09G Transmission parts, repair guidelines, problems, manuals
TF60SN, 6F21WA, AW6VWF1
Transmission general data
| Number of gears | Transmission Type | Drive | Torque (Nm) | ATF (full capacity) L | ATF (change) L | ATF type |
|---|---|---|---|---|---|---|
| 6 | AT | FWD | 280 | 7 | 4 | G 052 025 A2 |
The 09G (TF60-SN - according to Aisin Co classification) is the first 6-speed transmission which has been used since 2003 for virtually all FWD cars of Volkswagen and Audi family (A3, A4 and TT) with engine capacity from 1.4 up to 2.0 liters (Mini Cooper, Skoda Fabia, Polo)
The 09G is designed for torque up to 280 Nm.This solution is the successor of 5-speed AW55-50. It competes with the German transmission ZF 6HP19-/21 and considered to be more durable and relatively cheap in repair.
What are you looking for?
Overhaul Kit | Friction Kit | Friction | Steel Plate | Steel Kit | Band | Solenoid Kit | Solenoid EPC | Solenoid TCC | Pump | Shaft | Drum | Valve body | Torque converter | Hub | Piston | Piston Kit | Planetary Gear | Filter | Gasket | Bushing | Seal | Bearing | Pressure Plate | Stator | Differential | Retainer | Inhibitor Switch | Instruction manual | TOOLS & ACCESORIES | Sensor
Which cars run with this gearbox?
| Brand | Model | Year | Type | Engine |
|---|---|---|---|---|
| Audi | TT | 03-06 | 6 SP F/4WD | L4 1.8L |
| Saab | 9'3 | 09-11 | 6 SP FWD | L4 2.0L |
| Seat | TOLEDO | 12-16 | 6 SP FWD | L4 1.6L |
| Skoda | RAPID SPACEBACK | 13-16 | 6 SP FWD | L4 1.6L |
| Skoda | SUPERB | 09-13 | 6 SP F/4WD | L4 2.0L V6 3.2L |
| Volkswagen | GOLF | 07-16 | 6 SP FWD | L4 1.6L 1.8L 2.0L L5 2.5L |
| Volkswagen | JETTA | 98-16 | 6 SP FWD | L4 1.6L 1.8L 2.0L L5 2.5L |
| Volkswagen | NEW BEETLE | 97-16 | 6 SP FWD | L4 1.8L 2.0L L5 2.5L |
| Volkswagen | PASSAT | 11-16 | 6 SP FWD | L4 1.8L 2.0L L5 2.5L V6 3.6L |
| Volkswagen | POLO | 10-16 | 6 SP FWD | L4 1.6L |
| Volkswagen | TOURAN | 03-06 | 6 SP FWD | L4 1.6L 1.9L |
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- Accumulators, Accumulator Piston, Acummalator Kit, Accumulator Piston Kit
- Adapter, Adapters, Grommet Valvebody
- Bands, Brake band, Lining
- Bearings, brg, Mainbearing
- Cover Bolt, Cover Bolts, Mounting Bolt, Mounting Bolts, Pan Bolt, Pan Bolts, stud, studs, Split Pin
- Booster, Boosters, Boost Regulator, Boost Spring, Boost Valve, Lockup Boost, Booster kit, Kit Boost, Kit Boost Valve
- Vents, Case Vent, Case Vent Valve, Vent Hose Connector, Vent, Plastic Breather
- Bushings, Bush,
- Casing, casings, cases
- Case Covers, Cover, Dust Cover,
- Check Balls, Checkball, Checkballs, Balls, ball
- Connectors, loom
- Coolers, Oil Cooler, Heat Exchange, Heat Exchanger
- Differentials, Differential Carrier, Differential Carriers, Diff, Diff., Diff Housing Carrier
- Right Axle Seal, Seal Left Axle, Left Axle Seal, Seal Right Axle Shaft seal, Seal Drive Shaft, Seal MC Drive Shaft, Seal MC Drive, Axle Seal Left, seal axle, Seal Drive Shaft, Seal 4WD Left Axle, Axle Seal
- Drums, Contender Drum, Drum with Bearing, Reverse Drum, Drum Part
- Electrics, Electric, Electronic, Electronic Shift, Electronics, Pin Wiring, Relay Control Switch, Neutral Relay, Main Relay
- End Plugs, Tail Plug, Tail Plugs, Tailplug, Tailplugs
- Filters, Filter Cartridges, Filter Cartridge, Oil Pan Filter, Inlet, Filter Kit
