00028112020-Nr 300 6-Speed Automatic Transmission 09D PDF

Service.
Self-Study Programme
lksw
agen 300
AG. Volkswagen AG d
oes
n o ot g
yV ua
db ran
ir se tee
ho
ut or
6-speed automatic transmission 09D ss
a ac
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Design and function
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Compared to the 5-speed automatic transmission, the 09D 6-speed automatic transmission provides:
– a reduction in fuel consumption,
– a reduction in exhaust emissions,
– improved acceleration values and
– a reduction in noise.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
300_U2
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
This self-study programme provides you with the design and function of the new c
cted
by lksw
agen
Prote AG.
6-speed automatic transmission which is installed in the Touareg.
NEW Caution
Note
The Self-Study Programme describes the Please always refer to the relevant service
design and function of new developments! literature for up-to-date inspection, adjustment
The contents are not updated. and repair instructions.
2
At a glance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Selector lever . . . . . . a.g.en. A.G.. .Vo. lk.s.w.ag.e.n A. G. d. o. . . . . . . . . . . . . . . . . . . . 6

ksw es n
Vol ot g
d by ua
ran
e
ris tee
utho or
a ac
ss
ce
e
Design of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
hole
spec
es, in part or in w
t to the co
rrectness of i
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
l purpos
nf
ercia
orm
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
Check your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Operational diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Self-diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3
Introduction
The 09D 6-speed automatic transmission
was developed at the famous Japanese manufacturer of automatic transmissions, AISIN Co., LTD,
where it is manufactured.
In the development of the control unit software, the years of experience that Volkswagen
engineers have had with fuzzy logic-controlled driving programmes that depend on driving
situations and hindrances has been a determining factor.
This 6-speed automatic transmission, which has a very compact construction, is being
used for the first time in the Volkswagen Touareg.
Gearbox ventilation
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
300_002
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Spare parts number
co Vo
by lksw
cted agen
Prote AG.
AISIN model number
Manufacturer
Production date
Gearbox codes
300_081
Serial number of the manufacturer
4
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
Special gearbox features include:
pt
du
an
itte
y li
erm
ab
ility
• fuzzy logic-controlled switching • lifetime ATF filling
ot p
wit
programmes that depend on driver and , is n • The hill-holder function secures the vehicle
h re
hole
driving situations as well as switching from rolling back and permits hills to be
spec
es, in part or in w
programmes that depend on driving approached comfortably.
t to the co
impedance • selector lever and steering wheel Tiptronic
• a controlled converter bypass coupling switches
rrectness of i
l purpos
nf
ercia
or
Gearbox ventilation
m
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Electrical
connections
300_001.1
ATF cooler connections Multifunction switch
Technical data
Volkswagen designation AG6 - 09D

Gearbox codes with V10-TDI-engine EXG
with V6 engine EXL
ATF Lifetime filling
ATF filling amount with V10-TDI-engine 12 litres
with V6 engine 9.6 litres
Maximum torque transmission 750 Nm
Weight depending on engine 97 to 110 kg
including ATF
Emergency run in case of defective control unit 3rd gear and R gear
5
Selector lever
AG. Volkswagen AG d
agen oes
lksw not
d by Vo
The selector lever positions
gu
ara
rise nte
tho eo
au ra
ss P - Park c
ce
le
un
Before the selector lever can be moved out of the
pt
an
d
itte
y li
Park position, the ignition must be switched on.
rm
ab
pe
ility
In addition, the foot brake and the locking button
ot
wit
, is n
on the selector lever must be pressed.
h re
Locking button
hole
spec
es, in part or in w
R - Reverse
t to the co
The locking button on the selector lever must be
pressed to switch into reverse.
rrectness of i
l purpos
N - Neutral
The gearbox is idling in this position.
nform
ercia
No power is being transmitted to the wheels.

m
a
If the selector lever is in this position for a long
com
tion in
time, the foot brake must be pressed again to
r
te o
thi
activate the lever.
s
iva
do
r
rp
cum
fo
en
ng
D - Drive
t.
yi Co
Cop py
gh
t. In the Drive position, the forwards gears are
rig
ht
yri by
switched automatically.
cop Vo
by lksw
cted agen
Prote AG.
300_003
S - Sport
The control unit selects gears automatically
according to a ”sporty” switching characteristic
curve.
The individual gears are extended further.
Selector lever position and gear display in

dash panel insert
After the ignition is switched on, the current

P
selector lever position is displayed in the
R
N
dash panel insert.
D3 In positions ”D” and ”S”, the gear selected in the
S gearbox is also displayed.
123,4 km 12,3°C 123456 km
300_004
6
The Tiptronic
in the Touareg is available as a selector lever as

well as a steering wheel switch.
Selector lever Tiptronic
”+” Move up
The Tiptronic channel is reached by moving the
a gear
selector lever to the right out of the ”D” position.
”-” Move down The control unit for the automatic gearbox thus
a gear enters the Tiptronic mode.
The driver can now actively select gears.
300_006 lkswage es n
o ot g
Tiptronic channel byV ua
d ran
ir se tee
tho
u or
Steering wheel switches a ac
ss Steering wheel - Tiptronic switches
ce
le
un
pt
an
d
itte
y li
The steering wheel switches offer an optimal
erm
ab
ility
ergonomic actuation for gear selection.
ot p
wit
is n
Here you use:
h re
ole,
– the switch on the right to move up a gear.
spec
urposes, in part or in wh
and
t to the co
– the switch on the left to move down a gear.
rrectne
If the selector lever is in the ”D” or ”S” position
when the steering wheel switches are pressed,
ss o
the automatic transmission control moves into
cial p
f inform
Tiptronic mode.
mer
atio
Control automatically reverts to the previously
om
n
c
selected ”D” or ”S” programme if the steering

i
or
n thi
te
300_036 wheel switches are not pressed again.

sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
Gear display in the dash panel insert
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
The current gear is displayed in Tiptronic mode.
6 AG.
5
4
3
2
1
123,4 km 12,3°C 123456 km
300_005
7
Selector lever
Selector lever lock and ignition key

removal lock
Magnet for selector lever lock N110
This is located in the front on the selector lever

frame.
N110
It prevents the actuation of the selector lever
from the positions ”P” and ”N” when the brake is
not being applied.
How it works
Once the ignition has been turned on, the

magnet for the selector lever lock is put under
current by the control unit for automatic
transmission, thus blocking the selector lever.
If the control unit receives the signal ”brake 300_021
applied” via the CAN data bus, it cuts off current
to the magnet and the selector lever can be Selector lever frame
moved.
Effects of a signal drop-outwage es n 30
olks ot g
yV 31uara
db
ir se nte
If one of these two ho e E415
fails or if the magnet is aut signals or
ac
ss E408
faulty, the selector lever can be moved out of ”P”
ce
le
un
pt
and ”N” without applying the brake – assuming

an
N376
d
itte
y li
erm
the ignition is turned on.

