Automatic gearbox 09D Volkswagen R GmbH

Chapter overview

• Technical data
  1
• 1 General repair instructions
  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
  3
• 1.6 Gaskets and seals
  4
• 1.7 Oil
  4
• 1.8 Nuts and bolts
  4
• 1.9 Electrical components
  4
• 1.10 Guided fault-finding, vehicle self-diagnosis and test instruments
  5
• 2 Identification of gearbox
  6
• 3 Identification codes, engine allocation, Touareg 2003 ►
  7
• 4 Capacity
  8
• Torque converter
  9
• 1 Proper handling and installation of torque converter
  9
• 1.1 Checking torque converter
  9
• 1.2 Removing and installing torque converter oil seal
  9
• 1.3 Draining torque converter
  10
• 1.4 Installing torque converter
  11
• Controls, housing
  13
• 1 Connecting »tester«
  13
• 1.1 Connecting vehicle diagnosis, testing and information system VAS 5051
  13
• 2 Repairing selector mechanism
  15
• 2.1 Checking selector mechanism
  15
• 2.2 Dismantling and assembling selector mechanism
  16
• 2.3 Removing and installing selector lever handle
  17
• 2.4 Checking and adjusting selector lever cable
  20
• 2.5 Removing and installing gear selector cable
  21
• 2.6 Removing and installing cover
  23
• 2.7 Signal magnet for Tiptronic switch F189
  24
• 2.8 Removing and installing cover
  25
• 2.9 Releasing selector lever without electrical current (emergency release)
  26
• 2.10 Removing and installing selector lever position P solenoid N380
  27
• 2.11 Removing and installing selector lever lock solenoid N110
  28
• 2.12 Removing and installing selector lever locked in position P switch F319
  29
• 2.13 Removing and installing selector mechanism
  30
• 3 Renewing needle bearing for starter
  34
• 3.1 Renewing needle bearing for starter
  35
• 4 Removing and installing gearbox
  36
• 4.1 Removing and installing gearbox, vehicles with V10 TDI engine
  36
• 4.2 Transporting gearbox
  41
• 5 Checking and topping up ATF level
  43
• 5.1 Brief description
  44
• 5.2 Checking and topping up ATF level
  44
• 6 ATF lines and ATF cooler
  47
• 6.1 Assembly overview - ATF lines, vehicles with V10 TDI engine
  47
• 6.2 Removing and installing ATF lines and ATF cooler
  48
• 6.3 Cleaning ATF lines and ATF cooler
  50
• 6.4 Bleeding ATF system
  51
• 7 Automatic gearbox control unit J217
  52
• 7.1 Removing and installing automatic gearbox control unit J217
  52
• 8 Renew seals
  55
• 8.1 Renewing output shaft seal
  55
• 8.2 Renewing oil seals for selector shaft
  56
• Gears, control
  58
• 1 Removing and installing sump
  58
• 1.1 Removing
  58
• 1.2 Installing
  58
• 1.3 Specified torques
  59
• 2 Removing and installing ATF strainer
  60
• 2.1 Removing
  60
• 2.2 Installing
  60
• 2.3 Specified torques
  61
• 3 Overview - removing and installing valve body
  62
• 3.1 Removing and installing valve body
  62
• 3.2 Removing and installing gearbox output speed sender G195
  64
• 4 Removing, installing and adjusting multifunction switch F125
  65
• 4.1 Removing
  65
• 4.2 Installing and adjusting
  65