- Flanges, Drum Flanges, Drum Flange, Flange Yokes, Flange Yoke, Flange Kit, Rear Flange Kit, Yoke, Slip Yoke, Yokes, Flange
- Friction Discs, Frictions, fric, Friction Disc, Friction, Friction Plate, Friction Ring, fric., Clutch Plate, Friction Lining
- Friction kits, friction pack, friction set, High Energy Clutch Friction Module, Friction clutch
- Gaskets, gsk, gskt, , Cover Gasket, Cover Gaskets, Case Gasket, Case Gaskets, Filter Gasket,Filter Gaskets
- Gasket Pan, Pan Gaskets, Pan gasket, Filter Gasket,Filter Gaskets
- loom, Harnesses, Line Connector, Wiring, Cover Wiring, Cable, Signal Cable, Cable, Power Cord
- Housings
- Hubs, Hub Insert
- Inhibitor switches, Inhib.Swtch, Range Selector Switch, Selector, Range Switch, Position Switch, Gear Selector, ISM
- Input Shafts, Shaft input, Shaft Input/Main, Inputshaft
- manuals, Technical manual, Repair manual, service manual, Manual, VIDEO & AUDIO, tapes
- Mounting Pad, Mounting Ring, Transmission Mount, Transmission Mounts, Mounting Rings, Mounting Pads
- o-ring, o ring, 0ring, 0-ring, 0 ring, ORing, Ring, O-Rings, o-ring, O'Ring
- ohk, OHK kit, Overhauls, mok, Overhaul kit, Masterkit, Master kit, Master Overhaul, Repair package, Overhaul, Rebuild kit, Master Rebuild, Super Rebuild Bundle, Banner Kit, SUPER KIT, SUPERIOR KIT
- Pans, Crankcase, Oil Pan
- Piston Pins, Servo Pin, Piston Pin, Band Pin, Retaining Pin, Retaining Pins
- Pinions, Pinion Gear, Pinion Pin, Pinion Gear Shaft,
- Pipes, Modulator Pipe, Inlet Pipe, feed Pipe, oil pipe
- Pistons, Apply Piston, Pack Piston, High Piston, Damper Piston, Piston Damper, Piston Plate, Interm. Servo Pist, Piston Seals, Piston Seal Ring, Piston Seal Rings, Piston Seal, Piston Cover, Piston Covers, Rear Servo, servo piston, Piston Retainer, Piston Retainers, Servo kit, Super Servo, servo, Shift Pison
- Piston Kits, Piston Complete, Piston part, Piston Sets, Piston Set
- Planetary Gears, Planetary Gear Set, Planetary Gear Sets, Planet, Planetary Assembly, Planetary Component, Reaction Carrier, Planet
- Plungers, plung, Control Plunger, Control Plungers, Apply Control Plunger, Modulator Plunger
- Pressure Plates, Apply Plate, Backing Plate, Backing Plates, Backplate, Ret Plate, Dish Plate, Press Plate
- Pressure Sensors, Sensor Gov Pressure
- Pumps, Rotor, Vane, Vanes, Kit Pump Vane/Ring
- Regulators, Main Pressure Regulator, Main Pressure Reg, Pressure Regulator, Forward Regulator, Secondary Regulator, Pressure Reg, Press Reg
- Regulator Valves
- Repair Kit, Kit Case Repair,
- Retainers, Spring Retainer, Plug Retainer, Bearing Retainer
- Seals, Metal clad seal, Lip Seals, Connector Hole Seal, Lip Seal, Main Seal, Radial Lip Seal, Main Seal, Manual Seal, Oil Feed Seal, Side Cover Seal, Seal Cooler, Seal Oil Cooler, Case Seal
- Pump seal
- Seal Rings, Seal Ring, Sealing Rings, Piston Seal, S/Ring, SEALING RINGS S/Ring, Accumalator Seals
- Sensors
- Sump modification kit
- Shafts
- Reprogramming Kit, Kit Reprogram, Reprogram Competition, Kit Shift, Kit Auto Shift, Kit Stick Shift, Shift Correction Kit
- Sleeves, SLEEE, Ground Sleeve, Overlap Control Sleeve, Seal Ring Sleeve, Repair Sleeve, Regulator Sleeve, Modulator Sleeve, Pressure Sleeve, Piston Sleeve, Pinion Repair Sleeve, Damper Sleeve, Bore Sleeve, Boost Sleeve
