6-speed automatic gearbox 09G

Chapter overview

• Technical data
  1
• 1 General repair notes
  1
• 1.1 Gearbox
  1
• 1.2 Torque converter
  1
• 1.3 ATF
  1
• 1.4 Automatic gearbox control unit J217 with fuzzy logic
  1
• 1.5 Control units in vehicle
  1
• 1.6 Information on “09G gearbox”
  1
• 1.7 Tools
  2
• 1.8 Gearbox
  2
• 1.9 Gaskets, seals and oil
  3
• 1.10 Nuts and bolts
  3
• 1.11 Electrical components
  4
• 1.12 Guided fault finding, vehicle self-diagnosis and test instruments
  4
• 2 Capacities
  5
• 2.1 Planetary gearbox and final drive
  5
• 3 Code - engine allocation
  6
• 3.1 Gearbox codes
  6
• 4 Golf 2004 ►
  7
• 5 Golf Plus 2005 ►
  8
• 6 Golf 2009 ►
  9
• 7 Touran 2003 ►
  10
• 8 Passat 2006 ►
  11
• 9 Passat CC 2009 ►, CC 2010 ►
  12
• Torque converter
  13
• 1 Proper handling and installation of torque converter
  13
• 1.1 Identification of torque converter
  13
• 1.2 Draining torque converter
  13
• 1.3 Removing and installing torque converter oil seal
  14
• 1.4 Installing torque converter
  15
• Controls, housing
  16
• 1 Connecting »tester«
  16
• 1.1 Connecting vehicle diagnosis, testing and information system VAS 5051
  16
• 2 Electrical and electronic components and their locations
  18
• 3 Multifunction switch F125
  23
• 3.1 Removing multifunction switch F125
  23
• 3.2 Installing multifunction switch F125
  24
• 3.3 Adjusting multifunction switch F125
  25
• 4 Emergency release of selector lever
  27
• 5 Removing and installing selector lever handle
  28
• 5.1 Moving pushbutton to installation position in the handle
  30
• 6 Selector mechanism up to 02.2009
  33
• 6.1 Overview of selector mechanism up to 02.2009
  33
• 6.2 Removing and installing selector mechanism with selector lever
  34
• 6.3 Removing and installing selector lever cable
  34
• 6.4 Checking selector lever cable
  42
• 6.5 Adjusting selector lever cable
  43
• 7 Selector mechanism from 03.2009 onwards
  45
• 7.1 Overview - selector mechanism
  45
• 7.2 Removing and installing selector mechanism with selector housing
  46
• 7.3 Removing and installing selector mechanism without selector housing
  48
• 8 Checking selector mechanism
  50
• 8.1 Selector lever in “P” position and ignition switched on
  50
• 8.2 Selector lever in “N” position and ignition switched on
  50
• 8.3 Selector lever in position “Tiptronic”
  50
• 8.4 Ignition and light switched on
  50
• 8.5 Selector lever position display
  50
• 9 Removing and installing gearbox, Golf 2004 ►
  51
• 9.3 Removing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 kW engines
  57
• 9.4 Installing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 engines
  65
• 9.5 Torque settings, gearbox to engine
  66
• 10 Removing and installing gearbox, Golf Plus 2005 ►
  70
• 10.1 Removing gearbox, Golf Plus 2005
  70
• 10.2 Installing gearbox, Golf Plus 2005
  76
• 10.3 Torque settings, gearbox to engine
  77
• 11 Removing and installing gearbox, Touran 2003 ►
  81
• 11.1 Removing gearbox, Touran 2003
  81
• 11.2 Installing gearbox, Touran 2003
  85
• 11.3 Torque settings, gearbox to engine
  86
• 12 Removing and installing gearbox, Passat 2003 ►
  89
• 12.1 Removing gearbox, Passat with 1.6 l - 85 kW and 2.0 l - 110 kW engines
  89
• 12.2 Installing gearbox, Passat with 1.6 l - 85 kW and 2.0 l - 110 kW engines
  95
• 12.3 Torque settings, gearbox to engine
  96
• 12.4 Removing gearbox, Passat with 1.8 l - 118 kW and 2.0 l - 147 kW engines
  97
• 12.5 Installing gearbox, Passat with 1.8 l - 118 kW and 2.0 l - 147 kW engines
  103
• 12.6 Torque settings, gearbox to engine
  104
• 13 Removing and installing gearbox, Passat CC 2009 ►, CC 2010 ►
  106
• 13.2 Installing gearbox, Passat CC 2009, CC 2010 with 2.0 l 147 kW TFSI engine
  114
• 13.3 Torque settings, gearbox to engine
  115
• 14 Removing and installing gearbox, Golf 2009 ►
  117
• 14.1 Removing gearbox, Golf 2009 with 2.5 l - 125 kW engine
  117
• 14.2 Installing gearbox, Golf 2009 with 2.5 l - 125 kW engine
  125
• 14.3 Torque settings, Golf 2009 with 2.5 l - 125 kW engine
  126
• 15 Transporting gearbox
  128
• 16 ATF cooler for 1.6 l - 85 kW and 2.0 l - 110 kW engines
  129
• 16.1 Assembly overview - ATF cooler
  129
• 17.1 Overview
  130
• 18 Checking ATF level and topping up
  135
• 18.1 Checking ATF level
  137
• 18.2 Topping up ATF
  138
• 18.3 Draining and filling ATF
  139
• Gears, control
  141
• 1 Renewing oil seal for selector shaft
  141
• 2 Removing and installing ATF pan
  142
• 2.1 Removing
  142
• 2.2 Installing
  143
• 3 Removing and installing ATF strainer
  145
• 3.1 Removing
  145
• 3.2 Installing
  145
• 4 Removing and installing valve body
  146
• 4.1 Overview - valve chest
  146
• 4.2 Removing valve body
  148
• 4.3 Installing valve body
  151
• 4.4 Specified torques
  155
• 5 Removing and installing wiring harness for solenoid valves and senders
  156
• 5.1 Removing
  156
• 5.2 Installing
  156
• 6 Removing and installing gearbox input speed sender G182
  157
• 6.1 Removing
  157
• 6.2 Installing
  157
• 7 Removing and installing gearbox output speed sender G195
  158
• 7.1 Removing
  158
• 7.2 Installing
  158
• Final drive - differential
  159
• 1 Renewing oil seals for flange shafts
  159
• 1.1 Renewing oil seal for left flange shaft
  159
• 1.2 Renewing seal for right flange shaft
  160