ab
ility
ot p
wit
is n
h re
ole,
spec
J217
t to the co
E408 - button for starting/stopping the engine J518

E415 - switch for access and start
authorisation
rrectne
Kl.15
F319 - switch for selector lever locked in P
s
J217 - control unit for automatic gearbox

s o
cial p
J518 - switch for access and start

inform
mer
authorisation N110 F319 N380

atio
m
N110 - magnet for selector lever lock

o
n
c
i
or
N376 - magnet for ignition key removal lock

thi
e
300_041
t
sd
a
N380 - magnet for selector lever lock P

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8
The magnet for selector lever lock ”P” N380
is at the selector lever frame, as is the magnet for

the selector lever lock.
It prevents the selector lever from moving out of
the ”P” position when the ignition is switched off.
Switch F319
The ignition must be switched on to activate the
lock button.
lkswage es n
o ot g
byV ua
d ran
How it works ir se tee
tho
u or
a ac
ss
ce
le
The magnet N380 is without power when the

un
pt
an
d
itte
ignition is switched off, thus disabling the
y li
rm
ab
selector lever in the ”P” position.
pe
ility
ot
Magnet N380
wit
After the ignition is switched on, the magnet
, is n
h re
N380 receives power from terminal 15 and the
hole
spec
300_021
lock is lifted.
es, in part or in w
t to the co
The switch F319 signals to the access and start
authorisation control device that the selector 30
rrectness of i
lever is in the ”P” position. E415
l purpos
E408
N376
nform
ercia
Effects of a signal drop-out

m
a
com
tion in
r
te o
thi
J217
If one of the signals fails or the magnet for
s
iva
J518
do
r
selector lever lock ”P” is defective, then the

rp
cum
fo
en
g
selector lever cannot be moved out of the ”P” Kl.15

n
t.
yi Co
op
position. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
The disablement has to be manually unlocked for
agen N110 F319 N380
Prote AG.
towing the vehicle. 300_042
For this purpose the centre console covering is to
be removed and the magnet actuated by hand.
The selector lever has to be simultaneously

moved out of the ”P” position.
”Press”
300_021
9
Selector lever
The magnet for ignition key removal lock

N376
is located within the switch for access and start

authorisation E415 and prevents the ignition key
from being removed when the selector lever is in
a driving position. The ignition key removal lock
works electromechanically.
300_080
Inside tract
How it works
The magnet for the ignition key removal lock

300_038
N376 contains two spring-loaded locking pins
which engage into the inside tract of the inserted
ignition key if the selector lever is not in the ”P” N376 without power
position (N376 without power).
AG. Volkswagen AG d
agen oes
olksw not
The ignition key cannot be withdrawn. d by V gu
ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
300_039
ot
wit
, is n
h re
hole
Locking pins locked in place

spec
es, in part or in w
t to the co
N376 with power

rrectness of i
When the selector lever is in the 'P' position, a

l purpos
signal travels from the switch for the selector

lever in ”P” F319 to the access and start
nform
ercia
authorisation control unit J518.

m
The control unit then sends current to the magnet

com
tion in
for the ignition key removal lock N376.

r
te o
thi
The locking pins are pulled out by the magnets

s
iva
do
r
rp
and thus removed from the extended inside tract

um
fo
300_040
en
ng
of the ignition key.

t.
yi Co
Cop py
gh
t.
Locking pins removed
rig
ht
yri by
The ignition key can be withdrawn. cop Vo
by lksw
cted agen
Prote AG.
10
Electric circuitry
If the ignition is switched off and the selector 30

31
lever is in the ”P” position, a signal travels from
E415
the switch F319 to the access and start
E408
authorisation control unit J518.
N376
The control unit then sends current to the magnet
for the ignition key removal lock N376.
The locking pins are removed.
The ignition key can be withdrawn.
J217
J518
If the selector lever is not in the ”P” position when
the engine of a vehicle with start/stop buttons is Kl.15
switched off, the dash panel insert emits an
optical and acoustical warning. J285
The driver is thus informed that the selector lever n AG. Volkswagen AG do
lkswage es n
o N110 F319 N380 ot g
is not in the ”P” position. byV ua
d ran
ir se tee
tho
u or
a ac
ss
300_043
ce
le
un
pt
an
d
itte
y li
Effects of signal drop-out
rm
ab
pe
ility
ot
wit
, is n
The electromechanical lock cannot be released if
h re
hole
either the signal from the selector lever to the Emergency release button
spec
es, in part or in w
control unit J518 or the signal from the control
t to the co
unit to the switch for access and start
authorisation E415 fails.
rrectness of i
The key cannot be withdrawn.
l purpos
In these circumstances, the ignition lock has an

nform
mercia
a
... emergency release for the ignition key.
com
tion in
r
te o
thi
s
Press the emergency release button with a pen or

iva
”Press”
do
300_037
r
rp
cum
similar object to activate the emergency release

fo
en
ng
t.
for the ignition key. op
yi Co
py
C
While keeping the button pressed, turn the t. rig
gh ht
pyri by
Vo
ignition key to the left and remove it. co lksw
by
cted agen
Prote AG.
11
Design of gearbox
Fitting position of parts Simple

Torque converter Coupling K3 planetary gear set
lkswage es n
o ot g
byV ua
Converter
ir se
d bypass ran
o tee
th
au coupling or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
Drive side
yri
gh by
ht
cop Vo
by lksw
cted agen
Prote AG.
Starter ring gear
Gearbox input shaft ATF pump drive ATF pump Gearbox input speed Brake B1
sender G182
12
Dual
Coupling K1 planetary gear set Coupling K2
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Drive shaft
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
. Cop py
rig Parking lock wheel
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
300_022
Free-wheel Brake B2 Oil pan Gearbox output speed Parking lock

sender G195
13
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Design of gearbox authorise
d b ara
nte
eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Introductory description of
ot
wit
, is n
h re
functions
hole
spec
es, in part or in w
t to the co
The gearbox housing consists of an aluminium The gearbox is adapted to use with different
alloy. engines (V10 or V6) in the Touareg using
– the number of installed disc pairs for the
rrectness of i
The six forwards gears and the reverse gear are brakes and the couplings,
l purpos
switched using a Lepelletier arrangement of the – the size of the torque converter and
planetary gear sets. – the geometric adaptation of the torque
nform
ercia
m converter housing.
a
com
t
To switch the gears,
ion in
r
– three multi-disc couplings, The transmissions of the individual gears remain

te o
thi
s
iva
– two multiple disc brakes and the same for both engines.
do
r
rp
cum
fo
– a free-wheel
en
ng
t.
yi Co
are switched on or off using the electro- t. CopA transfer gearbox flanged onto the gearbox py
rig
mechanic-hydraulic control unit in the control opyri
gh distributes the torque to the axle drives.
by
Vo
ht
c
valve assembly. by lksw
cted agen
Prote AG.
The control unit for the automatic gearbox starts

the switching of the gears and monitors the
process for problems.
After the signals of the information senders
(sensors), the actuators are activated.
Activation takes place depending on driver,
driving situation and driving impedance
switching programmes.
Torque converter with converter

bypass coupling and ATF pump
The hydromechanical torque converter serves as
a starting element and increases the torque in
the transforming area.
It is equipped with a converter bypass coupling.