- solenoid, Shift Solenoid, Kickdown Solenoid, Control Solenoid Support, Solenoid Retainer, Interlock Solenoid, Solenoid Switch
- Solenoid Blocks, sol block, Brass Contact,
- EPC, Pressure Solenoid, Pressure Control Solenoid, Pressure Solenoid, PWM solenoid, Pressure Regulator Solenoid
- Solenoid package, solenoids, Solenoid Retainer, Solenoid Kit, pack, Solenoid Upgrade Kit, Solenoid Set, Shift Solenoid Upgrade Kit, Shift Solenoid Kit Set
- TCC sol, tcc solenoid, TCC Reg, TCC PWM
- Speed Sensors, Output Sensor, Input sensor, Reluctor, Shaft Sensor, Speed Sender, Sensor Input, Sensor Output, Sensor Input / Output, TURBINE SPEED, INPUT SPEED, VEHICLE SPEED
- spragg, Sprags, Mechanical Diode, Sprag Assembly, Sprag Cartridge, One Way Clutches, One Way Clutch, Roller Clutches, Roller Clutch, Low/Rev Diode, Retaining Plates, Retaining Plate, Accordion Spring, OWC
- Springs, Wave Spring, Spring Adjuster, Spring Disc, Torsion Spring, Return Spring, Piston Spring, Damper Spring, Damper Springs, Control Spring, Detent Spring, Drum Spring, Limit Spring, Return Sprng, Diaphragm Springs, Diaphragm Spring
- Steel Kits, Steel Set Kit, Steel Clutch Plate Kit, Steel kit, clutch steel, clutch steels, Steel set, steel pack, module kit, Steel Plate Clutch Kit, Steel Plate Kit, Steel Plate Module, Steel Plate Set, Steel Module
- Steel Plates, steel, Steels, steel disk
- Sun Gears, Sungear, Sungears, Sun Gear Retaining Ring, Final Drives, Final Drive, FinalDrive, SUN
- Supports, Centre Supp Rebuilt, central support. support central
- Manifolds, Switch Manifold, Switch Manifolds, Pressure Switch Manifold, Pressure Switch Manifolds, Switch, Manifold
- Washer, Washers, T/Washers, Thrust Washers, Selective Washers, Kit Washer, Drive Sprockets, Driven Sprockets, Drive Sprocket, Thrust Kit, Washer kit,
- Tool kits, Alignments, Alignment, Reamers, Reamer, Tool kit, Tool, Pressure Gauge, Clutch Aligning Tool, Clutch Removal Tool, Clutch Tool Supplement, Kit Installer, Air Test Plate, ADJUSTMENT TOOL, Thread Tap, Remover
- converter, t.converter,
- Tubes, Oil Tube
- Throttle Valve, Timing Valve, Operating, Relief Valve, Safety Valve, Control Valve, AFL Valve, Limit Valve, Actuator Feed Limit Valve, AFL Valve
- VB plate, Valve body plates, Valve body plate, ValveBody, V/Body, valve-body, v body, v-body, v/b, Orifice, Hydraulic control unit, HCU
- Overlap Control Valve Kit, Pressure Regulator Valve, Switch Valve Plug, Actuator Feed Limit
- Oversized Valve, flow control, Oversized Safety, Oversized, Flow Control, Valve pump flow control, Pump flow control valve, Oversized Pump Flow Control
Technical issues and repair guidelines
The 09K and 09M sub-modifications were released after testing and upgrade of the 09G transmission. They were used together with engines with the capacity equal up to 3.5 liters (TF-62SN -61SN, Passat, Superb, Transporter). Many other modifications of this transmission, which differ mainly in electric components and the valve body construction, can be encountered in the repair shops. Peculiarities of the TF60SN transmission are typical for most of 6-speed transmissions and are associated with fast ATF contamination by the friction lining of the torque converter which operates with slipping of the lockup clutch, and when the engine operates under unusually high temperature. The torque converter is rebuilt during each overhaul.
