCC

N88

1

2

4-5

Tim

ing

V

alv

e

TCC ApplyControl Valve

7000L

7000U

6000

BC1

P1Suction

P2Line

BC2

6001

7001U

6002

5000L

6003

6004(.075)

6005

7003U

7002U

7004U

6006

7001L

7002U

5001L

5000U

400

300L

401

5001U

5002L

6007

7005U

7006U

6008 6009 (.038)

5003L

6010 6017

5005L

7007U 7006U

7008U

60136014 6011

5004L

6015

7009U

6016

5006L

5002U

100L

204

6012

7010U

6018

5007L

6019

7011U 7011U

6020

5003U

5008L

101L

201

301L

402

5004U

5009L

7012U

60226021

7013U

60236024

5010L

7014U

6025

5011L

7015U

6027(.050)

5012L

7016U

60266028

5013L

6029

7002LX

7017U

6030

5014L

6031

7018U

60326033

7019U

603460356036603760386039

5015L

BC6 BC7

Front lube

7020U

BC10

Rear lube

7021U

5016L

6040

5017L

6041

(.032)

7022U

60436042

7023U

5018L

5016L5005U

403

302L

404

5019L5006U

60446045

BC14

7024U

5020L

60546047

7025U

BC15

P10Apply

5007U

405

303L

304L

406

5008U

407

5009U

305L

408

BC16

P10Rel.

5021L5010U

60486049

7026U

5022L

6050 6051

Rel. TapBC12

5023L

6052

7028U

7029U

5024L

6053

5011U

409

306L

X

X

60465025L5012U

410

307L

7017U

7030U

6055(.038)

5013U

5026L

5013U

5014U5014U

7031U

411 412

308L

413

5015U

309L

5014U

5027L

6056

301U

300U

5016U5028L

6057 6058 6059 6060

7032U

5029L

7033U

5030L

5026U

5026U

5016U

7037U

6065(.038)

5016U5042L

6061

X7003L

7004L

7004L

7035U

7036U

6062(.038)

6063(.038)

5031L

5017U

414

310L

6064

5032L

7040U

7038U

6066 6067 6068

5033L

7039U

6069

5034L

7005LX

7015U

5035L

60716070

7041U

5036L

5018U

4154165019U

311L

7042U

6072 6073 6074 6075 6076

5037L 5038L 5039L

5020U

7043U 7044U

203 202102L

5021U**

7006LX

6077

5041L

5022U5041L

417

312L

7027U

BC13

Diff. lube

6078

7034U

7045U

6079

5043L

7007L

7008L

X

X

6082(.038) 6081

5044L

7046U

7047U

6080(.038)

7009LX

7010LX

7011LX

5045L

7048U

6083

7012L

7013L

X

X

7049U

6084

7014L

7015L

X

X

7051U

7050U

6086

6087(0.38)

5048L

6085

5047L

5047L

6088 6089

7052U

6090

5049L

5023U

5050L

5024U

200

103L

103L

205

5025U

5051L6091 K1 Tap

BC8

6092

7053U

6093

5052L

6094

7054U

7055U

7055U

7055U

5053L

6095

5027U

5027U

5027U

5027U

104L104L

206

5054L

6096

7056U

X

7079U

7057U

7058U

6098(.050) 6097 6099

5055L

7059U

6100 6101

BC4

BC9

5056L 5056L

5056L

6103 6102

7060U

5057L

5046L

5028U

105L

5029U5058L

5058L

7061U

7061U

61046105(.050)

5061L

6110

7063U

6111

5062L

5059L

6106 6107

5060L

6108

7062U

6109

BC18

7064U

6112

5063L

6113 6114 6115

5064L

7065U

5065L

6116 6117

7066U

5066L

6118(.050)

5030U5067L

7067U

209 210

106L

5031U

211

107L

6119(.025)

7068U

5068L **

6120 6121

7069U

5033U5069L

5033U

5070L 5034U

108L

212

7070U

6122

5035U

5071L

213

109L

7071U

6123(.025)

