5-speed automatic gearbox 09A

Chapter overview

• Technical data
  1
• 1 Repair instructions
  1
• 1.1 Repair instructions
  1
• 2 Gearbox identification
  5
• 2.1 Location on gearbox
  5
• 3 Identification codes, engine allocation, ratios, equipment
  6
• 4 Capacities of planetary gearbox and final drive
  7
• 5 Notes specific to 5-speed automatic gearbox 09A
  8
• 5.1 Gearbox repair
  8
• Torque converter
  10
• 1 Torque converter
  10
• 1.1 Identification of torque converter
  10
• 1.2 Draining torque converter
  10
• 1.3 Removing and installing torque converter oil seal
  11
• 1.4 Installing torque converter
  12
• Controls, housing
  13
• 1 Connecting Volkswagen tester and selecting functions
  13
• 2 Electrical and electronic components and their locations
  15
• 2.1 Tiptronic switch F189
  18
• 3 Repairing selector mechanism
  19
• 3.1 Checking selector mechanism
  19
• 3.2 Checking and adjusting selector lever cable
  20
• 3.3 Checking operation of the ignition key withdrawal lock
  21
• 3.4 Removing and installing selector mechanism
  22
• 3.5 Dismantling and assembling shift mechanism
  25
• 3.6 Removing and installing selector lever lock solenoid N110
  28
• 3.7 Removing and installing selector lever cable
  30
• 3.8 Removing and installing locking cable
  33
• 3.9 Adjusting locking cable
  35
• 4 Checking gearbox
  37
• 5 Removing and installing gearbox
  38
• 5.1 Removing gearbox
  40
• 5.2 Transportation of automatic gearbox, securing gearbox to repair stand
  45
• 5.3 Installing gearbox
  47
• 5.4 Torque settings
  48
• 6 Checking ATF level and topping up
  50
• 6.1 Checking ATF level
  50
• 6.2 Topping up ATF
  53
• 6.3 Renewing ATF
  53
• 7 Gearbox repair
  55
• 8 Position of selector elements
  57
• 9 Dismantling and assembling gearbox
  58
• 9.1 Dismantling gearbox
  58
• 10 Assembling gearbox
  61
• 11 Removing and installing ATF cooler
  78
• 11.1 Dismantling and assembling procedure
  79
• Gears, control
  81
• 1 Housing cover for planetary gearbox
  81
• 1.1 Assembly overview
  81
• 1.2 Pressure accumulator for brake “B4”
  83
• 2 1st through 3rd gear clutch “K1”
  85
• 2.1 Overview - “K1” components
  85
• 2.2 Dismantling and assembling “K1” clutch housing
  85
• 3 Reverse gear clutch “K2” and 3rd through 5th gear clutch “K3”
  87
• 3.1 Overview - “K2” plates
  87
• 3.2 Overview - “K3” plates
  88
• 3.3 Overview - “K2/K3” clutch housing
  89
• 4 5th gear clutch “K4”
  91
• 4.1 Overview - “K4” components “from above”
  91
• 4.2 Overview - “K4” components “from below”
  92
• 5 Valve body
  94
• 5.1 Removing and installing valve body
  95
• 6 Removing and installing sender in gearbox
  103
• 6.1 Removing and installing gearbox input speed sender G182
  103
• 7 Renewing oil seal for selector shaft
  106
• 8 Removing, installing and adjusting multifunction switch F125
  107
• 8.1 Removing multifunction switch F125
  107
• 8.2 Installing and adjusting multifunction switch F125
  108
• Final drive - differential
  110
• 1 Renewing oil seals for flange shafts
  110
• 1.1 Assembly overview
  110
• 1.2 Renewing oil seal for left flange shaft
  111
• 1.3 Renewing seal for right flange shaft
  113