Volkswagen 01M Transmission. Manual - part 36

   The Japanese company AISIN Co., LTD is the
manufacturer and developer of the Rear Wheel Drive
TR-60SN transmission, which is a 6 speed, fully
automatic and electronic controlled gearbox.
Volkswagen engineers were also involved, in
conjunction with Aisin, in the development process
for their vehicles and they gave it the 09D
designation. Vehicle applications   and transmission
codes known at time of printing, are shown in Figure
1.
   The 09D transmission is used in a wide variety of
applications and engine sizes.   As a result, the number
of friction plates and three or four pinion carriers, will
vary depending on torque load requirements of the
specific vehicle.   The 09D transmission uses a gear
ratio sensitive system, requiring the correct
transmission interchange, if that becomes necessary.
   The Transmission Control Module (TCM) is
mounted external from the transmission 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.
   TR-60SN (09D) transmissions use a Lepelletier type
gear set arrangement, which consists of a simple
planetary with the sun gear splined to the pump stator
and coupled with a Ravigneaux type, dual planetary.
This is similar to but not the same, as the type of
planetary that was used in the FMX. This arrangement
allows the sun gears and the planetary pinions of the
Ravigneaux planetary gear-set to be driven at
different speeds and makes six forward speeds and
reverse possible, with only five clutch packs and one
freewheel.
   Lepelletier's brilliant idea has led to several different
manufacturers using this gear set arrangement in their
own versions of six forward speeds transmissions.
   Refer to Figure 2 for the component locations and the
clutch application chart for each gear.

GENERAL DESCRIPTION

Figure 1

VEHICLE APPLICATION CHART

VEHICLE

YEAR

ENGINE

CODES

AISIN

AUDI, Q7
PORSCHE, CAYENNE

TOUAREG

2007-Up
2003-Up

2003-Up

4.2L (V8) 257 kW
3.2L (V6) 162 kW

3.2L (V6) 162 kW

3.2L (V6) 177 kW

3.6L (V6) 206 kW

4.2L (V8) 228 kW

4.2L (V8) 257 kW

3.0L (V6 Diesel) 165 kW

4.9L (V10 Diesel) 230 kW

4.9L (V10 Diesel) 258 kW

09D
09D

09D

HPH,

BAA, BMX,

EXL, EXQ, HAM,

BAA, BMX, EXP,

GLK, HAM, HAP,

BHK,

HPG, HZW, JXU,

FCS, GLH, HAU,

HZV,

AXQ, BAR, BHX,

HPH, JXS, KMF,

KRK,

GLD, GTK, HAQ,

HZX

JXV,

TR60SN
TR60SN

TR60SN

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COMPONENT APPLICATION CHART

Gear

1st Gear

2nd Gear

3rd Gear

4th Gear

5th Gear

6th Gear

Rev Gear

K-1

Clutch

K-2

Clutch

K-3

Clutch

B-1

Clutch

B-2

Clutch

On*

On**

Hold

4.148

2.370

1.556

1.155

0.859

0.686

3.394

F-1

Sprag

Torque

Conv.

Clutch

Gear

Ratio

(Model

Dependant)

* The B-2 Clutch is applied in "Tiptronic Mode" 1st gear, only for engine braking.
** During normal driving operation, the Torque Converter Clutch may be applied in 3rd thru 6th gear.

Figure 2

Clutch

Sprag

Clutch

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09D

300

036

EXQ

TR-60

0 9 0

4 0 2

02DG

3000

AISIN

CO. L

JP AN

SERI

AL NO

09D 300 036D

EXQ

TR-60SN

0 9 0 4 0 2

02DG300074

AISIN AW
CO. LTD
JP AN1
SERIAL NO.

Volkswagen Part Number

Fill Plug

Breather

AISIN Model Number

Build Date

Year

Month
Day

Transmission Code

Serial Number

0 9 0 4 0 2

IDENTIFICATION TAG LOCATION AND INFORMATION

TRANSMISSION IDENTIFICATION

Figure 3

   The transmission identification tag is located on the
left hand side of the transmission case, as shown in
Figure 3.   All of the information from the ID tag will
be needed to order anything from the dealer for this
transmission.   Currently there are no hard parts
available from the dealer so you will have to rely on
aftermarket sources if hard part replacement becomes
necessary.

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573

44-01

D 3

21 36

>Fe/

Zn<

57344-01
09D 321 361

>Fe/Zn<

"Check" Plug

Required

Fluid Level

"Stand Pipe"

"Drain" Plug

Oil Level

Check Plug

"O" Ring

Seal

  To "Check" for the correct fluid level, you must
remove the "check" plug, which is located in the
corner of the pan, and is removed with a 16 mm allen
wrench, as shown in Figure 4 and 5.
   We have provided you with a cut-away drawing of
the bottom oil pan and the check plug so that you will
understand how this system works.   Notice that the oil
pan actually has a "stand-pipe", as shown in Figure 4,
that is stamped into and extends up above the pan
rail,and is our way to establish the proper fluid level in
the transmission.
(A) Engine must be running and the manual shift
lever placed in the Park position.
(B) Tranmission must be at operating temperature
and parked on level surface.
(C) By removing the "Check" plug from the oil
             pan, the fluid should just trickle over the
           "stand-pipe" and out through the center of the
           stand-pipe in the oil pan, as shown in Figure 4.
(D) Always replace the "O" ring on the check plug
               and torque check plug to 28 N·m (20 ft.lb.)
     The "Drain" plug can be removed, using a 40 Torx
bit, to facilitate in   draining the fluid for transmission
removal, or filter change.   The pan gasket can be re-
used as long as there is no damage.

To "Fill" or "Add" fluid to the transmission, there is
a fill plug located on the left side of the case just above
and left of the manual lever seal, as shown in Figure 3.
Only the approved type of ATF fluid should be used,
as shown below. Damage may result if the proper
fluid is not used.

CHECK FLUID LEVEL AND SPECIFICATION

Fluid Requirements

VW Part No. G 052 025 A2

(Esso JWS 3309) Lifetime Fluid

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Figure 4

Figure 5

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