Starting at an engine speed of 1000 rpm, the
control unit for the automatic gearbox can close
this coupling.
This transfers the engine torque directly to the 300_022a
drive input shaft. ATF pump
Torque converter
Converter bypass coupling
Starter ring gear
14
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
Starter ring gear
an
itte
y li
erm ATF pump drive
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
The figure shows the
rrectness of i
torque converter of the V10-TDI.
l purpos
nform
ercia
300_063
m
at
Torque converter
om
ion
c
in t
or
his
ate
do
riv

p
cum
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Function cted
by
”Closed”
lksw
agen
Prote AG.
The control unit for the automatic gearbox Solenoid valve N91
controls the solenoid valve N91. The solenoid
valve opens or closes the converter bypass
coupling depending on the engine's speed and
torque.
If the converter bypass coupling is to be closed,

the solenoid valve opens the oil reservoir 300_034
upstream of the converter bypass coupling. As a
result, the oil pressure in this reservoir decreases;
the oil pressure downstream of the converter
bypass coupling closes the converter bypass ”Open”
coupling.
Solenoid valve N91
When the solenoid valve N91 closes the oil flow

again, the pressure upstream of the converter
bypass coupling builds up again and the
converter bypass coupling opens.
300_033
15
Design of gearbox
The ATF pump
is a gear pump and is driven by the ATF pump

drive (pump gear shaft) of the torque converter.
It suctions the ATF from the oil pan of the

gearbox through the oil sieve.
olkswagen AG
AG. Vpressure
The ATF pump generates the wworking
s agen does
olk not
for: d byV gu
ar
e an
ris tee
utho or
a ac
– the multi-disc
ss couplings
and multiple disc
ce
le
un
brakes,
pt
an
d
itte
y li
– the lubrication circulation system and
rm
ab
pe
ility
– the coolant circulation system. 300_064
ot
wit
, is n
h re
hole
The ATF is cooled in a cooler.
spec
es, in part or in w
This cooler is located in front of the engine cooler
t to the co
(as seen in the driving direction).
rrectness of i
l purpos
nform
mercia
a
com
tion in
ATF cooler Engine cooler Drive

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
300_035
300_062 Pressure side Suction side
Engine ATF pump in

automatic
transmission
16
lkswage es n
o ot g
byV ua
d ran
ir se tee
The Lepelletier arrangement autho
or
ac
ss
ce
le
un
pt
is based on a simple planetary gear set and a The sun wheels of the dual planetary gear set
an
d
itte
y li
subsequent dual planetary gear set according to are driven with the transmitted output speed of
rm
ab
pe
ility
Ravigneaux. the simple planetary gear set.
ot
wit
, is n
The planetary carriers of the dual planetary
h re
hole
spec
Lepelletier's brilliant idea was to drive gear set are driven with the gearbox input
es, in part or in w
speed.
t to the co
the sun wheels and the planetary carriers of the As a result, the sun wheels and the
dual planetary gear set at different speeds. planetary carriers have different speeds.
rrectness of i
Due to these different input speeds in the dual
l purpos
planetary gear set, the potential transmission In this automatic gearbox, six forwards and
doubles compared to a five-gear automatic one reverse gear bring Lepelletier's brilliant idea
nform
ercia
gearbox to ten gears minus one gear. to life.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Simple
c
cted
by Dual lksw
agen
Prote AG.
planetary gear set planetary gear set
Gearbox input shaft Drive shaft
300_022k
Output speed,
simple planetary gear set Sun wheel Planetary carrier
17
Design of gearbox
The simple planetary gear set
consists of: The input torque is guided through the simple

– a sun wheel, planetary gear set on two paths:
– an internal gear and – from the gearbox input shaft without
– 5 planetary wheels with V10-TDI engine n AG. Vand agen AG do transmission via the coupling K2 on the
olksw
wage es n
3 planetary wheels with V6 Volks
engine, which are planetary
ot g carrier of the dual planetary gear
by ua
sed ran
– guided by the planetaryho
r carriers.
i set andtee
ut or
ss
a – through the ac simple planetary gear set with
ce
le
transmission to couplings K1 and K3.

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Planetary carrier Sun wheel

Planetary gear
h re
hole
spec
es, in part or in w
Internal gear
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co 300_072
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
K3 cted K1 agen
Prote AG. K2
Gearbox input shaft
300_022k
Simple
planetary gear set
18
The dual planetary gear set,
also known as the Ravigneaux planetary gear The multi-disc coupling K3 provides the
set, consists of: connection between the planetary carrier of the
– an internal gear simple planetary gear set and the small sun wheel
– a planetary carrier of the dual planetary gear set.
– two sun wheels with different diameters and The multi-disc coupling K2 provides the
– short and long planetary wheels. connection between the transmission input shaft
and the planetary carriers of the dual planetary
The multi-disc coupling K1 provides the gear set.
connection between the internal gear of the
simple planetary gear set and the large sun
wheel of the dual planetary gear set.
Long AG. Volkswagen AG d

agen oes
olksw not
planetary
by V gear gu
ara
ed nte
oris e
th or
au ac
ss Planetary carrier
ce
e
nl
pt
du
an
itte
y li
erm
ab
Internal gear
ility
ot p
Large
wit
, is n
h re
sun wheel
hole
spec
es, in part or in w
Small
t to the co
sun wheel
rrectness of i
Short
l purpos
planetary gear 300_073
nf
ercia
orm
m
atio
Planetary carrier
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
300_022k
Small Dual Large

sun wheel planetary gear set sun wheel
19
Design of gearbox
The multi-disc couplings
drive the two sun wheels and the planetary

carriers of the dual planetary gear set when
they are closed.
Depending on the gear to be switched, they are
placed under ATF pressure by the control unit for
the automatic gearbox via a solenoid valve in
the control valve assembly; this closes them. 300_022e
Each multi-disc coupling is supplied with
ATF pressure by another solenoid valve.
The number of installed disc pairs per coupling
varies with the maximum torque that can be
transmitted. AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
The multi-disc coupling K1 rise nte
tho eo
au ra
ss c
ce
le
is closed in gears 1 to 4 and is controlled by the

un
pt
an
d
itte
solenoid valve N90.
y li
rm
ab
pe
ility
ot
wit
It is compensated for centrifugal pressure.
, is n
h re
hole
spec
300_065
es, in part or in w
In the V10-TDI, for example, seven multi-disc
t to the co
pairs are installed.
rrectness of i
l purpos
The multi-disc coupling K2

nform
mercia
is closed in gears 4 to 6.
a
com
tion in
r
te o
thi
It is controlled by the solenoid valve N282.

