Volkswagen 01M Transmission. Manual - part 93

INTRODUCTION

AUDI, JETTA, PASSAT,

09G/09M Transaxle

18635 S.W. 107 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 . This includes all text illustrations,
tables and charts.

The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

1st Printing

March, 2010

We wish to thank Volkswagen® for the information that has made this booklet possible.

DALE

ENGLAND

FIELD SERVICE CONSULTANT

KRUSE

TECHNICAL CONSULTANT

WAYNE COLONNA

PRESIDENT

PETER

LUBAN

TECHNICAL CONSULTANT

JIM

DIAL

TECHNICAL CONSULTANT

GREGORY

LIPNICK

TECHNICAL CONSULTANT

JON

GLATSTEIN

TECHNICAL CONSULTANT

DAVID

CHALKER

TECHNICAL CONSULTANT

GREG

CATANZARO

TECHNICAL CONSULTANT

GERALD

CAMPBELL

TECHNICAL CONSULTANT

  The Japanese company AISIN Co., LTD is the manufacturer and developer of the Front Wheel Drive TF60SN
transaxle, which is a 6 speed, fully automatic and electronic controlled transaxle.  Volkswagen engineers were
also involved, in conjunction with Aisin, in the development process for their vehicles and they gave it the
09G/09M designation. BMW gave it the designation 6F21WA for their Mini-Cooper.
  The 09G/09M transaxle is used in a wide variety of applications and engine sizes.  As a result, the number of
friction plates, planetary ratios, intermediate ratios and final drive ratios will vary depending on torque load
requirements of the specific vehicle.   The TF60SN transaxle uses a gear ratio sensitive system, requiring the
correct transaxle interchange.  The TF60-SN is used in the BMW Mini Cooper, Volkswagen and Audi vehicles.
This transaxle is  referred to as the TF60-SN, 09G, 09M, 6F21WA and in some overseas vehicles as 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, case cover and the
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.
  The 09G/09M transaxle uses a Lepelletier arrangement, using a simple planetary coupled with a Ravigneaux
planetary. This arrangement makes six forward speeds and reverse possible, with only five clutch packs and one
freewheel.
  This manual contains the procedures necessary to diagnose, rebuild and/or repair the 09G/09M transaxle and is
intended for automotive technicians that are familiar with the operation of automatic transmissions.

Technical Service Information

    The  Japanese  company  AISIN  Co.,  LTD  is  the
manufacturer and developer of the Front Wheel Drive
TF-60SN  transaxle,  which  is  a  6  speed,  fully
automatic  and  electronic  controlled  transaxle.
Volkswagen  engineers  were  also  involved,  in
conjunction with Aisin, in the development process
for  their  vehicles  and  they  gave  it  the  09G/09M
designation.  BMW's designation for the same unit is
6F21WA.    US  and  Overseas  Vehicle  applications,
known at time of printing, are shown in Figure 1.
  The 09G/09M transaxle is used in a wide variety of
applications and engine sizes.  As a result, the number
of friction plates, planetary ratios, three or four pinion
carriers, transfer gear ratios and the final drive ratios
will vary depending on torque load requirements of
the specific vehicle.   The 09G/09M transaxle uses a
gear  ratio  sensitive  system,  requiring  the  correct
transaxle interchange, if that becomes necessary.
  There are also versions of this transaxle that have an
"Integral  Cooler"  bolted  directly  to  the  transaxle
converter  cover  and  pipe  engine  coolant  to  the
transaxle. Some versions have a "Remote" mounted
cooler  and  pipe  transaxle  fluid  to  the  cooler.    This
affects  changes  to  the  case,  converter  cover,  valve
body  and  spacer  plate.    None  of  these  parts  are
interchangeable with one another.

