WWW.ALL-TRANS.BY A U D I , J E T TA , PA S S AT, 09G/09M INDEX GENERAL DESCRIPTION AND VEHICLE APPLICATION CHART .................................... COMPONENT APPLICATION CHART ..................................................................................... IDENTIFICATION TAG LOCATION AND INFORMATION ................................................... SPEED SENSOR INFORMATION ..............................................................................................
WWW.ALL-TRANS.BY INTRODUCTION AUDI, JETTA, PASSAT, 09G/09M Transaxle 1st Printing March, 2010 The Japanese company AISIN Co., LTD is the manufacturer and developer of the Front Wheel Drive TF60SN transaxle, which is a 6 speed, fully automatic and electronic controlled transaxle. Volkswagen engineers were also involved, in conjunction with Aisin, in the development process for their vehicles and they gave it the 09G/09M designation. BMW gave it the designation 6F21WA for their Mini-Cooper.
WWW.ALL-TRANS.BY Technical Service Information GENERAL DESCRIPTION The Japanese company AISIN Co., LTD is the manufacturer and developer of the Front Wheel Drive TF-60SN transaxle, which is a 6 speed, fully automatic and electronic controlled transaxle. Volkswagen engineers were also involved, in conjunction with Aisin, in the development process for their vehicles and they gave it the 09G/09M designation. BMW's designation for the same unit is 6F21WA.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT APPLICATION CHART K3 K1 Clutch Clutch B1 Clutch F1 Roller Clutch B2 K2 Clutch Clutch CLUTCH APPLICATION CHART Gear 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear Rev Gear K-1 K-2 K-3 B-1 B-2 Clutch Clutch Clutch Clutch Clutch On On On On On* On On On On Hold On** On** On** On** On** On On On On F-1 Torque Engine Engine 1.8L, Roller Conv. 1.6L, 2.0L Ratio*** Ratio**** Clutch Clutch On 4.148 2.370 1.556 1.155 0.859 0.686 3.394 4.
TRANSAXLE IDENTIFICATION The paper ID tag stuck to the side of the case, as shown in Figure 3, carries the OEM part number along with the build date and serial number. The only place we have found a "Transaxle Code" is ink stamped or etched on the transaxle case, in the location shown in Figure 3. In the example shown the transaxle code is "GGZ". Note: For the newest transaxle code information that is available to us, See Page 124.
WWW.ALL-TRANS.BY Technical Service Information ELECTRONIC COMPONENTS Input Speed Sensor (G182) The Input Speed Sensor (G182) is located in the transaxle case below the valve body, as shown in Figure 6, and retained with a bolt. The ISS has a White connector that mounts on a bracket with a valve body bolt and goes through the 8-way case connector, also shown in Figure 6. The ISS is triggered by the external lugs on the K-2 clutch housing to determine exact transaxle turbine speed.
SPEED SENSOR LOCATIONS Output Speed Sensor Location Input Speed Sensor Location Wiring Harness from 8 terminal Case Connector (ISS, OSS & TFT) CCP6A09212 ABY6A09412 FBX6A08574 CCP6A09214 9173 T5 DCB6A09064 EO GAU6A06894 WWW.ALL-TRANS.BY Technical Service Information Wiring Harness from 14 terminal Case Connector (All Solenoids) OSS Blue Clip Connector (G195) ISS White Clip Connector (G182) Transmission Fluid Temp.
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ELECTRONIC COMPONENTS (CONT'D) Transaxle Fluid Temp Sensor (G93) The Transaxle Fluid Temp Sensor (G93) is located in the valve body and is mounted with a retaining plate, as shown in Figure 7. Notice in Figure 8 that an "O" ring is required, as it is mounted into an oil passage. The TFT is an integral part of the 8-way case connector and wire harness assembly. The TFT is a negative temperature coefficient sensor, which means that as temperature rises the resistence decreases, as shown in Figure 8.
WWW.ALL-TRANS.BY Technical Service Information INDIVIDUAL SOLENOID FUNCTION AND RESULT OF FAILURE N88 Solenoid (No. 1 Solenoid) The N88 Solenoid is an On/Off solenoid and is On and Open in gears 4th through 6th. If this solenoid fails in the Closed (Off) position, 4th through 6th gear will not be available. N89 Solenoid (No. 2 Solenoid) The N89 Solenoid is also an On/Off solenoid and is On and Open, to allow the apply of the torque converter clutch.
WWW.ALL-TRANS.BY Technical Service Information ELECTRONIC COMPONENTS (CONT'D) SOLENOID OPERATION On/Off Solenoids (N88), (N89) These solenoids both operate in exactly the same manner, as shown in Figure 11, based on commands from the TCM. Both of the On/Off solenoids are "Normally Closed". These two solenoids operate in conjunction with the Pulse Width Modulated (PWM) solenoids to provide the proper gear ratio for the current road conditions. Refer to Figure 11 for operational checks.
WWW.ALL-TRANS.BY Technical Service Information PWM SOLENOID (n91) "NORMALLY VENTED" Solenoid "OFF" (De-Energized) Solenoid "ON" (Energized) .032" Orifice .032" Orifice Solenoid Feed Solenoid Feed Out To TCC (Blocked) Out To TCC (Open) Exhaust (Open) Exhaust (Blocked) 4.0 - 8.
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WWW.ALL-TRANS.BY Technical Service Information ELECTRONIC COMPONENTS (CONT'D) Pass-Thru Case Connectors There are 2 pass-thru case connectors and internal wire harness assemblies used on these units. One is an 8-way connector that serves all of the internal sensors and one 14-way connector that serves all of the solenoids, as shown in Figure 15. As stated previously, the transaxle temp sensor is an integral part of the 8-way connector and wire harness assembly, as shown in Figure 15.