s
iva
do
r
rp
cum
fo
en
g

n
t.
yi Co 300_022d
Cop py
t. rig
gh ht
yri by
In the V10-TDI, for example, seven multi-disc cop
by
Vo
lksw
cted agen
pairs are installed. Prote AG.
300_066
20
The multi-disc coupling K3
is controlled by the solenoid valve N92 and is

closed in gears 3, 5 and R.
In the V10-TDI, for example, five multi-disc pairs

are installed. 300_022c
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c Multi-disc
ce
e
pairs
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
300_067
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Information regarding the design and function of couplings that are compensated for
centrifugal pressure can be found in SSP 172.
21
Design of gearbox
The multiple disc brakes
secure parts of the planetary gear sets when

they are closed.
To do this, they are submitted to ATF pressure by
the control unit for the automatic gearbox via a
solenoid valve or via the manual slider.
The multiple disc brakes are supported on the 300_022b

gearbox housing by their exterior discs.
The multiple disc brake B1
brakes the small sun wheel of the dual agen

AG. Volkswagen AG d
oes
lksw not Exterior
planetary gear set. byV
o gu
ara
d
It is closed in gears 2 to 6 and is controlled by ris
e nte discs
utho eo
ra
the solenoid valve N283. s a c
s
ce
le
un
pt
an
d
itte
In the V10-TDI, for example, six multi-disc pairs
y li
rm
ab
are installed.
pe
ility
ot
wit
, is n
h re
hole
300_069
spec
es, in part or in w
t to the co
The multiple disc brake B2
rrectness of i
brakes the planetary carriers of the dual
l purpos
planetary gear set.

It is controlled without a solenoid valve using the
nform
ercia
selector lever via the manual slider.

m
a
com
It is closed in Reverse and, in the Tiptronic mode, tion in

r
te o
in 1st gear.
thi
s
iva
do
r
rp
300_022f
um
fo
In the V10-TDI, for example, seven multi-disc

en
ng
t.
yi Co
pairs are installed. . Cop py
rig
ht ht
rig by
copy Vo
cted
by lksw
agen Interior
Prote AG.
discs
300_069
22
The free-wheel
connects the planetary carriers wofagthe . Volkswagen AG

dual
en AG does
olks not
planetary gear set with the V
ygearbox housing. gu
d b ar
e an
ris tee
tho or
au ac
If the exterior when the ringssturns clockwise
ce
e
nl
interior ring is braked, the bodies stand up and
pt
du
an
itte
y li
form a torsion-free connection between the
erm
ab
ility
interior and exterior rings.
ot p
300_022h
wit
, is n
Free-wheeling is ”locked”.
h re
hole
If the turning direction switches to anticlockwise,
spec
es, in part or in w
this connection breaks down.
t to the co
Free-wheeling works in ”D”- 1st gear and
rrectness of i
”S” – 1st gear, ”tension” in the locking direction. ”free”
l purpos
In Tiptronic mode, 1st gear ”thrust” secures free-

wheeling of the multiple disc brake B2.
nform
ercia
This permits ”engine braking”.

m
at
om
ion
c
in t
or
his
ate
do
riv
”locked”
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Interior ring
Exterior ring
300_068 300_082
23
Design of gearbox
The parking lock
mechanically secures the vehicle from rolling

away.
The parking lock is activated purely mechanically
using the selector lever cable when the vehicle is
at a standstill.
It engages in the parking lock wheel on the
driveshaft and prevents turning of the driveshaft
300_022g
and thus of the vehicle wheels.
The clamp pushes the parking lock in the gear

teeth of the parking lock wheel and secures it.
Connecting rods AG. Volkswagen AG d Connecting rods

agen oes
Selector lever cable olksw Parking lock not for parking lock
for parking lockby V gu
a
connection ed ran
ris tee
tho or
au ac Clamp
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
300_061 300_018
m
at
om
Parking lock wheel

io
Selector shaft
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
24
Hillholder function
The hill-holder function secures the vehicle from rolling back and permits hills to be approached
comfortably.
How it works n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
ised ran
If the control unit for the automatic gearbox thor Free-wheeling is released and the tee
vehicle
or
starts
au ac
detects an incline due to the driving impedancess comfortably only after the starting torque is
ce
e
nl
while simultaneously detecting a driving speed of greater than the slope descending force.
pt
du
an
itte
”zero”, it switches into 2nd gear.
y li
erm
ab
In 2nd gear, the vehicle cannot roll back because
ility
ot p
wit
, is n
the internal gear of the dual planetary gear set
h re
hole
would have to turn in reverse against the locking
spec
es, in part or in w
free-wheel.
t to the co
rrectness of i
l purpos
Assignment table
nf
ercia
The following table shows in which gear the individual multi-disc couplings and multiple disc brakes are
orm
m
atio
closed.
om
n in
or c
thi
te
sd
iva
o
r
Component
rp
cu
o
m
f
en
ng
Gear K1 K2 K3 B1 B2 F
t.
yi Co
Cop py
.
*
rig
1st gear X X
t
gh ht
pyri by
Vo
co lksw
by
2nd gear X Prote
cted X AG.
agen
3rd gear X X
4th gear X X
5th gear X X
6th gear X X
R gear X X
* ”Engine braking”
The braking force of the ”pushed” engine in The multiple disc brake B2 is closed in 1st gear
particular driving situations – such as steep only in Tiptronic mode.
downhills – can be taken advantage of by
applying the 1st gear in Tiptronic mode.
25
Design of gearbox
Emergency run
Manual slider
After certain components fail, normal operation
of the automatic gearbox is no longer possible.
In this case, the automatic gearbox can be
operated only in emergency run.
In emergency run, the converter bypass coupling
is no longer closed and the gearbox is in
3rd gear in all forwards driving stages.
When the selector lever is switched to the ”R”
position, the manual slider is shifted, thus
applying the Reverse gear.
The emergency run mode is indicated by a

different display in the dash panel insert.
The ”Effects of signal drop-out” section in the 300_075

