SSP_291_d1.pdf

Service Training

6-speed Automatic Gearbox 09G

Self-Study Programme 291

Dynamics and economy

Brief technical description

The 6-speed automatic gearbox 09G sets new

standards in the segment of transversely mounted

multi-step automatic gearboxes

6-speed automatic gearbox using

the Lepelletier planetary gear set concept.

* of 6.05 provides ﬂexibility in

use (sport or economy mode).

ratio spread

• Low weight

• Wide

ratio spread

Only ﬁve gear shifting components are required.

Highly compact, lightweight and powerful.

• Compact gearbox dimensions

There are three gearshift modes to choose from:

sport program and manual gear selection by

tiptronic.

• High shifting speed

• High level of shift comfort

In triponic mode, it is possible to start in second

gear.

* you will ﬁnd an explanation of the terms/

paragraphs marked with an asterisk as of page 72

This Self-Study program gives general descriptions of the 09G gearbox and shows the special features in

combination with the Audi A3 ‘04 and Audi TT.

291_117

The basics for this Self-Study Programme are covered in the multimedia training course "Power

Transmission 2" and in the previously published self-study programmes on multi-step automatic gearboxes.

Reference

Note

The Self-Study Programme is not a Repair Manual!

The values given are intended as a guideline only and refer

to the software version valid at the time of publication of the SSP.

For maintenance and repair work, always refer to the current technical literature.

The wide

Contents

General

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05

Sectional view of gearbox 09G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06

Gearbox periphery

Gear selector of the Audi A3 ‘04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08

Selector lever locks on the Audi A3 ‘04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Ignition key removal lock on the Audi A3 ‘04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Gear selector of the Audi TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Tiptronic steering wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Gearbox subassemblies

Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Torque converter lock-up clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Oil supply/lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Planetary gear/shifting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Shift logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Description of gears/torque curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Gearbox control

Function diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Automatic gearbox control unit J217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Interfaces/auxiliary signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

CAN information exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Distributed functions in the Audi A3 ‘04/Dynamic Shift Program DSP . . . . . . . . . . . . . . . . . . . . . . . . . 68

Tiptronic gearshift strategy/sport program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Service

Emergency running/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Glossary

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

General

Introduction

The 6-speed automatic gearbox 09G is used in the

Audi A3 ‘04 and Audi TT.

* has been

increased to 6.05. This ﬁgure surpasses that of all

front/transversely mounted multi-step automatic

gearboxes currently on the market and matches the

ratio spread of variable automatic gearboxes.

spread

The gearbox is a conventional multi-step automatic

with hydrodynamic torque converter and

electrohydraulically operated planetary gear.

The Lepelletier gear set concept, as found

previously in the Audi A8 gearbox 09E, is used in

gearbox 09G.

The 09G gearbox is developed and manufactured

by the Japanese transmissions specialist

AISIN AW CO., LTD.

The advantage of the Lepelletier gear set concept is

its simple, space-saving and low-weight design.

It combines a simple planetary gear train with a

Ravigneaux gear seat further down. This allows a

harmonious 6-speed transmission to be achieved

using only ﬁve gear shifting components.

In association with Audi's development engineers,

the gearbox has been adapted to suit the

characteristics speciﬁc to each vehicle and engine*.

Compared to the predecessor gearbox (model 09A),

the weight of gearbox 09G has been reduced by

19.5 kg from 102 kg to 82.5 kg, even though a sixth

gear has been added.

This was achieved by using the Lepelletier gear set

concept and through selective optimisation of

component parts.

The six forward gears and reverse gear are engaged

by three multi-plate clutches and two plate brakes.

Reference

For further information on the Lepelletier gear

set concept, refer to SSP 283.

291_002

291_001

With the additional gear, the

Speciﬁcations

Developer/manufacturer

AISIN AW CO, LTD Japan

Designations

Manufacturer: TF-60SN

Audi AG:

AQ250-6F

Service:

09G

Gearbox type

electrohydraulically controlled 6-speed

planetary gear (multi-step automatic gearbox)

with hydrodynamic torque converter and slip-

controlled converter lock-up clutch for front-

wheel drive and transverse installations

Control

hydraulic control unit integrated in the oil sump

with external electronic control unit

Dynamic Shift Program DSP with separate

sport program in "Position S" and the tiptronic

shift program for manual gearshifts (optionally

available with tiptronic steering wheel)

To rque

in Nm

up to over 300 Nm depending on type

Ratios:

Planetary gear

(for engine codes

GSY 1.6 l and

GJZ 2.0 l FSI)

First gear 4.148

Second gear 2.370

Third gear 1.556

Fourth gear 1.155

Fifth gear 0.859

Sixth gear 0.686

Reverse gear 3.394

Idler

Z52/49 1.061 (GSY and GJZ)

Final drive

Z61/15 4.067 (GSY) or Z58/15 3.867 (GJZ)

i constant*

4.316 (GSY) or 4.102 (GJZ)

(GSY/GJZ)

6.05

ATF speciﬁcation

G 052 025 A2, Esso JWS 3309

Capacity

7.0 litre (reﬁlling) lifetime ﬁlling

Weight

in kg

approx. 82,5

Overall length

in mm

approx. 350

The gearbox in the Audi A3 ‘04 (with 1.6 l FSI and

2.0 l FSI engines) is conﬁgured as a so-called

5+E gearbox. Max. speed is reached in ﬁfth gear.

Sixth gear is an overdrive gear which reduces

engine revs, improves driving comfort and

increases fuel economy.

The gearbox in the Audi TT is conﬁgured as a

so-called sport gearbox.

Max. speed is attained in sixth gear.

Sixth gear provides closer ratios and enhanced

driving dynamics.

Reference

* You can ﬁnd an explanation of the marked

terms/paragraphs as of page 72.

Spread*

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