ELECTRONIC COMPONENTS (CONT'D) Pass-Thru Case Connectors (Cont'd) The connectors however are not always in the same locations. The 09G, 09K, and Mini-Cooper will all have the 8-way sensor connector located in the left front location and the 14-way solenoid connector in the left rear location, as shown in Figure 16. Notice, also in Figure 16, that the 09M transaxle has the 8way sensor exiting the rear of the case and the 14-way solenoid connector located where the 8-way connector is usually located.
WWW.ALL-TRANS.BY Technical Service Information ELECTRONIC COMPONENTS (CONT'D) Pass-Thru Case Connectors (Cont'd) The Volkswagen 09G transaxles observed are shown in Figure 19. Notice on these models there are 2 different mountings for the 8-way connector to the case. "Some" cases are equipped with both mounting holes, so mark the location before you disassemble.
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WWW.ALL-TRANS.BY Technical Service Information RESISTANCE CHART THROUGH 14-WAY CASE CONNECTOR Solenoid Number (Name) Positive Meter Lead Terminal No. (Wire Color) Negative Meter Lead Terminal No. (Wire Color) Ohms Resistance Solenoid No. 1 (N88) 1 (White) Case Ground 10.0 - 16.0 Solenoid No. 2 (N89) 2 (Black) Case Ground 10.0 - 16.0 Solenoid No. 3 (N90) 7 (Lt. Blue) 8 (Lt. Green) 4.0 - 8.0 Solenoid No. 4 (N91) 11 (Lt. Green) 12 (Brown) 4.0 - 8.0 Solenoid No.
WWW.ALL-TRANS.BY Technical Service Information View looking into the TCM (J217) 1 3 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 View looking into the 52 pin TCM (J217) Connector Solenoid Number (Name) Solenoid No. 1 (N88) Solenoid No. 2 (N89) Solenoid No. 3 (N90) Solenoid No. 4 (N91) Solenoid No. 5 (N92) Solenoid No. 6 (N93) Solenoid No. 9 (N282) Solenoid No.
ELECTRONIC COMPONENTS (CONT'D) Transaxle Range Switch (Mulit-function Switch) The Transaxle Range Switch (TRS) is located on the top of the transaxle, as shown in Figure 23. The TRS is a mechanical multi-position switch with 6 sliding contacts, four selector position switches, one reverse switch and one switch for positions P/N, for starting control. Diagnosis The only ignition voltage sent to the switch goes in at terminal 10 and goes through only the reverse switch, as shown in Figure 24.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE RANGE SWITCH SCHEMATIC FROM 2004 AUDI HOT IN RUN/START Black/Green Yellow P/N SWITCH Gray/Black Black/Green REV SIG Yellow Yellow 21 NOT USED 9 7 5 3 1 10 8 6 4 Yellow/Blue 22 36 10 47 POS SIG POS SIG POS SIG POS SIG GROUND TO STARTER RELAY Yellow Black/Green TCM TO SHIFT LEVER ASSEMBLY TERMINAL 7 (SEE WIRE SCHEM.
WWW.ALL-TRANS.BY Technical Service Information SHIFT QUADRANTS Selector Lever The appearance of the selector lever, as shown in Figure 25, will vary between the different vehicle applications. However, the operation and function remains the same with the use of the TF-60SN. Steering Wheel Paddles Steering wheel paddles are available as options,as shown in Figure 25, and they also will vary in appearance with the different vehicle applications.
WWW.ALL-TRANS.BY Technical Service Information TIPTRONIC UPSHIFT AND DOWNSHIFT Steering Wheel Paddles Steering wheel paddles are available as options,as shown in Figure 25, and they also will vary in appearance with the different vehicle applications. However, operation and function remains the same with the TF-60SN. These operational paddles are found in the steering wheel on the left and right hand side, as shown in Figure 25. Upshifts and downshifts occur by tapping the appropriate paddle.
TYPICAL VOLKSWAGEN/AUDI WIRE SCHEMATIC HOT IN RUN/START FUSE 15 (5A) FUSE 31 (20A) FUSE 7 (10A) Red/Violet Black/Green FUSE HOLDER AT LEFT END OF DASH HOT IN RUN/START TO SHIFT LEVER ASM.
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VOLKSWAGEN "VAG" to obd11 DIAGNOSTIC TROUBLE CODES vag 18010 obd11 P1602 DESCRIPTION Voltage supply too low 18255 18554 P1847 P2122 DTC in ABS problem Throttle position sensor signal too low G79 19146 P2714 N91-SV4 Torque Converter Clutch PWM Solenoid, Circuit (Open or Short) 19147 19148 P2715 P2716 N91-SV4 Torque Converter Clutch PWM Solenoid, Circuit (short to B+) N91-SV4 Torque Converter Clutch PWM Solenoid, electrical circuit fault 19155 19156 P2723 P2724 N92-SV5 K1 Clutch control Solenoid
WWW.ALL-TRANS.BY Technical Service Information COOLER INFORMATION Integral Cooler Some models use an ATF cooler that is mounted on the converter housing and integrated into the engine cooling circuit, as shown in Figure 33. With this arrangement cooler fluid is sent directly into the cooler and returned to the lube circuit. Engine coolant is piped to the integral cooler and returned to the cooling system with a constant circulation.
PRESSURE TAP LOCATIONS AND "INTEGRAL COOLER" INFORMATION Models that use the "Integral Cooler" use air flow to cool the engine coolant that is sent to the integral cooler and then returned to the cooling system. The transaxle cooler fluid is fed directly into the cooler and returned to the lubrication circuit. For flow control, a distributor pipe is installed into the supply side of the Integral Cooler. NOTE: Do not install distributor pipe in the return side of the Integral Cooler.
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COOLER INFORMATION There are two distinctly different style lubrication systems used in TF-60SN (09G/09M) transaxles. As a result, there are 2 different transaxle cases, 2 different converter housings and 2 different valve body to case spacer plates. Integral Cooler Some models use an ATF cooler that is mounted on the converter housing and integrated into the engine cooling circuit, as shown in Figure 35. With this arrangement, cooler fluid is sent directly into the cooler and returned to the lube circuit.