5072L

6124

** 5037U

6125(.050)

5036U5073L

7072U

214

110L 110L

215

6126

5038U5075L

6127(.050)

7073U

7074U

216

111L

217

5039U5076L

218 219

113L

112L

6155 6128

7075U

BC5

6151

7076U

5077L **5078L

5078L

6130

7077U

6131

5040U

5079L

6132

7078U

5080L

61336134(.050) 6135 6136

5081L

5082L

6140613961386137

5083L

7080U 7081U

5084L

5042U5088L

221

115L

114L

220

5041U5085L

5085L

6141614761426144614361456146

7084U7082U

5087L

5086L

7083U

BC3

116L

222

5043U

225224

117L

5044U

223

5045U

118L

226

5046U

5047U

227

119L

119L

120L

228

5048U

125L

229

5049U

230

121L

6148

5089L

5090L

61496150

7085U

BC11

5091L

5091L

5051U

419

5050U5091L

418421

420(.025)

314L313L

5092L

5092L

**

**

231(.025)

5052U

122L

232

123L

233

234(.025)

5053U

5093L

6129

X304U

X

X302U

303U

61526153

5094L

235

124L

6154

7086U

315L

422(.035)C

KV

9

CKV8

TFTCK

V1

CK

V2

Ck Ball 1

CK

V 6

CK

V 4

CK

V 5

CK

V 3

CK

V 7

CK

V11

CK

V1

0

Ck Ball 2

P-Ckv-2 P-Ckv-4

P-Ckv-1

P-Ckv-5

P-Ckv-3

Blocked

SolenoidMod. Valve B

B2 RelayValve(M1) B2 Switch

Valve

SolenoidMod. Valve A

TCC SwitchValve

Secondary Reg. Valve

Primary Reg. Valve

B2 SwitchValve(M1)

K1 RelayValve

K2 RelayValve

B1 SwitchValve

K3 ControlValve

B1 RelayValve

3-4 TransitionValve

K3/B13 Way Check

Valve

K3 RelayValve

RelayValve

K1 Reg. Valve

K2 Reg. Valve

B1 Reg. Valve K3 Reg.

Valve

ManualValve

K1Accum

K3Accum

K2Accum

B2Accum

Forward Engagement Control Accumulator

FILTER

SUMP

NV

N93 LP

NA

N92 K1

NA

N282K2

NA

N283B1

NA

N90K3

NA

NC

N89NC

RANGE"Park"

"09G”

Legend

Line Pressure

Suction/P.R. Exhaust

= Connected circuit

TCC Release

TCC Apply

Solenoid Mod "A" pressure

Solenoid Mod "B" pressure

N-93/Line Pressure Control

Cooler/Lube Circuit

** = Blocked by spacer plate

Secondary Reg. pressure

(.038)





SolenoidDUTY /State

Mod

LOW

RANGE"Park"

"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH


9


(.075)

(.038)

(.050)

X

Front lube

Rear lube

(.032)

Apply Release

Rel. Tap

X

X

(.038)

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

**

**

**

**

(.025)

**

**

X

X

X

(.038)

(.038) (.050)

(.050)

(.050)

(.025)

(.025)

(.050)

(.050)

(.050)

(.025)

x

(.025)

x

X

(.038)

X

B1 Tap

K3 Tap

K2 Tap

B2 Tap

N92K1

HIGH

N282K2

HIGH

N283B1

HIGH

N90K3

HIGH

N89OFF

N91TCCLOW

N93LP

MOD

N88OFF

NC NC

NV NA NA NA NA NA

K3Accum.

K1Accum.

K2Accum.

B1Accum.

Pump


B2 SwitchValve

K3 ControlValve

B1 RelayValve

K3/B1 3 WayCheckValve

PressureMod. Valve

TCCSwitchValve B2 Switch

Valve(M1)

B1 Switch V. K3 Relay

V.