Typical repair procedures for the 09G (TF-61SN \TF-60SN) transmission
Typical overhaul of the 09G transmission involves reassembly and replacement of following spare parts:
- A set of 4 problematic pistons consisting of a piston / retainer pair for a problematic package К2 (С2) and retainers of clutches K1 and K3 is almost always changed together with seals and gaskets (overhaul kit). It is recommended to replace friction clutches together when the К2 package burns out completely and the rest of friction linings are stained with burnt ATF
- Abnormal operation of the TF60-SN valve body often manifests itself in problems with 4-5-6 speeds. Error codes - P0734, P0735 or P0729 signal that solenoids and valves of the valve body are worn / clogged. The solenoids are rebushed with the help of the Bushings Repair Kit.
- The transmission pump is the next stage in the repair process. The axle deformation, surface damage and bushing cranking are caused by an uneven wear out of friction lining and related thereto vibrations. The tool kit of bushings (5 pieces) also gets replaced. The most deformed bushings are: bushings of sun gear, rear cover, pump, and package К3 (С3).
The typical malfunction can be described as follows:
1-st stage. The torque converter friction gets actuated with slippage starting from the 3-rd gear, without waiting for the levelling of the transmission and engine shaft RPM. The friction element gets damaged and contaminates ATF with hard and sticky powder.
2-nd stage. Plungers and valves get blocked and give less oil pressure to one of the packages, and as a result, worn parts have leakages, oil overflows, critical decrease of pressure in the clutch packs.
One of the most complicated cases is the wearout of the valve body and/or one of its irreplaceable components. Then it is required to change the entire valve body. Another reason the valve body failure is the replacement of solenoids which exhausted their performance potential. Preliminary, it is required to check the wiring and electrics contacts. It is rare that problems are caused by the shaft speed sensors ISS and OSS, they are cleaned and the ATF is washed off. The replacement of pump and semi-axle seals is also performed quite frequently.
The pump bushing (46.9x43.9x14.8) is replaced, if the wear-out reaches 0.10 mm. First of all, friction components and clutch steel discs K2 4-5-6 (C2) are examined for wear. Clearances in clutch packages affect the quality of switching and hard parts wear-out. It is required to change the Piston К2 (C2) and the retainer. The retainer K1 is also replaced quite frequently. The cause of this problem is solved by replacing the repair clutch of the rear cover. It is more rarely that you have to replace spare parts of the K3 package. In many cases, the clutch drum wear-out leads to some kicks (impact) while shifting gears. The factory clearance (gap) is 1.4 mm. When the clearance (gap) increases up to 1.8 mm, then kicks become noticeable. Such friction components are replaced to stop the wearout chain reaction.
Problems with the rear planetary gear are mainly explained by slipping of insufficiently lubricated bushings. The torque converter is one of the typical problems for 6-speed automatic transmissions. It works with a wide “slippage mode”. The pressure for blocking is provided not by simple electric valve, but by the PWM solenoid. This mode of operation increases the car efficiency, but enormously speeds up the process of wear-out for the torque converter friction lining.
Instruction manuals and useful links Suggest your link
| Link type | Source | Description |
|---|---|---|
| media.cylex.com | 6-speed automatic gearbox 09G Service | |
| www.atra.com | Disassemble the Solenoids 09G | |
| www.evosoft.dk | Design and Function Self-Study Program 09G | |
| www | www.at-manuals.com | Solenoid/clutch application chart 09G |
| Sonnax | Valve Body Layout TF-60SN | |
| Sonnax | Vacuum test AW TF-60SN, BMW 6F21WA, VW/AUDI 09G, 09K, 09M | |
| drive.google.com | Repair manual 09G 09M | |
| drive.google.com | 09G 09M Design and function |