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WWW.ALL-TRANS.BY Technical Service Information CASE PASSAGE IDENTIFICATION WITH "INTEGRAL COOLER" Transaxle Case (Conv.
WWW.ALL-TRANS.BY Technical Service Information PUMP PASSAGE IDENTIFICATION (CONV. COVER SIDE) WITH "INTEGRAL COOLER" To B1 Pressure Tap Cooler Return To VB (5) Thru Pump Cooler Return To VB (6) Thru Pump TCC Apply TCC Release Front Planet Lube (3) K3 K1 B1 Pump Outlet (Line) Pump Inlet (Suction) PUMP PASSAGE IDENTIFICATION (CONV.
WWW.ALL-TRANS.BY Technical Service Information Fluid Level Stand-Pipe Check Plug Figure 41 CHECK FLUID LEVEL AND SPECIFICATION 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 10 mm allen wrench, as shown in Figure 41. 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.
WWW.ALL-TRANS.BY Technical Service Information CAUTION: There are 3 different lengths of the "stand-pipe" for VW, depending on vehicle and/or model. If the wrong oil pan or "stand-pipe are installed, the result will be a transaxle that is slipping, or a transaxle that is overfilled. Either way, it is a concern. At the time of this printing we have seen only 1 "stand-pipe" for the BMW Mini-Cooper with the 09G.
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WWW.ALL-TRANS.BY Technical Service Information OIL PAN AND GASKET IDENTIFICATION The various oil pans and oil pan gaskets are identified for you in Figure 47, on Page 39 and they will not interchange. Notice that the 8 bolt gasket is used on the 09G and the Mini-Cooper. Gaskets are the same but the pans, filters and stand-pipe are different. OIL FILTER IDENTIFICATION The various oil filters are identified for you in Figure 48 and 49 and again, the filters will not interchange from model to model.
WWW.ALL-TRANS.BY Technical Service Information 09K Filter-03 Transporter ......... 05-ON Pan Side VB Side 09M Filter-04 Passat ......... 06-ON Pan Side VB Side 09G Filter-05 Mini-Cooper .........
SAFETY PRECAUTIONS Service information provided in this manual by ATSG is intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools and equipment could cause injury to you or others. The service procedures we recommend and describe in this manual are effective methods of performing service and repair on this unit. Some of the procedures require the use of special tools that are designed for specific purposes.
TRANSAXLE DISASSEMBLY (CONT'D) 5. Remove the 2 transaxle range switch retaining bolts and range switch, as shown in Figure 51. Note: The contact lever adjusting nut must not be loosened (See Figure 51). 6. Remove the integral cooler (if equipped) and set aside for flushing. 7. Remove and discard the 2 filter seals (4) & (6), as shown in Figure 51. Note: Notice that some models are equipped with a flow control distributor pipe in the supply side of cooler, as shown in Figure 51.
WWW.ALL-TRANS.BY Technical Service Information 14 15 13 12 11 AG 02 4- 1 34 36 57 21 < 3 o JP G e/Z 09 >F VW TRANSAXLE DISASSEMBLY (CONT'D) 8. Remove the bottom oil pan bolts (8 on "09G") and remove the bottom oil pan, as shown in Figure 52. 9. Remove and discard the bottom oil pan gasket, as shown in Figure 52. 10. Remove the three oil filter retaing bolts and remove the oil filter, as shown in Figure 53. 11.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) CAUTION, CAUTION, CAUTION, CAUTION Before proceeding with the disassembly process it is "Imperative" that you now log the color of the wires going to each and every solenoid to use as a reference for final assembly. The wire colors are different between models and year of manufacture. 18 19 12. Remove the internal manual shift lever retaining nut, using pliers or vice-grip to hold shift lever, as shown in Figure 55.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 14. Remove the bolts retaining the blue connector output speed sensor bracket and white connector input speed sensor brackets (See Figure 57). 15. Remove the bolt retaining the TFT sensor and the retaining bracket, as shown in Figure 57. 16. Remove the connectors from both speed sensors, both pressure switches (if used), as shown in Figure 57. 17.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 22. Remove only the 12 valve body to case bolts that are identified in Figure 59. Note: Valve body retaining bolts may vary in length from model to model. 23. Remove the wire harness retaining brackets, as shown in Figure 60. Note: Wire harness retaining brackets will vary from model to model. 24. Remove the valve body assembly, as shown in Figure 60. 25. Set valve body assembly aside for component rebuild section.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 26. Remove the B1 accumulator piston and springs from transaxle case, as shown in Figure 61. Note: The number of B1 accumulator springs vary depending on year and model. Best is to tag springs for identification. 27. Remove the output speed sensor retaining bolt and output sensor, as shown in Figure 62. Note: This bolt has 8 mm head, 18 mm long. 28.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 29. Remove the retaining bolt from 8-way connector and carefully remove the 8-way connector and wiring harness assembly, through the case bore, as shown in Figure 63. Note: Remove and discard the case connector "O" ring and temp sensor "O" ring. 30. Remove retaining bolt from 14-way connector and carefully remove the 14-way connector and wiring harness assembly through the case bore, as shown in Figure 63.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 31. Position transaxle so that converter housing is facing up, as shown in Figure 64. 32. Remove the 21 converter housing bolts shown in Figure 65, using a 12 mm socket or wrench. Note: Converter housing bolt configuration will vary depending on model and year. Some locations have "stud" bolts (See Figure 65). TRANSAXLE DISASSEMBLY (CONT'D) 33.
