Technical Service Information

AUDI/PORCHE/SAAB/VOLVO/VW
AISIN 09G, 09D, TF80, AW 55-50SN WITH VARIOUS SHIFT COMPLAINTS

COMPLAINT: Before or after overhaul, vehicles equipped with Aisin transmissions may exhibit various
shift complaints such as harsh 2-3, 3-5 and N-R, or a harsh N-D and 5-4, or a harsh 3-4
and/or coast downshift clunks.

CAUSE: The cause may be a loss of lube pressure due to worn pressure regulator valve bores
(primary/secondary), worn bushings, excessive end play and/or failed bonded balance
pistons. The K1, K2 and K3 clutch assemblies are equipped with these bonded counter
balance pistons. Using K3 as an example from an 09G transmission (figures 1 and 2), the
balance piston function is to hold "counter" or "back" pressure on the K3 apply piston.
The balance piston is fed from the lube circuit, and its purpose is to provide a small
amount of pressure to assist the release of the K3 clutch. It also acts as an accumulator
during application of the K3 clutch (figures 3 and 4). The bonded piston has three notches
where the retaining snap ring is located allowing a controlled leak of this pressure, and
when the bonded rubber is worn this will allow a larger volume of pressure loss which can
cause the harsh applications. The K1 can cause a harsh N-D and 5-4 shift, the K2 can
cause a harsh 3-4 shift and the K3 can cause a harsh 2-3, 3-5 and N-R shift.

CORRECTION: Most Aisin Seiki transmissions utilize a primary and secondary pressure regulator valve from
which lube originates and has its pressure control. Should either one of these valves wear into
the bore it can drop lube pressure (figure 5).

Check lube pressure with a pressure gauge. There should be approximately 6 to 10 psi of lube
during operating temperature. If pressure runs close to zero psi, these regulator valve bores
will need to be inspected. Bushing wear and loose end play can also cause a loss of lube
pressure in addition to failed counter balance bonded pistons. All of which will need to be
either repaired or replaced restoring circuit integrity.

Refer to figure 6 for the TF80- SC pressure tap locations

Refer to figure 7 for the TF81-SC pressure tap locations
Refer to figure 8 for the TF60-SN pressure tap locations
Refer to figure 9 for the TR60-SN pressure tap locations
Refer to figure 10 for the AW55-50SN pressure tap locations

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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

K3 CLUTCH DRUM EXPLODED VIEW

K3 BALANCE
PISTON K3 CLUTCH
ASSEMBLY

K3 RETURN
SPRING

K3 CLUTCH
PISTON

K3 CLUTCH
DRUM

Copyright © 2012 ATSG

Figure 1
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
K3 CLUTCH CROSS-SECTIONAL VIEW

Pump
K3 Clutch Drum

K3 Clutch
Apply Piston

K3 Clutch
Balance Piston
K3 Clutch
Balance Piston
Controlled leak

Stator Support K3 Clutch

K3 Clutch Balance Piston
Piston Feed Feed (Lube circuit)
Copyright © 2012 ATSG
Figure 2

K3 CLUTCH "OFF"

Pump
K3 Clutch Drum

K3 Clutch
Apply Piston

K3 Clutch
Balance Piston
K3 Clutch
Balance Piston
Controlled leak

K3 Clutch
Stator Support K3 Clutch Balance Piston
Piston Feed Feed (Lube circuit) Copyright © 2012 ATSG
Figure 3
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

K3 CLUTCH "ON"
Pump
K3 Clutch Drum

K3 Clutch
Apply Piston

K3 Clutch
Balance Piston
K3 Clutch
Balance Piston
Controlled leak
K3 Clutch
Balance Piston
Stator Support
K3 Clutch Feed (Lube circuit)
Piston Feed
Copyright © 2012 ATSG
Figure 4

09G LUBE CIRCUIT

To Cooler
.058”

Secondary PR To Front
Trans Lube

To Rear
Trans Lube
.032”
.032”
To Diff.
Lube
.045”

.076” .032” TFT

.032”
x

x
Pump Primary PR

Copyright © 2012 ATSG

Figure 5 12-12
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

TF80-SC
AM6
AF40
TF-80
AF40/6
TCC
Apply

C1

TCC
Release Line

C2
C3
Lube
B2

B1

Copyright © 2012 ATSG

Figure 6

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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

TF81-SC
AF21
AW6A-EL

TCC Apply

Line

C3 C2

Lube

B2

Copyright © 2012 ATSG

Figure 7

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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

TF860-SN
09G
09M
09K
Lube
(Some Models)

57 G 30 021 03
3

02 5H
34 0 68
09 C2T 280

4 - 03
03 Z
GG
V
W
A
G
SG
F

40

09
5
10 1 - 1
04

G
-1 TCC
30
0C
3
00
2T 3
0 2 5H
16
8 AU
Release
O
Z

FA
B-2
B-1 Clutch
Clutch
Lube
K-3
Clutch
In Case Below K-2
Fluid Fill Device
Note: All Transaxles Clutch
Are Not Equipped With
Fluid Fill Device
K-1
Clutch Copyright © 2012 ATSG

Figure 8

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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

TR860-SN
09D

B2 Clutch
"Small" Cavity

B2 Clutch
"Large" Cavity

Lube

K1 Clutch
K3 Clutch

"From Cooler" "To Cooler"

Copyright © 2012 ATSG

Figure 9

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AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information

AW55-50SN
RE5F22A
AF23/33-5

4-5 Clutch (C3)

1-2/Reverse (B5)

Forward Clutch (C1)

Lube

Direct Clutch (C2)

Copyright © 2012 ATSG

Figure 10

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AUTOMATIC TRANSMISSION SERVICE GROUP