Sensors and Actuators chapter describes which
components must fail to lead to emergency run.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
26
Torque transmission in the Touareg
The torque of the engine is transferred to the In addition, there is a switchable reduction in the
automatic gearbox using the torque converter. transfer gearbox.
As there is no axle drive within the automatic If this is switched on, the drive speed of the
gearbox, a transfer gearbox is flanged onto the wheels is reduced by a factor of 2.7, thus
automatic gearbox. agen
A G. Volkswagen AG do increasing the drive torque.
lksw es n
The engine torque is transferred
yV
o from the ot gu
db ara
rise
driveshaft of thehgearbox to the transfer In nthe
tee transfer gearbox, the torque is transferred
o
ut o
gearbox. ss
a furtherr acbetween the front and rear axles using
ce
e
In the transfer gearbox, the torque is distributed cardan shafts.

nl
pt
du
an
itte
between the front and rear axles, depending on The differential of the rear axle to the transfer
y li
erm
ab
the load. gearbox can also be locked using an
ility
ot p
wit
The transfer gearbox can be locked. This fixes the electromechanical multi-disc coupling.
, is n
h re
torque distribution between the front and rear
hole
spec
axles.
es, in part or in w
t to the co
Each axle receives 50 % of the torque.
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
Engine Front axle drive

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Transfer gearbox
Automatic gearbox
Rear axle drive
300_008
27
System overview
Sensors
Gearbox input speed sender G182
Gearbox output speed sender G195
Multifunctional switch F125

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Gearbox oil temperature sender G93

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Sender 1 G193 and sender 2 G194

l purpos
for hydraulic pressure

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
Switch for Tiptronic F189

r
rp
cu
o
m
f
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Switch for Tiptronic in steering wheel E438 and E439
Diagnostic
connector
28
CAN data bus
Actuators Control units
Solenoid valves in
Engine control unit
control valve assembly
N88, N89
Solenoid valves in
control valve assembly
N90, N91, N92,
N93, N282, N283 Control unit for transfer gearbox
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Magnet for selectored b ara
ris nte
o eo
lever lock N110uth ABS control unit ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Control unit with display unit

rrectne
in dash panel insert

ss o
cial p
f inform
80 90 100
4 70 110
3 5 60 120
mer
50 130
2 6 40 140
30 150
1
atio
7 20 160
m
km/h 170
0 8 0 180
23 : 54 23 : 54
o
23 : 54
n
c
i
or
n thi
te
sd
a
300_031
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
29
Sensors
The gearbox input speed sender G182
is located within the gearbox.

It is inserted in the housing of the ATF pump and
uses a ring gear on the turbine shaft to determine
the gearbox input speed.
It works according to the Hall principle.

Within the sender, there is an IC switch which
activates the Hall sender.
300_009
Signal utilisation
The control unit for the automatic gearbox uses

the signal to detect the difference between the
engine speed and the gearbox input speed.
Using this speed difference, the slip of the
converter bypass coupling is controlled up to
a speed of 2000 rpm using the solenoid
valve N91. agen
AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le

un
pt
an
d
itte
y li
rm
ab
The converter bypass coupling is closed without
pe
ility
ot
wit
slip.
, is n
h re
300_013k
The engine speed is used as the replacement
hole
spec
speed.
es, in part or in w
t to the co
Sender G182
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
30
Turbine shaft
Sender G182
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Ring gear on turbine shaft
hole
300_011
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Electric circuitry
nform
ercia
G182
m
G182 - gearbox input speed sender

at
om
ion
c

in t
or
his
ate
+
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
J217
300_044
31
Sensors
The gearbox output speed sender G195
is located above the control valve assembly and

is screwed onto the gearbox housing.
It determines the working speed of the automatic
gearbox.
It scans the outer teeth of the internal gear on
the rear planetary gear set.
300_010
It works according to the Hall principle.
Within the sender, there is an IC switch which
activates the Hall sender.
Signal utilisation n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
sed ran
The control unit uses thehorgearbox output speed
i tee
t or
au
to start switching thessgears according to the ac ce
e
switching plan.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole

spec
es, in part or in w
t to the co
The speed signal of the ABS control unit is used

as the replacement speed.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
32
Sender G195
300_012
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Electric circuitry ho eo
aut ra
ss c
ce
e
nl
G195
pt
du
G195 - gearbox output speed sender

an
itte
y li
erm
ab
ility
ot p
wit
, is n
+ h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
J217
m
at
om
ion
c
in t
r
300_045
o
his
ate
do
priv
cum
for
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
33
Sensors
The multifunction switch F125
is screwed onto the exterior of the gearbox.

Its duty is to further transfer the selector lever
settings in automatic operation to the control unit
gen AG
. Volkswagen AG
does
lkswa not
for the automatic gearbox. byV
o gu
d ara
e
The multifunction switch is connected
oris with the nte
eo
uth ra
selector shaft and the selector
ss a lever cable. c
ce
e
nl
pt
du
an
itte
If the multifunction switch is replaced, a position
y li
erm
ab
to the selector shaft must be set.
ility
ot p
wit
If the switch is incorrectly set, the engine cannot
, is n
h re
be started.
hole
spec
300_020
es, in part or in w
t to the co
rrectness of i
l purpos
Signal utilisation Effects of signal drop-out
nform
ercia
As long as the difference between forwards and

m
The control unit for the automatic gearbox starts
at
om
io
reverse gears can be determined, there are no
n
the switch programmes according to the setting
c
in t
or
his
e
of the multifunction switch. effects on the switch programmes.

at
do
priv
cum
for
en
g
If the Reverse gear signal is defective, the

n
t.
yi Co
op
gearbox enters the emergency run.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
34
Connection for selector lever cable
Lever for manual slider swage es n
o (lever/selector shaft)
lk ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Multifunction switch t. Cop
Selector shaft py 300_029
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Electric circuitry
F41 - reverse gear switch

F125 - multifunction switch J518 F41
J217 - control unit for automatic gearbox J217
J518 - control unit for access and start
authorisation
15a
F125
31
300_046
35
Sensors
The gearbox oil temperature sender G93
is located in the control valve assembly within

the ATF.
It checks the ATF temperature and reports this to
the control unit for the automatic gearbox.
It is an NTC resistor (NTC - negative temperature

coefficient), i.e. the electrical resistance of the
sender drops with increasing temperature.
300_016
Signal utilisation
Example of an NTC resistor characteristic curve
oC,
Starting at an ATF temperature of 150 the
105
torque converter bypass coupling
AG . Volkswagis closed
en AG more
agen does
lksw n
frequently. by V o ot g
ua
ed ran
If this does orisnot result in cooling of the ATF, tee
th or
u
reduction
ss
a of the engine torque is initiated ac 104
oC.
ce
le
starting at 170
un
pt
an
d
itte
y li
rm
ab
Ω Resistance

pe
ility
ot
103
wit
, is n
h re
Harder gear shifts may occur.