WWW.ALL-TRANS.BY Technical Service Information NEW DESIGN OIL PUMP GASKET 54 62 54 53 55 A 61C 53 2 3 53 56 56 73 61 56 TRANSAXLE DISASSEMBLY (CONT'D) 35. Remove the six oil pump retaining bolts, as shown in Figure 67. Note: There are 3 different lengths and position is critical. Label if necessary. 36. Remove the oil pump assembly, as shown in Figure 67, and set aside for component rebuild. Note: Number 1 thrust washer may be stuck to back of oil pump (See Figure 67). 37.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 40. Remove the "rolled" pin from the inside detent lever using a 3/16" punch and hammer, as shown in Figure 69. Note: There is a safety band around the inside detent lever that must be removed first. Only way to get it off is to break it and discard it. The safety band will not be reused. 41.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 44. Remove the B1 clutch apply ring and return spring assembly, as shown in Figure 71. 45. Remove the K3 clutch housing assembly, as shown in Figure 71, and set aside for the component rebuild section. Note: Number 2 thrust washer may be stuck to back of K3 clutch housing. 46. Remove the front planetary as an assembly, by lifting assembly straight up using the input shaft, as shown in Figure 72.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 47. Seperate and inspect front planetary components, as shown in Figure 73. 48. Remove K1 clutch housing assembly, as shown in Figure 74, and set aside for the component rebuild section. 49. Remove the K3 clutch housing drive hub, as shown in Figure 74, along with the number 6 thrust bearing and bearing race.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 50. Remove the B1 clutch pack from the B1 clutch housing, as shown in Figure 75. 51. Remove the B1 clutch housing retaining snap ring, as shown in Figure 76, and remove the B1 clutch housing. Note: This snap ring is identified by two small "turn-outs" at snap ring ends, as shown in Figure 76.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 52. Remove the 2 parking rod guide retaining bolts using a 10mm socket, as shown in Figure 78, and remove parking rod guide. Note: It is not necessary to remove the inside detent spring unless it is damaged. 53. Remove the park pawl pivot pin case plug from rear of case, as shown in Figure 77. 54 Remove and discard case plug "O" ring seal, as shown in Figure 77. 55.
WWW.ALL-TRANS.BY Technical Service Information PARK ROD GUIDE INSIDE DETENT SPRING 7 146 147 Figure 78 148 TRANSAXLE DISASSEMBLY (CONT'D) 56. Remove park pawl anti-rattle spring and pivot pin, as shown in Figure 79. 57. Remove the park rod roller and pin assembly, as shown in Figure 79. 58. Remove the park pawl as shown in Figure 79. 149 Continued on Page 58 7 Z 0 4051 - 1 - 1 1004 03C2T02168 09G 300 035H 146 147 148 149 PARK ROD ROLLER AND PIN ASSEMBLY.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 59. With the parking pawl removed, you can now remove the transfer driven gear and pinion gear assembly and the final drive assembly, as shown in Figure 80, and set aside for the component rebuild section. 60. Remove the six center support retaining bolts, as shown in Figure 81, using a T-50 Torx bit or a 14mm socket.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 62. Remove the snap ring retaining F1 roller clutch, as shown in Figure 82. Note: This snap ring is .050" in thickness. 462 63. Carefully install the style of vice-grips that are shown in Figure 82, to the splines of the small sun gear. 64. Use the vice-grips as a handle to remove the F1 roller clutch and rear planetary gear-set as an assembly, as shown in Figure 82, and set aside for the component rebuild section. 65.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 67. Remove the K2 clutch housing assembly along with the number 9 thrust bearing and races, as shown in Figure 84, and set aside for component rebuild section. Note: Number 9 front thrust bearing race may be stuck to the small sun gear in rear gear-set. 68. Remove the number 11 thrust bearing and race, as shown in Figure 84. Note: Number 11 thrust bearing may be stuck to rear of K2 clutch housing. 69.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE DISASSEMBLY (CONT'D) 71. Apply compressed air to the B2 clutch passage in the case, as shown in Figure 86, to loosen the B2 clutch piston. 72. Remove the B2 clutch piston from transaxle case as shown in Figure 87. 73. Remove and discard the inner and outer "O" ring seals, as shown in Figure 88. 74. This completes transaxle disassembly. N U.S.
WWW.ALL-TRANS.BY Technical Service Information 556 560 557 556 555 558 559 554 554 553 552 550 COMPONENT REBUILD CONVERTER COVER ASSEMBLY 1. Disassemble the converter cover parts using Figure 89 as a guide. 2. Clean all converter cover parts thoroughly and dry with compressed air. 3. Inspect all converter cover parts thoroughly and replace as necessary. WARNING: At time of this printing, there are not any new "hard parts" available from the manufacturer for this unit.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) 561 563 562 564 7 Z 0 4051 - 1 - 1 1004 03C2T02168 561 562 563 564 09G 300 035H TRANSAXLE CASE ASSEMBLY 1. Clean all transaxle case parts thoroughly and dry with compressed air. 2. Inspect all case parts thoroughly and replace as necessary. WARNING: At time of this printing, there are not any new "hard parts" available from the manufacturer for this unit. The only source will be used aftermarket suppliers. 3.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) TRANSAXLE CASE ASSEMBLY (CONT'D) 7. Lubricate the "O" ring seal surfaces of the case with a liberal amount of Trans-Jel®. 8. Install the B2 clutch apply piston into the case, as shown in Figure 93. Note: This piston must be oriented properly as it installs in one direction only. The piston tab without spring seal must be installed into slot as shown in Figure 93. 9.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) OIL PUMP ASSEMBLY 1. Disassemble the oil pump using Figure 95 as a guide. 2. Clean all oil pump assembly parts thoroughly and dry with compressed air. 3. Inspect all oil pump assembly parts thoroughly and replace as necessary. WARNING: At time of this printing, there are not any new "hard parts" available from the manufacturer for this unit. The only source will be used aftermarket suppliers.
COMPONENT REBUILD (CONT'D) OIL PUMP ASSEMBLY (CONT'D) 4. Install new "O" ring seals into the grooves on B1 clutch apply piston, as shown in Figure 96, and lube with small amount of Trans-Jel®. 5. Install new pump body to converter housing "O" ring seal, as shown in Figure 97, and lube with small amount of Trans-Jel®. 6. Install new pump body bushing as necessary using the proper driver (See Figure 97). 7. Install new converter hub seal into pump body, as shown in Figure 97, using proper driver. 8.
