General Repair Information
General Repair Information
Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in this repair information, are summarized here.
Safety Precautions
Observe the following to avoid personal injury and vehicle damage:
There is a risk of injury and accident from accidentally engaging a gear when the engine is running.
• Move the selector lever into the "P" position and set the parking brake before working with the engine running.
Torque Converter
The torque converter is equipped with a slip controlled torque converter lockup clutch. The lockup clutch closes depending on load and speed. The 2nd, 3rd, 4th, 5th and 6th gears can be mechanically driven (without slip).
Automatic Transmission Fluid
Automatic Transmission Fluid (ATF) change intervals, Refer to the Maintenance Intervals.
Use only the ATF listed as a replacement part in the Parts Catalog. Other fluid can cause malfunctions or transmission failure.
The ATF level inside the transmission and inside the final drive are checked and filled at the same time.
Transmission Control Module J217 with Fuzzy Logic
Determining the driving situation and driving resistance dependent shift point occurs automatically.
Advantages:
• It is shifted depending on consumption
• Maximum engine output is always available
• Individual adaptation of shift points in all driving situations
• Gear shift points are infinitely variable
Control Modules
The installed locations of all vehicle control modules and other useful information can also be found in.
Information on the "Transmission 09G"
For additional information on the 09G automatic transmission, refer to the Self-Study Program, 851503, 6-Speed Automatic Transmission 09G/09M, Design and Function
Special Tools
A complete list of special tools and shop equipment used in the repair information can be found at the beginning of each repair section and at the end of each repair group under "Special Tools".
On smaller fasteners with minimal tightening specifications, uncertainties often exist. For these fasteners the torque wrench (V.A.G 1783) can be used.
Transmission
The "6-speed automatic transmission 09G" has 6 hydraulically controlled forward gears. By passing the torque converter slip, 2nd, 3rd, 4th, 5th and 6th gears become mechanically driven gears if the lockup clutch is closed.
• Do not run the engine and do not tow the vehicle if the transmission pan is removed or if there is no transmission fluid inside the transmission.
• Always clean the bolt connection points and the area around them first, and then loosen them.
• When installing the transmission, make sure the alignment sleeves are correctly seated between the engine and transmission.
• Place removed parts on a clean surface and cover them so that they do not get dirty. Use foil, paper and a lint free cloth.
• Only install clean components: Remove the replacement parts from their packaging just prior to installing them.
• Carefully cover or seal unpacked components if repairs cannot be performed immediately.
• With the transmission removed, secure the torque converter so that it cannot fall out.
Transmissions With and Without Filler Tube
Here, for example, is a filler tube - arrow - as it was installed in older transmissions is illustrated. This tube has been omitted.
You also do not need the old filler hole with the red cap because the ATF is drained and filled at the lower hole when necessary. The height of this overflow tube corresponds to the height of the ATF level.
To drain, the overflow tube is removed.
• After installing, check ATF level and fill. Refer to => [ ATF Level, Checking and Filling ] Testing and Inspection.
• Capacities, refer to the Fluid Capacity Tables.
O-rings, Seals and Gaskets
• Always replace the O-rings, seals and gaskets.
• After removing the seals, check the sealing surfaces on the housing or shaft for burrs resulting from removal or damage.
• Coat O-rings with clean ATF before installing them to prevent crushing the O-rings during installation.
• Use ATF only. Other types of lubricants cause faults to occur in the transmission hydraulics.
• Before installing a seal, coat the sealing lips and the space between them with sealing grease for seal (G 052 128 A1).
• The open side on the seal faces the fluid.
• Checking the ATF level. Refer to => [ ATF Level, Checking and Filling ] Testing and Inspection.
Be cautious when dealing with ATF. Dispose of the drained ATF properly. Bear in mind that: One drop of transmission fluid can contaminate 1000 liters (264 gallons) of drinking water.
Bolts and Nuts
• Loosen or tighten bolts and nuts for the covers or housings diagonally.
• The tightening specifications stated apply to non-lubricated nuts and bolts.
• Use a wire brush to clean the threads of bolts that were installed using liquid locking fluid. Install the bolts using liquid locking fluid (AMV 185 101 A1).
• Clean the threaded holes for the self-locking bolts or for the bolts coated with liquid locking fluid. Otherwise there is a risk that the bolts will shear the next time they are removed.
• Always replace self-locking nuts and bolts.
Electrical Components
You have probably received a electrical shock at one time, when touching a metal item. The reason behind this is the electrostatic charge to the human body. This charge can damage the electrical components on the transmission and the selector mechanism.
- Touch a grounded object, such as, a water pipe or a vehicle hoist, before working on electrical components. Do not touch the connector or open electronic components directly.
Guided Fault Finding, OBD and Test Instruments
Before beginning any service work on the automatic transmission, determine the cause of the damage using "Guided Fault Finding".
Perform Guided Fault Finding using, for example, the vehicle diagnostic tester Vehicle Diagnosis, Testing and Information System (VAS 5051 B). Refer to => [ Tester, Connecting ] Testing and Inspection.
Guided Functions finds the ATF temperature quickly. Refer to => [ Tester, Connecting ] Testing and Inspection.