hole
spec
es, in part or in w
t to the co
102
rrectness of i
l purpos
101
nform
-40 0 40 80 120 160

ercia
Temperature oC
m
a
com
300_074
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
36
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Geber G93
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
cop
by
300_013a Vo
lksw
cted agen
Prote AG.
Electric circuitry
J217
G93 - gearbox oil temperature sender
G93
300_047
37
Sensors
The sender 1 G193 and sender 2 G194

for hydraulic pressure
have the same design and are located in the

control valve assembly.
They monitor the ATF pressure behind the safety
slides in the control valve assembly.
This prevents couplings that do not correspond to
the switch programme from closing.
As a result, blocking of the gearbox is hindered.
olkswagen AG
wag en AG. V does
They function as diaphragm pressure senders. olks not
byV gu
ara
If the ATF pressure reaches a critical value, the rised nte
ho 300_015
eo
pressure membranes are bent, closing the aut ra
ss c
electrical circuit.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Electrical connection
es, in part or in w
t to the co
Signal utilisation
The signal is used to monitor the clutch control
rrectness of i
unit.
l purpos
Pressure
If the ATF pressure is incorrect, the clutches are membrane
nform
ercia
not activated.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
or

f
en
ng
t.
yi Co
Cop py
t. rig
gh
Incorrect pressure signals can have effects in the
ht
pyri by
Vo
co lksw
by
control unit of the shifting unit. Prote
cted AG.
agen
300_019
Oil pressure
38
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
Sender G194
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
300_013b
Sender G193
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Electric circuitry
G193 - sender 1 for hydraulic pressure, G193 G194

automatic gearbox
G194 - sender 2 for hydraulic pressure,
p p
automatic gearbox
J217
300_048
39
Sensors
The switch for Tiptronic F189 Selector lever covering
is located under the selector lever covering on

the plate.
A ferromagnetic ”contact maker” is attached to

each blind of the selector lever.
The combination of the contact maker on blind 2
and the three Hall sensors on the plate form the Hall sensor ”Contact maker”
switch for Tiptronic F189.
When the blinds are moved, the contact makers
change their position under the plate. In this way,
a different Hall sensor is always activated – AG. Volkswagen AG d
agen oes
”switched” – and sends a signal to the control y Volksw not
gu
d b ara
unit for the automatic gearbox. orise nte
th eo
au ra
c
ss
ce
le
un
pt
300_027a
an
d
Signal utilisation
itte
y li
erm
ab
ility
ot p
Blind 2
In the Tiptronic channel, tipping ”to the front”
wit
is n
Plate
h re
results in moving up a gear and tipping ”to the
ole,
Blind 1
spec
back” results in moving down a gear by the
t to the co
control unit for the automatic gearbox.
rrectness
Effect of signal drop-out
o
cial p
f inform
mer
When the signal drops out, the Tiptronic function atio

om
using the selector lever can no longer be used.

n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
F189
Electric circuitry
en
ng
i t.
py Co
t. Co py
rig
h ht
rig
F189 - switch for Tiptronic copy by
Vo
lksw
by
J217 - control unit for automatic gearbox Prote
cted AG.
agen
J519 - control unit for on-board network

(The link to the selector lever lighting
is required.)
J519
J217
300_049
40
The switches for Tiptronic in the steering wheel
F438 and F439
n AG. Volkswagen AG d
are located to the left and right behind the wage oes
Volks not
gu
y
steering wheel. db ara
ise r nte
utho eo
ra
a c
ss
ce
e
nl
pt
du
The gears are switched by tipping the switches
an
itte
y li
towards the steering wheel.
erm
ab
ility
ot p
wit
, is n
The
h re
hole
spec
right switch (E438) is used to move up a gear ”+”
es, in part or in w
t to the co
and the
left switch (E439) is used to move down a gear ”-”.
rrectness of i
l purpos
Signal utilisation 300_028
nf
ercia
orm
m
atio
m
In Tiptronic mode, these switches can also be used E439 E438

o
n in
or c
to change gears. The switching signal is sent to the
thi
te
sd
a
control unit for the automatic gearbox.

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi
If the Tiptronic switches on the steering wheel are
Co
Cop py
ht. rig
pressed in the automatic mode, the gearbox py
rig E438
by
ht E439
co Vo
control unit enters the Tiptronic mode. by lksw
cted agen
Prote AG.
If the Tiptronic switches on the steering wheel are
no longer pressed, the gearbox control unit
automatically enters the Automatic mode.
J527
If the signal drops out, the Tiptronic functions using

the steering wheel switch can no longer be used.
300_050
Electric circuitry
E438 - switch for Tiptronic in the steering wheel

J527 - control unit for steering wheel electronics
41
Actuators
Solenoid valves
Solenoid valves are used as electrohydraulic switching elements in the electronically controlled
automatic gearbox.
There are switching solenoid valves (yes/no valves) and control solenoid valves (modulation valves).
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
The solenoid valve N88 ised
nte
or
ut
h Solenoid valve eN8 or
a ac
ss
works as a yes/no solenoid valve, opening or
ce
le
un
pt
closing an ATF channel.
an
d
itte
y li
erm
ab
ility
ot p
If the solenoid valve is open, the gears 4 to 6 can
wit
is n
h re
be activated.
ole,
spec
The solenoid valve also improves the switching
t to the co
transition from 5th to 6th gear.
If it is not under power, the solenoid valve is
rrectne
closed.
ss o
cial p
f inform
mer
300_013c
atio
om
n
c
i
or
n thi
te
sd
va
Effect of signal or actuator drop-out

i
o
pr
cum
r
fo
en
ng
i t.
py Co
The gears 4 to 6 can no longer be activated. t. Co J217 py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Electric circuitry

N88 - solenoid valve
N88 N89 N90 N91
300_051
42
The solenoid valve N89
Solenoid valve N89
is located in the control valve assembly.
It works as a yes/no solenoid valve, opening or

closing an ATF channel.
When the solenoid valve is opened, the

ATF pressure on the converter bypass coupling
is increased.
If the solenoid valves N88 and N89 are opened

simultaneously, the brake B2 closes so that the
AG. Volkswagen AG d
”engine brake” is effective in Tiptronic mode, agen oes
olksw not
byV gu
1st gear. ised ara
nte
or
h 300_013d
eo
aut ra
ss c
If it is not under power, the valve is closed.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
If the signal to the solenoid valve N89 drops out,
l purpos
the converter bypass coupling can no longer be J217

subjected to the maximum ATF pressure.
nf
ercia
or
Driving with the ”engine brake” is impossible.
m
m
atio
om
n in
or c
thi
te
sd
a
Electric circuitry
iv
o
r
rp
cu
o
m
f
en
ng
i t.
py Co
J217 - control unit for automatic gearbox t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
N88 N89 N90 N91