COMPONENT REBUILD (CONT'D) OIL PUMP ASSEMBLY (CONT'D) 10. Install the oil pump body alignment dowels, as shown in Figure 99, if removed. 11. Install the oil pump inner and outer gears into the pump body, as shown in Figure 99, with the "dots" facing up. 12. Lubricate the gears with small amount proper transaxle fluid. 13. Measure the gear to face clearance on both the inner and outer gears using a feeler gage or a depth micrometer, as shown in Figure 100.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) OIL PUMP ASSEMBLY (CONT'D) 15. Torque the eight oil pump cover to pump body bolts down to 11 N·m (97 in.lb.), as shown in Figure 102, using a criss-cross pattern. 16. Lubricate the "O" ring seal surfaces in the oil pump cover with small amount of Trans-Jel®. 17. Install the B1 clutch apply piston into the oil pump cover, as shown in Figure 103. 18.
COMPONENT REBUILD (CONT'D) K3 CLUTCH HOUSING ASSEMBLY 1. Disassemble the K3 clutch housing assembly using Figure 106 as a guide. 2. Clean all K3 clutch housing parts thoroughly and dry with compressed air. 3. Inspect all K3 clutch housing parts thoroughly for wear and/or damage, replace as necessary. WARNING: At time of this printing, there are not any new "hard parts" available from the manufacturer for this unit. The only source will be used aftermarket suppliers.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) K3 CLUTCH HOUSING ASSEMBLY (CONT'D) 4. Install new inner and outer "O" ring seals in the grooves of the K3 clutch apply piston, as shown in Figure 107. 5. Lubricate both seals with a small amount of Trans-Jel® and install K3 clutch apply piston into K3 housing, as shown in Figure 108. 6. Install the return spring assembly into the K3 clutch housing, as shown in Figure 108.
WWW.ALL-TRANS.BY Technical Service Information K3 CLUTCH HOUSING ASSEMBLY (CONT'D) 9. Install K3 clutch pack beginning with a steel plate and alternating with frictions, as shown in Figure 109, until you have installed the proper quantity, as the quantity may vary. Note: All friction plates should be soaked in proper fluid for 30 minutes before installing. 110 109 10. Install the K3 clutch backing plate on top of the last friction, as shown in Figure 109, with step side facing up.
COMPONENT REBUILD (CONT'D) K1 CLUTCH HOUSING ASSEMBLY 1. Disassemble the K1 clutch housing assembly using Figure 111 as a guide. 2. Clean all K1 clutch housing parts thoroughly and dry with compressed air. 3. Inspect all K1 clutch housing parts thoroughly for wear and/or damage, replace as necessary. WARNING: At time of this printing, there are not any new "hard parts" available from the manufacturer for this unit. The only source will be used aftermarket suppliers.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) K1 CLUTCH HOUSING ASSEMBLY (CONT'D) 4. Install the number 6 thrust bearing race into the K3 clutch housing drive hub, as shown in Figure 112. 5. Install the number 6 thrust bearing into the K3 clutch housing drive hub with needles facing down, as shown in Figure 112. 6. Set the completed K3 clutch housing drive hub assembly aside for the minute. 132 133 7.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) K1 CLUTCH HOUSING ASSEMBLY (CONT'D) 9. Lubricate the seal surfaces of K1 clutch apply piston and install the piston into K1 clutch housing, as shown in Figure 115 10. Install the K1 clutch apply piston return spring, as shown in Figure 115, and ensure springs are engaged in apply piston spring pockets. 11. Lube the balance piston seal and install piston, as shown in Figure 115. 12.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) K1 CLUTCH HOUSING ASSEMBLY (CONT'D) 14. Install the K1 clutch backing plate on top of the last friction, as shown in Figure 117, with step side facing up. Note: Notice the number stamped on top side of backing plate, which is an indicator that it is selective, but as yet, no selectives available. 15. Install the K1 clutch backing plate snap ring, as shown in Figure 117. Note: This snap ring is .064" thick. 16.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) K2 CLUTCH HOUSING ASSEMBLY 1. Disassemble the K2 clutch housing assembly using Figure 120 as a guide. 2. Clean all K2 clutch housing parts thoroughly and dry with compressed air. 3. Inspect all K2 clutch housing parts thoroughly for wear and/or damage, replace as necessary. WARNING: At time of this printing, there are not any new "hard parts" available from the manufacturer for this unit.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) K2 CLUTCH HOUSING ASSEMBLY (CONT'D) 4. Install the K2 apply piston inner "O" ring seal in the bottom groove of housing, as shown in Figure 121. Note: Body of this "O" ring measures .105". 5. Install the K2 balance piston inner "O" ring seal in the center groove of housing, as shown in Figure 121. Note: Body of this "O" ring measures .055". 6.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) K2 CLUTCH HOUSING ASSEMBLY (CONT'D) 11. Install the K2 clutch pack beginning with a steel plate and alternating with frictions, as shown in Figure 124, until you have installed the proper quantity, as the quantity may vary. Note: All friction plates should be soaked in proper fluid for 30 minutes before installing. 500 12.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) K2 CLUTCH HOUSING ASSEMBLY (CONT'D) 15. Turn the K2 clutch housing assembly over and install the number 11 thrust bearing, as shown in Figure 126, with the needles facing up. 16. Retain the number 11 thrust bearing with liberal amount of Trans-Jel®. 17. Turn the K2 clutch housing assembly over again and install the number 9 "rear" thrust bearing race, as shown in Figure 127, and retain with a small amount of Trans-Jel®. 18.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) REAR PLANETARY ASSEMBLY 1. Disassemble the rear planetary assembly using Figure 129 as a guide. Note: Front sun gear is captured and cannot be removed from rear planetary carrier. 3. Clean all rear planetary parts thoroughly and dry with compressed air. 3. Inspect all rear planetary parts thoroughly for any wear and/or damage, replace as necessary.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) REAR PLANETARY ASSEMBLY (CONT'D) 4. Place the rear planetary carrier on a flat work surface, as shown in Figure 130. 5. Install the number 7 thrust washer, as shown in Figure 130, and retain with Trans-Jel®. Note: This is the only "bronze" washer. 6. Install the F1 roller clutch onto the planetary carrier, as shown in Figure 130, by rotating carefully in a counter-clockwise direction until fully seated. 7.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) REAR PLANETARY ASSEMBLY (CONT'D) 8. Install the number 8 "front" thrust bearing race into the pocket of front sun gear in planetary carrier, as shown in Figure 133. 9. Install the number 8 thrust bearing into carrier, as shown in Figure 133. 473 10. Install the number 8 "rear" thrust bearing race on the front side of rear sun gear, as shown in Figure 134, and retain with Trans-Jel®. 11.
