Volkswagen 01M Transmission. Manual — part 93

INTRODUCTION

AUDI, JETTA, PASSAT,

09G/09M Transaxle

AUTOMATIC TRANSMISSION SERVICE GROUP

18635 S.W. 107 AVENUE

CUTLER BAY, FLORIDA 33157

(305) 670-4161

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

March, 2010

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

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

GREG

CATANZARO

TECHNICAL CONSULTANT

GERALD

CAMPBELL

TECHNICAL CONSULTANT

The Japanese company AISIN Co., LTD is the manufacturer and developer of the Front Wheel Drive TF60SN
transaxle, which is a 6 speed, fully automatic and electronic controlled transaxle. Volkswagen engineers were
also involved, in conjunction with Aisin, in the development process for their vehicles and they gave it the
09G/09M designation. BMW gave it the designation 6F21WA for their Mini-Cooper.
The 09G/09M transaxle is used in a wide variety of applications and engine sizes. As a result, the number of
friction plates, planetary ratios, intermediate ratios and final drive ratios will vary depending on torque load
requirements of the specific vehicle. The TF60SN transaxle uses a gear ratio sensitive system, requiring the
correct transaxle interchange. The TF60-SN is used in the BMW Mini Cooper, Volkswagen and Audi vehicles.
This transaxle is referred to as the TF60-SN, 09G, 09M, 6F21WA and in some overseas vehicles as 09K. As a
result there are a variety of different case and part configurations. Some of these units have the heat exchanger
attached to the transmission while others use a remote heat exchanger. This alters the case, case cover and the
valve body and if incorrect parts are used, severe planetary failure will occur. This manual covers these
differences so that this mistake will not happen to you.
The 09G/09M transaxle uses a Lepelletier arrangement, using a simple planetary coupled with a Ravigneaux
planetary. 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 09G/09M transaxle and is
intended for automotive technicians that are familiar with the operation of automatic transmissions.

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3

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

The Japanese company AISIN Co., LTD is the
manufacturer and developer of the Front Wheel Drive
TF-60SN transaxle, which is a 6 speed, fully
automatic and electronic controlled transaxle.
Volkswagen engineers were also involved, in
conjunction with Aisin, in the development process
for their vehicles and they gave it the 09G/09M
designation. BMW's designation for the same unit is
6F21WA. US and Overseas Vehicle applications,
known at time of printing, are shown in Figure 1.
The 09G/09M transaxle is used in a wide variety of
applications and engine sizes. As a result, the number
of friction plates, planetary ratios, three or four pinion
carriers, transfer gear ratios and the final drive ratios
will vary depending on torque load requirements of
the specific vehicle. The 09G/09M transaxle uses a
gear ratio sensitive system, requiring the correct
transaxle interchange, if that becomes necessary.
There are also versions of this transaxle that have an
"Integral Cooler" bolted directly to the transaxle
converter cover and pipe engine coolant to the
transaxle. Some versions have a "Remote" mounted
cooler and pipe transaxle fluid to the cooler. This
affects changes to the case, converter cover, valve
body and spacer plate. None of these parts are
interchangeable with one another.

This transaxle is very similar to the AF40-6
transmission but with 3 very significant differences.
One is the B1 brake band has been eliminated and
replaced with a B1 clutch pack. Second is the rear
cover that gave access to the C/K2 clutch has been
eliminated. Third the Transmission Control Module
(TCM) is mounted external from the transaxle which
makes typical electrical diagnosis available to the
technician.
The TCM controls both shift timing and shift feel
with the use of eight solenoids. The TCM monitors
gear ratio through the input and output shaft hall effect
speed sensors. It also can determine the rate of change
and adapt the shifts as the friction elements wear.
All TF-60SN (09G) transaxles use a Lepelletier
arrangement, which consists of a simple planetary
with the sun gear splined to the pump stator and
coupled with a Ravigneaux planetary. This allows the
sun gears and the planetary pinions of the Ravigneaux
planetary gear-set to be driven at different speeds.
This arrangement makes six forward speeds and
reverse possible, with only five clutch packs and one
freewheel.
Refer to Figure 2 for the component locations and the
clutch application chart for each gear.