K1 Reg Valve

B1

Re

g V

alv

e

K3 Reg Valve

ManualValve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve

Solenoid Mod.Valve A

B2 RelayValve(M1)

4-5

Tim

ing

Va

lve

(.038)

Forward Engagement Accumulator

B1

K3

K1

B2

K2

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen

N93Accum.

K2 RegValve

BC4

BC9

BC5

BC3

BC11

(.038)

X

SumpFilter

Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



B2 Tap

K3 Tap

B1 RelayValve

(.0

38

)

(.0

75

)

(.038)

(.0

50

)

X

Front lube

Rear lube

(.0

32

)

Apply Release

Rel. Tap

X

X

(.0

38

)

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

**

**

**

**

(.0

25

)

**

**

(.0

38

)

(.0

38

) (.0

50

)

(.0

50

)

(.0

50

)

(.0

25

)

(.0

25

)

(.0

50

)

(.0

50

)

(.0

50

)

(.025)

x

(.0

25

)

x

X

(.0

38

)

X

B1 Tap

K2 Tap

N92K1

HIGH

N282K2

HIGH

N283B1

HIGH

N90K3

LOW

N89OFF

N91TCCLOW

N93LP

MOD

N88OFF

NC NC

NV

K3Accum. K1

Accum.K2

Accum.B1

Accum.


B2 SwitchValve

K3 ControlValve


PressureMod. Valve


Valve(M1)

B1 Switch V.

K1 Reg Valve

B1

Re

g V

alv

e

K3 Reg Valve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve


K3 Relay

V.

ManualValve

B2 RelayValve(M1)

4-5

Tim

ing

Va

lve

X

X

X


(.038)

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen

B1

K3

K1

B2

K2


BC4

BC9

BC5

BC3

BC11





SolenoidDUTY /State

Mod

LOW

RANGE"Reverse”

"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH


NA NA NA NA NA

(.038)

X

K2 RegValve

Pump

N93Accum.

SumpFilter

Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



B1 RelayValve

K3 ControlValve

B2 SwitchValve

K1Accum.

(.038)

81112

(.075)

(.038)

(.050)

X

Front lube

Rear lube

(.032)

Apply Release

Rel. Tap

X

X

(.038)

X

(.038)

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

BC4

BC9

**

**

**

BC5

**

BC3

BC11

(.025)

**

**

(.038)

(.038) (.050)

(.050)

(.050)

(.025)

(.025)

(.050)

(.050)

(.050)

(.025)

x

(.025)

x

X

(.038)

X

B1 Tap

K3 Tap

K2 Tap

B2 Tap

N92K1

LOW

N282K2

HIGH

N283B1

HIGH

N90K3

HIGH

N89OFF

N91TCCLOW

N93LP

MOD

N88OFF

NC NC

NV

K3Accum.

K2Accum.

B1Accum.



PressureMod. Valve


Valve(M1)


V.

K1 Reg Valve

B1 R

eg

Valv

e

K3 Reg Valve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve


ManualValve

B2 RelayValve(M1)

4-5

Tim

ing

Valv

e

X

X

X


(.038)

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen

B1

K3

K1

B2

K2






SolenoidDUTY /State

Mod

LOW

RANGE"Drive"1st Gear

"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH


NA NA NA NA NA

K2 RegValve

Pump

N93Accum.

SumpFilter

Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



K3 Relay

V.


B1 RelayValve

B1Accum.

K1Accum.

(.0

38

)

(.0

75

)

(.038)

(.0

50

)

X

Front lube

Rear lube

(.0

32

)

Apply Release

Rel. Tap

X

X

(.0

38

)

X

(.038)

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

**

**

**

**

(.0

25

)

**

**

(.0

38

)

(.0

38

) (.0

50

)

(.0

50

)

(.0

50

)

(.0

25

)

(.0

25

)

(.0

50

)

(.0

50

)

(.0

50

)

(.025)

x

(.0

25

)

x

X

(.0

38

)

X

B1 Tap

K3 Tap

K2 Tap

B2 Tap

N92K1

LOW

N282K2

HIGH

N283B1

LOW

N90K3

HIGH

N89OFF

N91TCCLOW

N93LP

MOD

N88OFF

NC NC

NV

K3Accum.

