General Repair Information
General Repair Information
Transmission
The 6 speed automatic transmission 09M is equipped with 6 hydraulically activated forward gears. With the lockup clutch closed, 2nd, 3rd, 4th, 5th and 6th gears become mechanically driven gears by passing the torque converter slip.
Torque Converter
The torque converter is equipped with a slip controlled torque converter lockup clutch. When the lockup clutch is closed, and depending on load and speed, 2nd, 3rd, 4th, 5th and 6th gears can be driven mechanically (without slip).
Tools
A list of special tools and workshop equipment required for repair procedures in this service information can be found at the start of each repair group section and in the "Special Tools" catalog.
It is often the case that safety hazards are caused by bolts that are tightened with using incorrect tightening specifications. These bolts can be tightened using torque wrench (5-60 Nm) (V.A.G 1783).
Transmission
• If a cover is removed from the transmission or the transmission has no fluid, do not run the engine and do not tow the vehicle.
• Always clean connection points and their vicinity first and then loosen them.
• When installing the transmission, make sure the alignment sleeves are correctly installed between the engine and transmission.
• Place removed parts on a clean surface and cover them so they do not become contaminated. Do not use foil or paper. Use lint free cloths only!
• Only install clean components: Install replacement parts immediately after removing them from their packaging.
• Carefully cover or seal unpacked components if repairs cannot be performed immediately.
• Secure the torque converter on a removed transmission in order to keep it from falling out.
Transmission With and Without Filling Tube
Here is an example of a filler tube as it was installed in older transmissions. This tube has been deleted.
You also do not need the old filler hole with the red cap because the Automatic Transmission Fluid (ATF) is drained and filled at the lower hole when necessary. The height of this rising tube corresponds to the height of the ATF level.
To drain, the rising tube is removed.
• After installing, check the ATF level and top off, if necessary. Refer to => [ Automatic Transmission Fluid Level, Checking and Filling ] Automatic Transmission Fluid Level, Checking and Filling.
Automatic Transmission Fluid
CAUTION!
Be cautious when dealing with ATF. Dispose of drained ATF properly. Remember: one drop can contaminate 1,000 liters of drinking water.
ATF does not just lubricate the transmission.
The fluid also transports the finest differential abrasive particles to the filter, ensures the lubricating film does not wear off the differential tooth flanks and at the same time, it acts as a switch valve pressure medium to enable it to perform its functions.
It also seals the selector lever and helps clutch friction lamellae when shifting gears. It conserves and transports warmth, minimizes noise. The ATF has many tasks, and it does not matter if all of this takes place in the heat of the equator or in the cold of the earth's arctic poles. ATF meets some very high demands!
ATF and Troubleshooting ATF Check
You have already read what ATF can do. There is only thing is cannot do: disappear without a trace.
ATF can only be missing if it has leaked from the transmission.
- Check on where it has leaked from the transmission. Repair this leak first.
The ATF is a filled for life filling. ATF does not need to be replaced when servicing.
The ATF is available as a replacement part.
The ATF level in the transmission and in the final drive are checked and filled together => [ Automatic Transmission Fluid Level, Checking and Filling ] Automatic Transmission Fluid Level, Checking and Filling.
Do not mix any additives with the ATF, do not add other ATFs.
Drained ATF must not be reused.
Transmission Control Module with Fuzzy Logic
Determining the driving situation and driving resistance dependent shift point occurs automatically.
Advantages:
• It is shifted depending on consumption
• Highest engine performance is always available
• Individual adaptation of shift points in all driving situations
• Gear shift points are infinitely variable
Control Modules
All control module installed positions in the vehicle and further useful information can also be found in.
O-rings, Gaskets and Seals
• Always replace O-rings, gaskets and seals.
• Before installing radial shaft seals, fill the area between the sealing lips half way with sealing grease (G 052 128).
• The open side of the seal face toward the oil.
• Check the ATF level after installing.
CAUTION!
Be cautious when dealing with ATF. Dispose of drained ATF properly. Remember: one drop of ATF can contaminate 1,000 liters of drinking water.
Bolts and Nuts
• To secure the covers and housings, loosen and tighten bolts or nuts in a diagonal sequence.
• The tightening specifications stated apply to non-lubricated nuts and bolts.
• Clean the bolt threads that were installed using locking fluid, using a wire brush. Next, install the bolts using locking compound (AMV 185 100 A1).
• All threaded holes in which self locking bolts are threaded must be cleaned of remaining locking fluid using a tap. Otherwise there is a risk that the bolts will shear the next time they are removed.
• Replace self locking bolts and nuts.
Electrical Components
You have probably received a electrical shock at one time, when touching a metal item. The reason for this is the electrostatic charge that is built up in the human body. This charge can lead to malfunctions when contacting the electrical components of the transmission and the gear selector.
- Touch a grounded object, for example, a water pipe or a hoist, before working on electrical components! Do not make direct contact with connector contacts.
Guided Fault Finding, On Board Diagnostic and Test Instruments
Before performing service work on the transmission, the cause of damage must be determined as exactly as possible via "Guided Fault Finding".
Guided Fault Finding is performed with the tester. Refer to => [ Vehicle Tester, Connecting and Selecting Functions ] Scan Tool Testing and Procedures.
Guided Functions allows you to find the ATF temperature as quickly as possible. Refer to => [ Vehicle Tester, Connecting and Selecting Functions ] Scan Tool Testing and Procedures.