COMPONENT REBUILD (CONT'D) REAR PLANETARY ASSEMBLY (CONT'D) 12. Install the completed sun gear assembly into rear planetary carrier, as shown in Figure 135, by rotating into position. 13. Place a 1-1/8", 1/2" drive socket on the rear sun gear, as shown in Figure 136. 14. Gently roll the complete assembly over while holding the socket in place until the planetary assembly is setting upright on the socket, as shown in Figure 137. Note: This will retain the seated position of the two sun gears. 15.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) FRONT PLANETARY ASSEMBLY 1. Disassemble the front planetary assembly using Figure 129 as a guide. 3. Clean all front planetary parts thoroughly and dry with compressed air. 3. Inspect all front planetary parts thoroughly for any wear and/or damage, replace as necessary. WARNING: At time of this printing, there are not any new "hard parts" available from the manufacturer for this unit.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) FRONT PLANETARY ASSEMBLY (CONT'D) 4. Install the number 5 thrust bearing onto back side of input shaft and front planet ring gear, as shown in Figure 139, with needles facing up and retain with Trans-Jel®. Note: Number 5 thrust bearing race already installed on K1 clutch housing. 5. Install two new sealing rings into the grooves of input shaft, as shown in Figure 139. 6.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) FRONT PLANETARY ASSEMBLY (CONT'D) 8. Install three new sealing rings in the grooves of input shaft, as shown in Figure 142. 9. Install the front planetary carrier assembly into planetary ring gear, as shown in Figure 143, by rotating into position. Note: Ensure number 4 thrust washer and number 3 thrust bearing race are in place. 10. Install the number 3 thrust bearing, as shown in Figure 143, with needles facing down. 11.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) COMPLETED FRONT PLANETARY ASSEMBLY CENTER SUPPORT ASSEMBLY 1. You can disassemble center support assembly using Figure 145 as a guide. Note: It is not necessary nor recommended to disassemble center support, as visual damage would require complete replacement anyway. If replacement is necessary, ensure that you recieve the proper tooth count for transfer drive gear. 3.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) COMPONENT REBUILD (CONT'D) TRANSFER/PINION GEAR ASSEMBLY 1. Disassemble transfer driven gear/pinion gear assembly, using Figure 146 as a guide. Note: Press is required to remove the tapered roller bearings. 3. Clean all transfer driven gear/pinion gear parts thoroughly and dry with compressed air. 3. Inspect all transfer driven gear/pinion gear parts thoroughly for any wear and/or damage, replace as necessary.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) VALVE BODY ASSEMBLY 1. Disassemble the main valve body components using Figure 148 and 149 as a guide. Note: All valve body bolt lengths are found in the legend and must be positioned properly. 2. Clean all valve body components thoroughly and dry with compressed air. Note: Do not submerge solenoids in solvent. 3. Inspect all valve body components thoroughly for any damage.
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WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) VALVE BODY ASSEMBLY (CONT'D) 4. Disassemble lower valve body and place valves, springs and retainers on appropriate trays exactly as they were removed, as shown in Figure 150. Small parts are shown in Figure 151. Note: Tag the "Linear" solenoids on removal, as they are position sensitive. 5. Clean all lower valve body parts thoroughly and dry with compressed air. Note: Do not submerge solenoids in solvent. 6.
WWW.ALL-TRANS.BY Technical Service Information "09G" UPPER VALVE BODY ASSEMBLY, EXPLODED VIEW 300 319 316 312 317 318 313 309 314 310 308 311 315 320 307 306 321 305 327 322 331 252 344 252 300 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 335 340 UPPER VALVE BODY ASSEMBLY. MAIN VALVE BODY SPACER PLATE. TCC APPLY AND RELEASE VALVE. TCC APPLY AND RELEASE VALVE SPRING. TCC APPLY AND RELEASE VALVE SPRING RETAINER.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) VALVE BODY ASSEMBLY (CONT'D) 9. Disassemble upper valve body and place valves, springs and retainers on appropriate trays exactly as they were removed, as shown in Figure 152. Small parts are shown in Figure 153. 10. Clean all upper valve body parts thoroughly and dry with compressed air. 11. Inspect all upper valve body parts thoroughly for any wear and/or damage.