K2Accum.


B2 SwitchValve

K3 ControlValve

PressureMod. Valve


Valve(M1)

B1 Switch V.

K1 Reg Valve

B1 R

eg

Valv

e

K3 Reg Valve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve


ManualValve

B2 RelayValve(M1)

4-5

Tim

ing

Valv

e

X

X

X


(.038)

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen

BC4

BC9

BC5

BC3

BC11

B1

K3

K1

B2

K2






SolenoidDUTY /State

Mod

LOW

RANGE"Drive"

2nd Gear

"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH


Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



NA NA NA NA NA

K2 RegValve

Pump

N93Accum.

SumpFilter


B1 RelayValve

K3 Relay

V.

(.0

38

)

(.0

75

)

(.038)

(.0

50

)

X

Front lube

Rear lube

(.0

32

)

Apply Release

Rel. Tap

X

X

(.0

38

)

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

**

**

**

**

(.0

25

)

**

**

(.0

38

)

(.0

38

) (.0

50

)

(.0

50

)

(.0

50

)

(.0

25

)

(.0

25

)

(.0

50

)

(.0

50

)

(.0

50

)

(.025)

x

(.0

25

)

x

X

(.0

38

)

X

B1 Tap

K3 Tap

K2 Tap

B2 Tap

N92K1

LOW

N282K2

HIGH

N283B1

HIGH

N90K3

LOW

N89OFF

N91TCCLOW

N93LP

MOD

N88OFF

NC NC

NV

K1Accum. K2

Accum.B1

Accum.

K3Accum.


B2 SwitchValve

K3 ControlValve

PressureMod. Valve


Valve(M1)

B1 Switch V.

K1 Reg Valve

B1

Re

g V

alv

e

K3 Reg Valve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve


ManualValve

B2 RelayValve(M1)

4-5

Tim

ing

Va

lve

X

X

X


(.038)

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen





SolenoidDUTY /State

Mod

LOW

RANGE"Drive"3rd Gear

"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH


BC4

BC9

BC5

BC3

BC11

B1

K3

K1

B2

K2


NA NA NA NA NA

(.038)

X

K2 RegValve

Pump

N93Accum.

SumpFilter

Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



K3 Relay

V.


B1 RelayValve

K2Accum.

K1Accum.

(.0

38

)

(.0

75

)

(.038)

(.0

50

)

X

Front lube

Rear lube

(.0

32

)

Apply Release

Rel. Tap

X

X

(.0

38

)

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

**

**

**

**

(.0

25

)

**

**

(.0

38

)

(.0

38

) (.0

50

)

(.0

50

)

(.0

50

)

(.0

25

)

(.0

25

)

(.0

50

)

(.0

50

)

(.0

50

)

(.025)

x

(.0

25

)

x

X

(.0

38

)

X

B1 Tap

K3 Tap

K2 Tap

B2 Tap

N92K1

LOW

N282K2

LOW

N283B1

HIGH

N90K3

HIGH

N89OFF

N91TCCLOW

N93LP

MOD

N88ON

NC NC

NV

K3Accum.

B1Accum.


B2 SwitchValve

K3 ControlValve

PressureMod. Valve


Valve(M1)

B1 Switch V.

K1 Reg Valve

B1

Re

g V

alv

e

K3 Reg Valve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve


ManualValve

B2 RelayValve(M1)

4-5

Tim

ing

Va

lve

X

X

X


(.038)

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen

BC4

BC9

BC5

BC3

BC11

B1

K3

K1

B2

K2






SolenoidDUTY /State

Mod

LOW

RANGE"Drive"

3-4 Transition

"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH


(.038)

X

NA NA NA NA NA

K2 RegValve

Pump

N93Accum.

SumpFilter

Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



K3 Relay

V.


B1 RelayValve

K3 ControlValve

K2Accum.

