Automatic gearbox 09D

Chapter overview

• Technical data
  1
• 1 Suggestions and criticism, general repair notes
  1
• 1.1 Suggestions and criticism of this workshop manual
  1
• 1.2 Information about 6-speed automatic gearbox 09D, general repair notes
  2
• 1.3 Brief overview - driveline guide
  2
• 1.4 Tools
  3
• 1.5 Gearbox
  4
• 1.6 Gaskets, seals
  4
• 1.7 Oil
  4
• 1.8 Nuts and bolts
  5
• 1.9 Electrical components
  5
• 1.10 Guided fault finding, vehicle self-diagnosis and testing
  5
• 2 Gearbox identification
  6
• 3 Identification codes, engine allocation, Touareg 2003 ►
  7
• 3.1 Allocation for vehicles with a petrol engine
  7
• 3.2 Allocation for vehicles with a diesel engine
  7
• 4 Capacity
  8
• Torque converter
  9
• 1 Proper handling and installation of torque converter
  9
• 1.1 Checking torque converter
  10
• 1.2 Removing and installing torque converter oil seal
  10
• 1.3 Draining torque converter
  11
• 1.4 Installing torque converter
  11
• Controls, housing
  14
• 1 Connecting »tester«
  14
• 1.1 Connecting vehicle diagnosis, testing and information system VAS 5051
  14
• 2 Repairing selector mechanism
  16
• 2.1 Checking selector mechanism
  16
• 2.2 Dismantling and assembling selector mechanism
  17
• 2.3 Removing and installing selector lever handle
  18
• 2.4 Checking and adjusting selector lever cable
  21
• 2.5 Removing and installing selector lever cable
  23
• 2.6 Removing and installing cover
  24
• 2.7 Signal magnet for Tiptronic switch F189
  25
• 2.8 Removing and installing cover
  27
• 2.9 Releasing selector lever without electrical current (emergency release)
  27
• 2.10 Removing and installing selector lever position P solenoid N380
  28
• 2.11 Removing and installing selector lever lock solenoid N110
  29
• 2.12 Removing and installing selector lever locked in position P switch F319
  30
• 2.13 Removing and installing selector mechanism
  31
• 3 Renewing needle bearing for starter
  35
• 3.1 Renewing needle bearing for starter
  36
• 4 Removing and installing gearbox
  37
• 4.1 Removing and installing gearbox, vehicles with R5 diesel engine
  37
• 4.2 Removing and installing gearbox - vehicles with V6 TDI
  50
• 4.4 Transporting gearbox
  67
• 5 Checking ATF level and topping up
  68
• 5.1 Brief description
  69
• 5.2 Checking ATF level and topping up
  69
• 6 ATF lines and ATF cooler
  73
• 6.1 Assembly overview - ATF lines, vehicles with R5 diesel engines
  73
• 6.2 Assembly overview - ATF lines, vehicles with V6 petrol engine and V6 TDI engine
  74
• 6.4 Removing and installing ATF lines and ATF cooler
  76
• 6.5 Cleaning ATF lines and ATF cooler
  78
• 6.6 Bleeding ATF system
  79
• 7 Control unit for automatic gearbox J217
  80
• 7.1 Removing and installing automatic gearbox control unit J217
  80
• 8 Renew seals
  83
• 8.1 Renewing output shaft seal
  83
• 8.2 Renewing oil seals for selector shaft
  84
• Gears, control
  86
• 1 Removing and installing oil pan
  86
• 1.1 Removing
  86
• 1.2 Installing
  86
• 1.3 Specified torques
  87
• 2 Removing and installing ATF strainer
  88
• 2.1 Removing
  88
• 2.2 Installing
  88
• 2.3 Specified torques
  89
• 3.1 Removing
  90
• 3.2 Installing
  90
• 4 Overview - removing and installing valve body
  92
• 4.1 Removing and installing valve body
  92
• 4.2 Removing and installing gearbox output speed sender G195
  94
• 5 Removing, installing and adjusting multifunction switch F125
  96
• 5.1 Removing
  96
• 5.2 Installing and adjusting
  96