WWW.ALL-TRANS.BY Technical Service Information VALVE BODY ASSEMBLY (CONT'D) 14. Install the plastic filter into the valve body spacer plate, as shown in Figure 154, with the open end towards spacer plate. Note: Gaskets are moulded to all spacer plates. 15. Temporarily install two of the long accumulator housing bolts through bottom of upper valve body, as shown in Figure 154, for alignment of the spacer plate. 16.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) 850 243 243 850 70 91 VALVE BODY ASSEMBLY (CONT'D) 21. As you lower the upper valve body and spacer plate assembly into place, temporarily installed accumulator bolts will start to automatically start to move out, as shown in Figure 156. 22.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) VALVE BODY ASSEMBLY (CONT'D) 26. Disassemble the accumulator 1 valve body and place valves, springs and retainers on appropriate trays exactly as they were removed, as shown in Figure 159. Note: All accumulator body pistons are the same, but the accumulator springs should be tagged for identification. 27. Clean all accumulator body parts thoroughly and dry with compressed air. 28.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) 245 246 70 91 VALVE BODY ASSEMBLY (CONT'D) 30. The TCC regulator boost valve sleeve has a slot for the retainer on only one side of the sleeve, as shown in Figure 160, and must be rotated to the proper position to accept the retainer. 31. Turn the accumulator body over and install the check valves and the check ball, as shown in Figure 159. 32.
WWW.ALL-TRANS.BY Technical Service Information "09G" ACCUMULATOR 2, EXPLODED VIEW 368 368 395 386 243 385 381 377 388 382 380 389 391 394 390 393 384 392 383 378 376 387 379 243 244 399 1 T 244 398 397 244 244 247 403 402 243 244 247 248 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 ACCUMULATOR 2 HOUSING TO UPPER V.B. (64 MM LENGTH)(3 REQ). ACCUMULATOR-2 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ).
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) 243 243 244 243 244 247 1 T 70 91 VALVE BODY ASSEMBLY (CONT'D) 35. Disassemble the accumulator 2 valve body and place valves, springs and retainers on appropriate trays exactly as they were removed, as shown in Figure 163. Note: All accumulator body pistons are the same, but the accumulator springs should be tagged for identification. 36. Clean all accumulator body parts thoroughly and dry with compressed air. 37.
WWW.ALL-TRANS.BY Technical Service Information COMPONENT REBUILD (CONT'D) VALVE BODY ASSEMBLY (CONT'D) 44. Turn the valve body assembly over, as shown in Figure 166, and install the five lower valve body to upper valve body retaining bolts. 45. Torque lower valve body to upper valve body bolts to 9 N·m (80 in.lb.). 46. Set the completed valve body assembly aside for the final assembly process. TRANSAXLE FINAL ASSEMBLY 1.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 475 ID STAMP 476 2 ROUNDED EDGE FACING DOWN 478 477 ROUNDED EDGE FACING UP 3. Install the B2 clutch apply plate, as shown in Figure 168, with the rounded edge facing up. 4. Install B2 clutch pack beginning with a friction plate onto the apply plate and alternating with a steel plate, as shown in Figure 168, until you have installed the proper quantity, as quantity may vary.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 8. Measure the B2 clutch clearance with a feeler gauge between the backing plate and friction plate, as shown in Figure 170. Note: There are no factory clutch clearance specifications available, but the clearances were the "traditional" .010" per friction plate through-out this unit. Refer to Figure 170 for B2 clutch clearance with 6 frictions. 9.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 11. Install the completed center support assembly, as shown in Figure 172, by rotating back and forth into position. 12. Install five of the six center support retaining shown in Figure 172, and hand tighten only the five installed bolts. Note: The sixth bolt cannot be installed until the park rod guide is installed, as the guide must go under the parking pawl.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 15. Install the parking pawl into the slot in transaxle case, as shown in Figure 174 and 175. 16. Install the parking pawl pivot pin through access hole in rear of case, as shown in Figure 176, using a small magnet. 17. Install new "O" ring onto parking pawl pivot pin case plug, as shown in Figure 176. 18. Install the parking pawl pivot pin case plug and torque to 14 N·m (10 ft.lb.), using a 55 Torx bit. 19.
WWW.ALL-TRANS.BY Technical Service Information PARK LINKAGE EXPLODED VIEW 143 145 144 149 146 GG 03 Z 09 C2T 280 3 57 G 30 0218 03 34 0 6 4 - 03 02 5H 142 141 W V G A 150 151 147 148 152 153 154 40 5 10 1 - 1 04 -1 09 G 30 0 03 C2 0 T0 35 21 H 68 O Z AU FA 141 142 143 144 145 146 147 PARK ROD GUIDE RETAINING BOLT (14 MM LENGTH). PARK ROD GUIDE. PARK ROD GUIDE RETAINING BOLT (28 MM LENGTH). PARK PAWL RETURN SPRING SLEEVE. PARK PAWL RETURN SPRING. PARK ROD ROLLER AND PIN ASSEMBLY.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 26. Install the B1 clutch housing with the opening towards the transfer driven gear, as shown in Figure 177, and insure lugs are engaged in slots in the center support. 27. Install the B1 clutch housing retaining snap ring with opening towards the transfer gear, as shown in Figure 177, and ensure it is fully seated in the center support.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 28. Install the B1 clutch "stepped" pressure plate, as shown in Figure 178, with "step" facing down. 29. Install B1 clutch pack beginning with a friction plate onto the pressure plate and alternating with a steel plate, as shown in Figure 178, until you have installed the proper quantity, as the quantity may vary. Note: All friction plates should be soaked in proper fluid for 30 minutes before installing. 30.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 37. Install the completed front planetary assembly, as shown in Figure 180, ensuring that number 5 thrust bearing and number 2 thrust washer are still in place. 38. Front planetary assembly must be rotated back and forth to engage K1 clutch frictions into the planetary hub until fully seated. 39. Install K3 clutch housing assembly, as shown in Figure 181, by rotating back and forth until it is fully seated.