(.038)

(.075)

(.038)

(.050)

X

Front lube

Rear lube

(.032)

Apply Release

Rel. Tap

X

X

(.038)

X

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

**

**

**

**

(.025)

**

**

(.038)

(.038) (.050)

(.050)

(.050)

(.025)

(.025)

(.050)

(.050)

(.050)

(.025)

x

(.025)

x

X

(.038)

X

B1 Tap

K3 Tap

K2 Tap

B2 Tap

N92K1

LOW

N282K2

LOW

N283B1

HIGH

N90K3

HIGH

N89OFF

N91TCCLOW

N93LP

MOD

N88OFF

NC NC

NV

K3Accum.

K1Accum. B1

Accum.


B2 SwitchValve

PressureMod. Valve


Valve(M1)

B1 Switch V.

K1 Reg Valve

B1

Re

g V

alv

e

K3 Reg Valve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve


ManualValve

B2 RelayValve(M1)

4-5

Tim

ing

Va

lve

X

X

X


(.038)

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen





SolenoidDUTY /State

Mod

LOW

RANGE"Drive"4th Gear

"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH


BC4

BC9

BC5

BC3

BC11

B1

K3

K1

B2

K2


(.038)

NA NA NA NA NA

K2 RegValve

Pump

N93Accum.

SumpFilter

Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



K3 Relay

V.


B1 RelayValve

K2Accum.

(.0

38

)

N89OFF

(.0

75

)

(.038)

(.0

50

)

X

Front lube

Rear lube

(.0

32

)

Apply Release

Rel. Tap

X

X

(.0

38

)

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

2**

**

**

**

(.0

25

)

**

**

(.0

38

)

(.0

38

) (.0

50

)

(.0

50

)

(.0

50

)

(.0

25

)

(.0

25

)

(.0

50

)

(.0

50

)

(.0

50

)

(.025)

x

(.0

25

)

x

X

(.0

38

)

X

B1 Tap

K3 Tap

K2 Tap

B2 Tap

N92K1

HIGH

N282K2

LOW

N283B1

HIGH

N90K3

LOW

N91TCCLOW

N93LP

MOD

N88OFF

NC NC

NV

K1Accum.

B1Accum.

K3Accum.


B2 SwitchValve

K3 ControlValve

PressureMod. Valve


Valve(M1)

B1 Switch V.

K1 Reg Valve

B1

Re

g V

alv

e

K3 Reg Valve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve


ManualValve

B2 RelayValve(M1)

4-5

Tim

ing

Va

lve

X

X

X


(.038)

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen

BC4

BC9

BC5

BC3

BC11

B1

K3

K1

B2

K2






SolenoidDUTY /State

Mod

LOW


"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH


(.038)

X

NA NA NA NA NA

K2 RegValve

Pump

N93Accum.

SumpFilter

Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



B1 RelayValve


(.0

38

)

7

(.0

75

)

(.038)

(.0

50

)

X

Front lube

Rear lube

(.0

32

)

Apply Release

Rel. Tap

X

X

(.0

38

)

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

2**

**

**

**

(.0

25

)

**

**

(.0

38

)

(.0

38

) (.0

50

)

(.0

50

)

(.0

50

)

(.0

25

)

(.0

25

)

(.0

50

)

(.0

50

)

(.0

50

)

(.025)

x

(.0

25

)

x

X

(.0

38

)

X

K3 Tap

K2 Tap

B2 Tap

N92K1

HIGH

N282K2

LOW

N283B1

LOW

N90K3

HIGH

N89OFF

N91TCCLOW

N93LP

MOD

N88OFF

NC NC

NV

K3Accum.

K1Accum.

K2Accum.

B1Accum.

B2 SwitchValve

K3 ControlValve


PressureMod. Valve


Valve(M1)


V.

K1 Reg Valve

B1

Re

g V

alv

e

K3 Reg Valve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve


ManualValve

B2 RelayValve(M1)

4-5

Tim

ing

Va

lve

X

X

X


(.038)

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen

B1 Tap

BC4

BC9

BC5

BC3

BC11

B1

K3

K1

B2

K2






SolenoidDUTY /State

Mod

LOW


"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH


(.038)

X

NA NA NA NA NA

K2 RegValve

Pump

N93Accum.