GENERAL DESCRIPTION

Figure 1

Copyright © 2010 ATSG

VEHICLE APPLICATION CHART

VEHICLE

YEAR

ENGINE

VW

AISIN

AUDI A3

AUDI A4

AUDI TT
AUDI TT

BMW Mini Clubman
BMW Mini Cooper
SEAT Altea (Non US)

SEAT Leon (Non US)
SEAT Toledo (Non US)

Volkswagen Beetle

Volkswagen Transporter

Volkswagen Jetta

Volkswagen Passat/Passat Wagon

Volkswagen Passat/Passat Wagon

Volkswagen Tiguan (Non US)

Volkswagen Touran (Non US)

2006-Up

2006-Up

2003-06
2004-08

2008-Up
2002-Up
2004-Up

2005-Up
2004-Up

2004-Up

2006-Up

2005-Up

2006-Up

2006-Up

2008-Up

2003-Up

2.0L

2.0L

1.8L

2.0L, 3.2L(V6)

1.6L
1.6L

1.8L, 1.9L, 2.0L, 2.5L

1.9L, 2.0L, 2.5L

1.9L, 2.0L, 2.5L

2.0L,

3.6L,

1.4L, 2.0L

1.6L, 1.9L, 2.0L

1.4L, 1.6L, 2.0L,

1.4L, 1.6L, 2.0L,

1.6L, 1.9L, 2.0L,

09G

09G

09G
09G

6F21WA
6F21WA

09G

09G
09G

09G

09K

09G

09G

09M

09M

09G

TF60SN

TF60SN

TF60SN
TF60SN

TF60SN
TF60SN
TF60SN

TF60SN
TF60SN

TF60SN

TF60SN

TF60SN

TF60SN

TF60SN

TF60SN

TF60SN

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Copyright © 2010 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

COMPONENT APPLICATION CHART

K3

Clutch

K1

Clutch

B1

Clutch

F1 Roller

Clutch

K2

Clutch

B2

Clutch

CLUTCH APPLICATION CHART

Gear

1st Gear

2nd Gear

3rd Gear

4th Gear

5th Gear

6th Gear

Rev Gear

Transfer Gear Ratio, Codes GSY, GJZ, FXA, (Driven=52T/Drive=49T) Ratio = 1.061

Final Drive Gear Ratio, Codes GSY, FXA, (15T/61T) Ratio = 4.067

Final Drive Gear Ratio, Codes GJZ, (15T/58T) Ratio = 3.867

K-1

Clutch

On

On

On

On

On

On

On

On

On

On

On

On

On

K-2

Clutch

K-3

Clutch

B-1

Clutch

B-2

Clutch

On*

On**

On**

On**

On**

On**

Hold

4.148

4.044

2.370

2.371

1.556

1.556

1.155

1.159

0.859

0.852

0.686

0.676

3.394

3.193

F-1

Roller

Clutch

Torque

Conv.

Clutch

Engine

1.6L, 2.0L

Ratio***

Engine

1.8L,

Ratio****

* The B-2 Clutch is applied in "Tiptronic Mode" 1st gear, only for engine braking.
** During normal driving operation, the Torque Converter Clutch can be applied in each gear.
*** Transaxle Codes (GSY 1.6L) and (GJZ 2.0L).
**** Transaxle Code (FXA 1.8L).

Figure 2

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F

S

G

AU

FA

AU

FA

VW

G

A

W

G

V

A

Z

0

G

2

03

3

G

8

0

2

3

2

16

C

T0

8

9

5

0

G

3

0 0H

0

3

3

-

2

57

4

0

4

0

-

-

4

1

1

5

1

2

0

03

6

C

21

8

T

O

Z

0

0

H

30

35

G

09

10

04

5

Copyright © 2010 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

4051 - 1 - 1

03C2T02168

Z

0

300 035H

09G

1004

GGZ 280303
03C2T02168
09G 300 035H
57344 - 02

Transaxle Code

Build Date

Day Mo Yr

OEM Part Number

OEM Part Number

Ink Stamp On Case

Build Date/Serial Number

Build Date/Serial Number

IDENTIFICATION TAG INFORMATION

{

TRANSAXLE IDENTIFICATION

Figure 3

The paper ID tag stuck to the side of the case, as
shown in Figure 3, carries the OEM part number
along with the build date and serial number. The only
place we have found a "Transaxle Code" is ink
stamped or etched on the transaxle case, in the
location shown in Figure 3. In the example shown the
transaxle code is "GGZ".

Note: For the newest transaxle code information
that is available to us, See Page 124.

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