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) ADJUSTMENT ROD 41. Measure the distance from case pump surface to the washer surface on the K3 clutch housing, as shown in Figure 182, using a straight edge and ruler, or a depth micrometer. Note: This measurement should match the measurement taken on disassembly to ensure that K3 clutch housing is fully seated. 42.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 7 Z 0 4051 - 1 - 1 1004 03C2T02168 09G 300 035H 46. Install "H" gage on transaxle pump surface, as shown in Figure 185, lower the adjustment rod to the surface of the number 1 thrust washer on the K3 clutch housing and tighten adjustment rod locking knob. 47. Now turn the "H" gage over and set it on the completed oil pump assembly, "with" the new design gasket and number 1 thrust washer in place, as shown in Figure 186.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 51. Assemble the park rod to the inside detent lever, as shown in Figure 188. 52. Install the inside detent lever and park rod into transaxle with park rod going through the park rod guide. 53. Install the manual shaft through the case bore, through the inside detent lever, as shown in Figure 188. 54.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 55. Install new design pump to case gasket over the dowels on oil pump, as shown in Figure 191, and retain with a small amount of Trans-Jel®. 56. Install two new case to converter cover seals in the case pockets, as shown in Figure 190, and retain with small amount of Trans-Jel®. 54 62 54 53 57. Install the oil pump and gasket assembly, as shown in Figure 190.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 60. Lube oil pump "O" ring and seal surface of the converter cover with Trans-Jel®. 61. Apply 1/8 inch bead of RTV sealant to converter cover, as shown in Figure 193. 62. Ensure oil pump to converter cover seal is still in place, as shown in Figure 195. 63. Install the converter cover assembly, as shown in Figure 195, using the chart in Figure 194 for the bolt locations. 64.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 65. Install new "O" ring seal onto the 8-way case connector, as shown in Figure 196, lube with a small amount of Trans-Jel®. 66. Install new "O" ring seal onto the 14-way case connector, as shown in Figure 196, lube with a small amount of Trans-Jel®. 67. Install new "O" ring seal onto the temp sensor, as shown in Figure 196, lube with small amount of Trans-Jel®. 68.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) Output Speed Sensor Location 70. Install the output speed sensor, as shown in Figure 197, and torque bolt to 7 N·m (62 in.lb.). Note: This bolt has 8 mm head, 18 mm long. 71. Install the input speed sensor, as shown in Figure 197, and torque bolt to 10 N·m (88 in.lb.). Note: This bolt has 10 mm head, 21 mm long. 72. Install the B1 accumulator springs and piston into the case as shown in Figure 198.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 35 35 36 36 35 36 35 35 37 36 34 73. With all wire harness' laid over pan rail, install the completed valve body assembly onto case, as shown in Figure 199. 74. Install the 12 valve body to case bolts and wire the wire harness retaining brackets, as shown in Figure 199. Note: Wire harness retaining brackets will vary from model to model. 75. Torque all valve body to case retaining bolts to 9 N·m (80 in.lb.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 76. Install the temp sensor into the valve body bore, install retaining bracket and torque the retaining bolt to 11 N·m (97 in.lb.) (See Figure 199). 77. Install the output speed sensor "blue" connector to valve body, as shown in Figure 201, torque the retaining bolt to 7 N·m (62 in.lb.). 78. Install the input speed sensor "white" connector to valve body, as shown in Figure 201, torque the retaining bolt to 7 N·m (62 in.lb.).
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 84. Some models use a locking tab washer and some models use a self locking nut with a centering washer below the nut. The models with the self locking nut have a shoulder on the nut that faces down toward the "centering" washer, as shown in Figure 204. 85. Using a pair of vice-grips to hold inside manual lever, as shown in Figure 203, torque the manual lever nut to 7 N·m (62 in.lb.). 86.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 14 15 13 12 11 CAUTION: Now is the time to recheck all of the electrical connections, all harness' in their proper retainers, no pinched wires, filter in place, etc...... AG 02 4- 1 34 36 57 21 < 3 o JP G e/Z 09 >F VW 87. Install new oil pan gasket to oil pan, as shown in Figure 206. Note: Pan gaskets have spacers incorporated in the gasket to prevent over-torque, and must be in place for all pan bolts. 88.
WWW.ALL-TRANS.BY Technical Service Information TRANSAXLE FINAL ASSEMBLY (CONT'D) 9 10 TAB MUST BE INSERTED IN RECESS IN HOUSING 8 7 6 3 5 2 GG 03 Z 0 9 C2 T 2 8 0 3 57 G 30 021 03 34 05 68 4 - 03 02 H 4 W V G A 91. Install the transaxle range switch, as shown in Figure 208, torque bolts to 11 N·m (97 in.lb.). 92. Install new special "O" ring seal on bottom of integral cooler, as shown in Figure 209, retain with small amount of Trans-Jel®.
TORQUE CONVERTER Torque Converter Code Letters GG 03 Z 09 C2T 280 3 57 G 30 021 03 34 0 68 4 - 03 02 5H QE AA WWW.ALL-TRANS.BY Technical Service Information W V G A 40 5 10 1 - 1 04 -1 09 G 30 03 0 C2 03 T0 5 21 H 68 O Z AU FA Copyright © 2010 ATSG Figure 210 TRANSAXLE FINAL ASSEMBLY (CONT'D) 98. Lubricate the outside diameter of the converter hub with small amount of Trans-Jel®, and install torque converter, as shown in Figure 210. 99.
WWW.ALL-TRANS.BY Technical Service Information BEARING AND WASHER LOCATIONS No. 2 No. 4 No. 7 No. 10 No. 1 No. 3 No. 5 No. 11 No. 6 No. 8 No. 9 NUMBER 1 THRUST WASHER: OIL PUMP TO K3 CLUTCH HOUSING. (PLASTIC) NUMBER 2 THRUST WASHER: K3 CLUTCH HOUSING TO FRONT PLANETARY CARRIER. NUMBER 3 THRUST BEARING: FRONT PLANETARY SUN GEAR TO FRONT PLANETARY RING GEAR. NUMBER 4 THRUST WASHER: FRONT PLANETARY CARRIER TO FRONT PLANETARY RING GEAR.
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WWW.ALL-TRANS.BY Technical Service Information TORQUE SPECIFICATIONS Component N•m Ft.Lb. Converter Housing to Case Oil Pump to Case 19 19 14 14 In.Lb.