SumpFilter

Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



(.0

38

)

(.0

75

)

(.038)

(.0

50

)

X

Front lube

Rear lube

(.0

32

)

Apply Release

Rel. Tap

X

X

(.0

38

)

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

**

**

**

**

(.0

25

)

**

**

(.0

38

)

(.0

38

) (.0

50

)

(.0

50

)

(.0

50

)

(.0

25

)

(.0

25

)

(.0

50

)

(.0

50

)

(.0

50

)

(.025)

x

(.0

25

)

x

X

(.0

38

)

X

B1 Tap

K3 Tap

K2 Tap

B2 Tap

N92K1

HIGH

N282K2

LOW

N283B1

LOW

N90K3

HIGH

N89ON

N91TCCHIGH

N93LP

MOD

N88OFF

NC NC

NV

K3Accum.

K1Accum.

K2Accum.

B1Accum.


B2 SwitchValve

K3 ControlValve

B1 RelayValve


PressureMod. Valve


Valve(M1)


V.

K1 Reg Valve

B1

Re

g V

alv

e

K3 Reg Valve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve


ManualValve

B2 RelayValve(M1)

4-5

Tim

ing

Va

lve

X

X

X


(.038)

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen

BC4

BC9

BC5

BC3

BC11

B1

K3

K1

B2

K2






SolenoidDUTY /State

Mod

LOW


TCC Apply

"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH


(.038)

X

NA NA NA NA NA

K2 RegValve

Pump

N93Accum.

SumpFilter

Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



K3 Relay

V.


B1 RelayValve

K1Accum.

(.0

38

)

(.0

75

)

(.038)

(.0

50

)

X

Front lube

Rear lube

(.0

32

)

Apply Release

Rel. Tap

X

X

(.0

38

)

(.038) X

X

Diff. lube

X

X

XX

X

X

X

X

X

K1 Tap

**

**

**

**

(.0

25

)

**

**

(.0

38

)

(.0

38

) (.0

50

)

(.0

50

)

(.0

50

)

(.0

25

)

(.0

25

)

(.0

50

)

(.0

50

)

(.0

50

)

(.025)

x

(.0

25

)

x

X

(.0

38

)

X

B1 Tap

K3 Tap

K2 Tap

B2 Tap

N92K1

LOW

N282K2

HIGH

N283B1

HIGH

N90K3

HIGH

N89ON

N91TCCLOW

N93LP

MOD

N88ON

NC NC

NV

K3Accum.

K2Accum.

B1Accum.


B2 SwitchValve

K3 ControlValve

PressureMod. Valve


Valve(M1)

B1 Switch V.

K1 Reg Valve

B1

Re

g V

alv

e

K3 Reg Valve

PrimaryReg. Valve

Secondary Reg V.

K2 Relay Valve

K1 Relay Valve

3-4 TransitionValve

Relay Valve


ManualValve

B2 RelayValve(M1)

4-5

Tim

ing

Va

lve

X

X

X


(.038)

CKV8

CKV2

CK

V1

P-Ckv-2

P-Ckv-4 P-Ckv-1

CK

V3

CKV4

CKV5

CKV6

P-Ckv-3

CKV11

P-Ckv-5

CKV10

CKV9

Ck Ball 1

Ck Ball 2

CK

V7

TFT

Sol. Mod. V.Screen

BC4

BC9

BC5

BC3

BC11

B1

K3

K1

B2

K2





SolenoidDUTY /State

Mod

LOW

RANGE"Drive"

Tiptronic 1st Gear

"09G”

HIGH




N88 Solenoid (NC)

N89 Solenoid (NC)

Off

Off

HIGH

HIGH

HIGH



(.038)

X

NA NA NA NA NA

K2 RegValve

Pump

N93Accum.

SumpFilter

Legend

Line Pressure


= Connected circuit

TCC Release

TCC Apply




Cooler/Lube Circuit



Documents

TF60 SN Tech Guide