Volkswagen 01M Transmission. Manual — part 35

INTRODUCTION

TOUAREG, AUDI Q7,

PORSCHE CAYENNE

TR60SN "09D" Transmission

AUTOMATIC TRANSMISSION SERVICE GROUP

18635 S.W. 107 AVENUE

CUTLER BAY, FLORIDA 33157

(305) 670-4161

1

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.

The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

Copyright © ATSG 2010

1st Printing

September, 2010

We wish to thank Volkswagen® for the information that has made this booklet possible.

GABE

DE

LOS

REYES

TECHNICAL CONSULTANT

DALE

ENGLAND

FIELD SERVICE CONSULTANT

ED

KRUSE

TECHNICAL CONSULTANT

WAYNE COLONNA

PRESIDENT

PETER

LUBAN

TECHNICAL CONSULTANT

JIM

DIAL

TECHNICAL CONSULTANT

GREGORY

LIPNICK

TECHNICAL CONSULTANT

JON

GLATSTEIN

TECHNICAL CONSULTANT

DAVID

CHALKER

TECHNICAL CONSULTANT

ROLAND

ALVAREZ

TECHNICAL CONSULTANT

GREG

CATANZARO

TECHNICAL CONSULTANT

GERALD

CAMPBELL

TECHNICAL CONSULTANT

The Japanese company AISIN Co., LTD is the manufacturer and developer of the Rear Wheel Drive TR60SN
transmission, which is a 6 speed, fully automatic and electronic controlled transmission. Volkswagen engineers
were also involved, in conjunction with Aisin, in the development process for their vehicles and Volkswagen
gave it the "09D" designation.
The TR60SN, 09D transmission is used in a wide variety of applications and engine sizes. As a result, the
number of friction plates, and planetary gears (3 or 4 pinion), will vary depending on torque load requirements
of the specific vehicle. The TR60SN transmission uses a gear ratio sensitive system, requiring the correct
transmission interchange. The TR60-SN is currently used in the Porsche Cayenne, Volkswagen Touareg, and
Audi Q7 vehicles.
The 09D transmission uses a Lepelletier arrangement, using a simple planetary coupled with a Ravigneaux
type, dual planetary. This is the same type of gear set that was used in the FMX. This arrangement makes six
forward speeds and reverse possible, with only five clutch packs and one freewheel.
This manual contains the procedures necessary to diagnose, rebuild and/or repair the TR60SN "09D"
transmission and is intended for automotive technicians that are familiar with the operation of automatic
transmissions.

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INDEX

TO U A R E G, A U D I Q 7 ,
P O R S C H E C AY E N N E

T R 6 0 S N " 0 9 D "

2

Copyright © ATSG 2010

AUTOMATIC

TRANSMISSION

SERVICE

GROUP

18635 S.W. 107 AVENUE

CUTLER BAY, FLORIDA 33157

(305) 670-4161

3
4
5
6
7
9

10

11

12
13
15
16
17
18
19
21
22
23
24
26
27
28
31

52
57
62
65
66
68
71
75
79
80
81
82
86
91

103

114
116
118

123
124
133
134

GENERAL DESCRIPTION AND VEHICLE APPLICATION CHART . . . . . . . . .
COMPONENT APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION TAG LOCATION AND INFORMATION . . . . . . . . . . . . ...
CHECK FLUID LEVEL AND FLUID SPECIFICATIONS . . . . . . . . . . . . . ...
SPEED SENSOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . ..
PRESSURE SWITCH AND FLUID TEMPERATURE SENSOR INFORMATION . . . . .
SOLENOID LOCATIONS AND IDENTIFICATION . . . . . . . . . . . . . . . . .
INDIVIDUAL SOLENOID FUNCTION AND FAILURE RESULT . . . . . . . . . . ..
SOLENOID APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . ..
SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
PASS-THRU CASE CONNECTORS AND WIRE HARNESS' . . . . . . . . . . . . ..
CASE CONNECTOR TERMINAL IDENTIFICATION . . . . . . . . . . . . . . . .
CASE CONNECTOR INTERNAL COMPONENT RESISTANCE CHARTS . . . . . . ...
TCM CONNECTOR INTERNAL COMPONENT RESISTANCE CHARTS . . . . . . . .
TRANSAXLE RANGE SWITCH OPERATION AND DIAGNOSIS . . . . . . . . . . ..
STANDARD AND TIPTRONIC SHIFT QUADRANTS . . . . . . . . . . . . . . . .
EMERGENCY "LIMP" MODE AND TOWING INFORMATION . . . . . . . . . . ...
TYPICAL WIRE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TROUBLE CODE DESCRIPTION . . . . . . . . . . . . . . . . .
PRESSURE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . ..
PRESSURE TAP LOCATIONS AND IDENTIFICATION . . . . . . . . . . . . . . .
OIL PASSAGE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . ..
COMPONENT REBUILD
TRANSMISSION CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . ..
K2 CLUTCH HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT, REAR RING GEAR ASSEMBLY . . . . . . . . . . . . . . .
REAR PLANETARY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
F1 SPRAG ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
SUN GEARS AND THRUST BEARINGS . . . . . . . . . . . . . . . . . . ...
K1 CLUTCH HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
K3 CLUTCH HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
TORQUE CONVERTER OPERATION, "2-Port" And "3-Port" Differences . . . . ...
OIL PUMP DIFFERENCES . . . . . . . . . . . . . . . . . . . . . . . .
TURBINE SHAFT DIFFERENCES . . . . . . . . . . . . . . . . . . . . ...
FRONT PLANETARY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . ...
VALVE BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . ..
"UPDATED" 2005-UP VALVE BODY INFORMATION . . . . . . . . . . . . ...
TRANSMISSION FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
B2 CLUTCH CLEARANCE MEASUREMENT . . . . . . . . . . . . . . . . . . ..
F1 ROLLER CLUTCH FREEWHEEL DIRECTION . . . . . . . . . . . . . . . . .
B1 CLUTCH CLEARANCE MEASUREMENT . . . . . . . . . . . . . . . . . . ..
TRANSMISSION END-PLAY MEASUREMENT . . . . . . . . . . . . . . . . . ..
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . ..
THRUST WASHER AND BEARING IDENTIFICATION . . . . . . . . . . . . . . .

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