    This  transaxle  is  very  similar  to  the  AF40-6
transmission but with 3 very significant differences.
One  is  the  B1  brake  band  has  been  eliminated  and
replaced  with  a  B1  clutch  pack.  Second  is  the  rear
cover that gave access to the C/K2 clutch has been
eliminated.   Third the Transmission Control Module
(TCM) is mounted external from the transaxle which
makes  typical  electrical  diagnosis  available  to  the
technician.
   The TCM controls both shift timing and shift feel
with the use of eight solenoids.   The TCM monitors
gear ratio through the input and output shaft hall effect
speed sensors. It also can determine the rate of change
and adapt the shifts as the friction elements wear.
    All  TF-60SN  (09G)  transaxles  use  a  Lepelletier
arrangement,  which  consists  of  a  simple  planetary
with  the  sun  gear  splined  to  the  pump  stator  and
coupled with a Ravigneaux planetary. This allows the
sun gears and the planetary pinions of the Ravigneaux
planetary  gear-set  to  be  driven  at  different  speeds.
This  arrangement  makes  six  forward  speeds  and
reverse possible, with only five clutch packs and one
freewheel.
  Refer to Figure 2 for the component locations and the
clutch application chart for each gear.

GENERAL DESCRIPTION

Figure 1

VEHICLE APPLICATION CHART

VEHICLE

YEAR

ENGINE

AISIN

AUDI A3

AUDI A4

AUDI TT
AUDI TT

BMW Mini Clubman
BMW Mini Cooper
SEAT Altea (Non US)

SEAT Leon (Non US)
SEAT Toledo (Non US)

Volkswagen Beetle

Volkswagen Transporter

Volkswagen Jetta

Volkswagen Passat/Passat Wagon

Volkswagen Tiguan (Non US)

Volkswagen Touran (Non US)

2006-Up

2003-06
2004-08

2008-Up
2002-Up
2004-Up

2005-Up
2004-Up

2004-Up

2006-Up

2005-Up

2006-Up

2008-Up

2003-Up

2.0L

1.8L

2.0L, 3.2L(V6)

1.6L
1.6L

1.8L, 1.9L, 2.0L, 2.5L

1.9L, 2.0L, 2.5L

2.0L,

3.6L,

1.4L, 2.0L

1.6L, 1.9L, 2.0L

1.4L, 1.6L, 2.0L,

1.6L, 1.9L, 2.0L,

09G

09G
09G

6F21WA
6F21WA

09G

09G
09G

09G

09K

09G

09M

09G

TF60SN

TF60SN
TF60SN

TF60SN
TF60SN
TF60SN

TF60SN
TF60SN

TF60SN

Technical Service Information

COMPONENT APPLICATION CHART

Clutch

F1 Roller

Clutch

CLUTCH APPLICATION CHART

Gear

1st Gear

2nd Gear

3rd Gear

4th Gear

5th Gear

6th Gear

Rev Gear

Transfer Gear Ratio, Codes GSY, GJZ, FXA, (Driven=52T/Drive=49T) Ratio = 1.061

Final Drive Gear Ratio, Codes GSY, FXA, (15T/61T) Ratio = 4.067

Final Drive Gear Ratio, Codes GJZ, (15T/58T) Ratio = 3.867

K-1

Clutch

K-2

Clutch

K-3

Clutch

B-1

Clutch

B-2

Clutch

On*

On**

Hold

4.148

4.044

2.370

2.371

1.556

1.155

1.159

0.859

0.852

0.686

0.676

3.394

3.193

F-1

Roller

Clutch

Torque

Conv.

Clutch

Engine

1.6L, 2.0L

Ratio***

Engine

1.8L,

Ratio****

* The B-2 Clutch is applied in "Tiptronic Mode" 1st gear, only for engine braking.
** During normal driving operation, the Torque Converter Clutch can be applied in each gear.
*** Transaxle Codes (GSY 1.6L) and (GJZ 2.0L).
**** Transaxle Code (FXA 1.8L).

Figure 2

0 0H

Technical Service Information

4051 - 1 - 1

03C2T02168

300 035H

09G

1004

GGZ 280303
03C2T02168
09G 300 035H
57344 - 02

Transaxle Code

Build Date

Day Mo Yr

OEM Part Number

Ink Stamp On Case

Build Date/Serial Number

IDENTIFICATION TAG INFORMATION

{

TRANSAXLE IDENTIFICATION

Figure 3

   The paper ID tag stuck to the side of the case, as
shown  in  Figure  3,  carries  the  OEM  part  number
along with the build date and serial number.  The only
place  we  have  found  a  "Transaxle  Code"  is  ink
stamped  or  etched  on  the  transaxle  case,  in  the
location shown in Figure 3.  In the example shown the
transaxle code is "GGZ".

Note: For the newest transaxle code information
that is available to us, See Page 124.

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