300_052
43
Actuators

Solenoid valve N90
is located in the control valve assembly.
It is a modulation valve that controls the

ATF pressure to the multi-disc coupling K1. AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
If it is not under power, the solenoid valve istho eo
au ra
closed. ss c
ce
le
In this switching state, the maximum ATF pressure un
pt
an
d
itte
y li
works on the coupling.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
300_013e
If the solenoid valve is defective or if it cannot be
rrectness of i
activated, switching of gears 1 to 4 may be
l purpos
harder.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
Electric circuitry ht. C J217
rig
ht
rig by
copy Vo
by lksw
cted agen
Prote
AG.
N88 N89 N90 N91 N92

300_055
44
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
The solenoid valve N91 ss
a ac
ce
le
un
pt
an
d
is located in the control valve assembly. itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
ATF pressure on the converter bypass coupling.
hole
spec
es, in part or in w
t to the co
If the solenoid valve N91 is not under power, the
converter bypass coupling is open.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
300_013f
iva
do
r
rp
cum
Solenoid valve N91
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The converter bypass coupling is not closed.

J217
Electric circuitry

N90 N91 N92 N93
300_057
45
Actuators
AG. Volkswagen AG d
The solenoid valve N92 agen oes
olksw not
byV gu
ara
ed
oris nte Solenoid valve N92
is integrated in the controluvalve
th assembly. eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
ATF pressure to the multi-disc coupling K3.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
closed.
In this switching state, the maximum ATF pressure
t to the co
works on the coupling.
rrectness o
cial p
f inform
mer
300_013g
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
If the solenoid valve is defective or if there is a

J217
fault in the circuit, switching of gears 3, 5 and R
may be harder.
Electric circuitry

N90 N91 N92 N93
300_053
46
AG. Volkswagen AG d
agen oes N93
Solenoid valve
olksw not
is located in the control valve assembly. d byV gu
ara
ise nte
or eo
h
aut ra
It is a modulation valve that controls the main ss c
ce
le
ATF pressure in the gearbox, depending on the
un
pt
an
d
itte
engine torque.
y li
erm
ab
ility
ot p
wit
If it is not under power, the solenoid valve is is n
h re
ole,
closed, so that the gearbox works with the
spec
maximum ATF pressure.
t to the co
rrectness o
cial p
f
300_013h
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
py
Effect of signal drop-out by co Vo
lksw
cted agen
Prote AG.

fault in the circuit, switching of all gears may be J217
harder.
Electric circuitry

N92 N93 N282 N283

300_058
47
Actuators agen
AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
is located in the control valve assembly. Solenoid valve N282
ility
ot p
wit
is n
h re
ole,
spec
ATF pressure to the multi-disc coupling K2.
t to the co
rrectne
closed.
In this switching state, the coupling is closed with
ss o
the maximum pressure.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
300_013i
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

fault in the circuit, switching of gears 4 to 6 may
J217
be harder.
Electric circuitry

N92 N93 N282 N283

300_054
48
Solenoid valve N283
is located in the control valve assembly. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
It is a modulation valve that controls the ir se tee
tho
u or
a ac
ATF pressure to the multiple-disc brake B1. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
The solenoid valve closes depending on the
ility
ot p
wit
, is n
current strength.
h re
hole
If it is not under power, the brake is closed with
spec
es, in part or in w
the maximum ATF pressure.
t to the co
rrectness of i
l purpos
300_013j
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
If the solenoid valve is defective or if there is a cop Vo
by lksw
cted agen
fault in the circuit, switching of gears 2 and 6 may Prote AG.
be harder. J217
Electric circuitry

N92 N93 N282 N283
300_056
49
Actuators by Volksw
agen
AG. Volkswagen AG d
oes
not
gu
ara
d
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
The magnet for selector lever lock N110
y li
rm
ab
pe
ility
ot
wit
is located in the selector lever frame.
, is n
h re
hole
spec
Magnet for selector
It is an electromagnet that prevents the selector
es, in part or in w
t to the co
lever lock N110
lever from moving out of the ”P” position when
the ignition is switched on.
rrectness of i
If the selector lever is to be moved from this
l purpos
position, the foot brake must be pressed.
nform
ercia
If the ignition is switched on, the control unit for

m
the automatic gearbox supplies the magnet with
a
com
tion in
power.
r
te o
thi
The magnet blocks the selector lever.
s
iva
do
r
If the foot brake is pressed, the control unit

rp
cum
fo
en
g
switches off the power to the magnet so that the

n
t.
yi Co
op
selector lever can be pressed. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
300_021a
If the solenoid valve is defective or if there is a J217

fault in the circuit, the selector lever can be
pressed without having to press the foot brake.
Electric circuitry

N110 - magnet for selector lever lock
N110
300_059
50
Check your knowledge
Which answers are correct?
One, several or all answers can be correct.
1. Name two types of solenoid valves that are used for the gearbox control unit.
...............................................................................................................................................................................
2. On which part(s) of the automatic gearbox are brakes B1 and B2 supported?
...............................................................................................................................................................................
AG. Volkswagen AG d
agen oes
o lksw not
b yV gu
3. Name the components of a simple isedplanetary gear set. ara
nte
or eo
uth ra
s a c
s
...............................................................................................................................................................................
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
4. What is the replacement interval for the ATF filling of the automatic gearbox?
h re
hole
spec
es, in part or in w
t to the co
a) 20,000 km
b) 2 years
rrectness of i
l purpos
c) none (lifetime filling)

nform
ercia
...............................................................................................................................................................................
m
a
com
tion in
r
te o
thi
s
iva
5. On which principle is the Lepelletier arrangement based?

do
r
rp
cum
fo
en
ng
t.
yi
a) two series-connected simple planetary gear sets Cop
Co
py
ht. rig
rig ht
py by
o Vo
b) one simple and one subsequent dual planetary gear set by c lksw
cted agen
Prote AG.
c) two series-connected dual planetary gear sets
sun wheel and planetary carrier; 4. c; 5. b

1. Yes/no valves and modulation valves; 2. On the gearbox housing; 3. Internal gear, planetary wheels,
Solutions
51
Operational diagram
Component
E438 - switch for Tiptronic in the steering wheel 15

