DSG.pdf

6-Speed Automatic Transmission

09G/09M

Design and Function

Self-Study Program

Course Number 851503

Volkswagen of America, Inc.

Service Training

Printed in U.S.A.

Printed 04/05

Course Number 851503

in this manual is based on the latest

information available at the time of printing and

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Always check Technical Bulletins and the latest

electronic service repair information that may

supersede any information included in this

booklet.

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Table of Contents

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6-Speed Automatic Transmission 09G/09M

Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Selector Lever Positions and Operation, Selector Lever Design in

2004 Golf, Selector Lever Design in 2004 Eurovan, Ignition Key

Removal Lock in 2004 Golf, Ignition Key Removal Lock in 2004

Eurovan

Transmission Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Transmission Section 09G, Transmission Section 09G - Schematic,

Planetary Gear/Shifting Elements, Torque Converter, Torque

Converter Lock-Up Clutch, ATF Supply/Lubrication, Section -

Automatic Transmission, Park Lock, Hydraulic Control, Torque Flow

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Example: 2004 Golf

Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Transmission Control Module (TCM) J217, Dynamic Shifting

Program DSP, Sport Mode “S , Emergency Running Mode,

Towing, Starter Interlock, Back-up Light, Sensors, Actuators,

Solenoid Valves, Electrical Pressure Control Valves, 2004 Golf

Functional Diagram, 2004 EuroVan Functional Diagram, 2004 Golf

CAN Databus Connections

Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Diagnostic

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Special Tools

Glossary

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Te r m s

Knowledge Assessment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

New!

The Self-Study Program provides you with information

regarding designs and functions.

Important/Note!

The Self-Study Program is not a Repair Manual!

For maintenance and repair work, always refer to the

current technical literature.

Introduction

6-Speed Automatic Transmission

09G/09M

The Japanese automatic transmission

manufacturer AISIN Co., LTD is the

developer and manufacturer of the 09G

transmission. Volkswagen engineers

developed the transmission in conjunction

with Aisin and adapted it to Volkswagen

vehicles.

The 09G/09M 6-speed automatic

transmission is installed in the following

Volkswagen vehicles:

Designation

Maximum Torque Transfer

Vehicles

09G

09M

184 lbs-ft (250 Nm)

332 lbs-ft (450 Nm)

2005 Jetta/New Beetle

2006 Passat

The transmission is adapted for use with

different engines and vehicles by varying:

• The number of disc pairs for clutches

and brakes

• The adaptation of the ATF pressure on

the clutches and brakes

• The configuration of gear pairs,

planetary gear sets (e. g. four instead of

three planetary gears), shafts and

bearings

• The reinforcement of housing

components

• The ratio of the final drive and the

intermediate drive

• The size of the torque converter

• The torque converter characteristic

curve of the torque boost (conversion

factor or conversion boost)

• The selector lever

• The ignition key removal lock

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