F125 - multifunction switch

F189 - switch for Tiptronic
F319 - switch for selector lever in P
G93 - gearbox oil temperature sender

G182 - gearbox input speed sender
E438 E439 F189
automatic gearbox
automatic gearbox
G195 - gearbox output speed sender

J527 - control unit for steering wheel electronics
J527
N88 - solenoid valve 1 J519
N89 - solenoid valve 2
N90 - solenoid valve 3 a
N91 - solenoid valve 4
J518 F41
N92 - solenoid valve 5 n AG. Volkswagen AG do
kswage es n
N93 - solenoid valve 6 yV
ol ot g
b ua
N110 - magnet for selector lever lockorised ran
tee
th or
N282 - solenoid valve 9 au ac
ss
ce
le
N283 - solenoid valve 10 a

un
pt
an
d
N380 - magnet for selector lever lock P

itte
y li
erm
ab
ility
J518
ot p
wit
is n
h re
ole,
spec
Additional signals
t to the co
F41 - reverse gear switch

rrectne
J518 - control unit for access and start

authorisation
ss
J519 - control unit for on-board network

o
cial p
f inform
N380
mer
1 Self-diagnosis F125 F319

atio
m
2 CAN data bus high

o
n
c
3 CAN data bus low

or
n thi
e
31
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
52
30
G182 G195 G193 G194
AG. Volkswagen AG d
agen oes
olksw not
y Vp p gu
d b ara
+ + rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
1 2 3
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
J217
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
N110 G93 N88 N89 N90 N91 N92 N93 N282 N283
300_032
53
Self-diagnosis
Diagnostics
For vehicle diagnostics, measurement and

AG. Volkswagen AG
agen does
lksw not
information systems
y Vo VAS 5051 and VAS 5052, gu
edb ara
is
the operating
r modes nte
ho t e or
au ac
ss
ce
e
– Guided error search and

nl
pt
du
an
itte
– Mobile vehicle self-diagnosis are available
y li
erm
ab
ility
ot p
wit
, is n
h re
The operating mode ”Guided error search”
hole
spec
es, in part or in w
t to the co
carries out a vehicle-specific check of all
installed control units for incorrect entries and
rrectness of i
automatically compiles an individual checking
l purpos
plan from the results.

Together with the ELSA information, such as
nf
ercia
circuit diagrams or repair guidelines, this orm

m
provides a specific target for trouble-shooting.

atio
om
n in
or c
VAS 5051 300_060

thi
e
Independent of this, you can compile your own

t
sd
iva
o
r
checking plan.
rp
cu
o
m
f
en
ng
The function and component selection py

i t.
Co
Co py
incorporates the checks that you select into the ht. rig
ht
rig by
checking plan; these can be processed in theby copy Vo
lksw
cted agen
continued diagnostics procedure in any order.
Prote AG.
Although the ”Vehicle self-diagnosis”
operating mode can still be used, ELSA no WO R KS H O P

EQUIPMENT
longer provides any additional information.
IrDA + -
VAS 5052
300_084
VAS 5052
54
Service
New tools
Setting gauge for multifunction switch T10173
This is required to set the multifunction switch

when repairs are completed.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte 300_076
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
Pressure piece T10174
, is n
h re
hole
spec
This is required to knock in the gaskets on the
es, in part or in w
t to the co
shaft for the multifunction switch.
rrectness of i
300_077
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
Pressure piece T10180

rp
cu
o
m
f
en
ng
t.
yi Co
op
This is required to knock in the gaskets of the gh
t. C py
rig
ht
yri
drive shaft. p by
co Vo
by lksw
cted agen
Prote AG.
300_078
Sleeve T10186
This must be placed on the serration of the drive

shaft before the gasket is attached to prevent
damage during attachment of the gasket.
300_079
55
Service. 300
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
For internal use only © VOLKSWAGEN AG, Wolfsburg

atio
om
All rights reserved. Technical specifications subject to change without notice.

c
i
or
n thi
e
000.2811.20.20Technical status 08/02

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
❀ This paper was produced from
gh
t. C py
rig
ht
yri by
cop chlorine-free chemical pulp. Vo
lksw
by
cted agen
Prote AG.

00028112020-Nr 300 6-Speed Automatic Transmission 09D PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

00028112020-Nr 300 6-Speed Automatic Transmission 09D PDF

Uploaded by

Copyright:

Available Formats

Service.

– a reduction in fuel consumption,

– a reduction in exhaust emissions,

– improved acceleration values and

Selector lever . . . . . . a.g.en. A.G.. .Vo. lk.s.w.ag.e.n A. G. d. o. . . . . . . . . . . . . . . . . . . . 6

Check your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

The 09D 6-speed automatic transmission

programmes that depend on driving approached comfortably.

Volkswagen designation AG6 - 09D

on the selector lever must be pressed.

No power is being transmitted to the wheels.

Selector lever position and gear display in

After the ignition is switched on, the current

in the Touareg is available as a selector lever as

Selector lever Tiptronic

The driver can now actively select gears.

Here you use:

– the switch on the right to move up a gear.

selected ”D” or ”S” programme if the steering

300_036 wheel switches are not pressed again.

Selector lever lock and ignition key

This is located in the front on the selector lever

Once the ignition has been turned on, the

and ”N” without applying the brake – assuming

the ignition is turned on.

E408 - button for starting/stopping the engine J518

J217 - control unit for automatic gearbox

J518 - switch for access and start

authorisation N110 F319 N380

N110 - magnet for selector lever lock

N376 - magnet for ignition key removal lock

N380 - magnet for selector lever lock P

is at the selector lever frame, as is the magnet for

The magnet N380 is without power when the

ignition is switched off, thus disabling the

Effects of a signal drop-out

selector lever lock ”P” is defective, then the

selector lever cannot be moved out of the ”P” Kl.15

The selector lever has to be simultaneously

The magnet for ignition key removal lock

is located within the switch for access and start

The magnet for the ignition key removal lock

Locking pins locked in place

N376 with power

When the selector lever is in the 'P' position, a

signal travels from the switch for the selector

authorisation control unit J518.

The control unit then sends current to the magnet

for the ignition key removal lock N376.

The locking pins are pulled out by the magnets

and thus removed from the extended inside tract

of the ignition key.

If the ignition is switched off and the selector 30

The electromechanical lock cannot be released if

control unit J518 or the signal from the control

In these circumstances, the ignition lock has an

Press the emergency release button with a pen or

similar object to activate the emergency release

Fitting position of parts Simple

Starter ring gear

Free-wheel Brake B2 Oil pan Gearbox output speed Parking lock

– three multi-disc couplings, The transmissions of the individual gears remain

The control unit for the automatic gearbox starts