Designed by the Japanese transmission firm Aisin Warner, the 09G transmission (also referred to as the TF-60 transmission) is a six speed automatic transmission that has been used in a number of FWD vehicles like the Audi A3, Audi TT, Mini Cooper, Volkswagen New Beetle and Volkswagen Jetta. When it was first introduced in the 2003 model year, it was considered state of the art, and a marked improvement over the 5-speed A55-50SN.
In order to control all six forward gears, the Volkswagen 09G employed a complicated system of electronic and hydraulic controls. There were a total of 8 09G solenoids: 4 of the linear solenoids directly control the clutches and brakes with spool valves inside the valve body, and the rest control the torque converter clutch and line pressure. However, there were a number of design flaws in the valve body that usually lead to some rather serious 09G transmission problems.
Common Problems with the Volkswagen 09G Valve Body
Two of the main causes of 09G valve body problems are electrical issues and pressure control problems that lead to leaks and premature wear/failure. Some of the issues attributed to these design flaws include:
Unusually harsh 1-2, 2-3, 3-4 shifts
Harsh downshifts
Slipping
Flared shifts
Shuddering and shaking
Overheating
All of these symptoms are usually caused by the following 09G valve body problems:
Failed Linear Solenoid
Excessive bore wear
Pressure Control Issues
Leaks
Stuck Valves
Warped Valve Body
In order to properly fix a 09G valve body, it will have to be modified beyond it’s stock form, to compensate for the design flaws that cause all of these problems. Companies like Street Smart Transmission do a good job of modifying the 09G valve body (they do things like modify the bores to improve fluid flow and eliminate premature solenoid failure), that way the whole transmission can function the way it was actually intended. To learn more about their remanufactured 09G valve body, click here.
Common 09G Transmission Problems
Dragging sensation or partial bind on 1st gear take-off
Problem – Drivers may experience a dragging or binding feeling when they try to take off from first gear.
Solution – One of the common 09G valve body problems is internal fluid control, which may have led to ATF contaminating the internal harness connector, causing one of the solenoids to partially apply a clutch or brake, resulting in the dragging sensation. This solenoid, clutch or brake will also be subjected to premature wear. To fix this issue, the internal wiring harness will have to be replaced.
Tiptronic switch failure
2003+ Volkswagen Beatle
Problem – The transmission may go into limp mode/failsafe mode, where it is locked into a single forward gear. The VW DTC 01045 will also be present.
Solution – This issue can be caused by a failed Tipronic switch F-189, and will require a new shifter assembly.
09G Transmission Technical Service Bulletins | TSBs
TSB 37 07 16 – Transmission will not shift out of Park – 09G transmission
2003 – 2005 Volkswagen New Beetle – 2005 Volkswagen New Beetle Convertible
Problem – Transmission may not be able to be shifted out of Park. There also may be no communication from the TCM download the PTCs.
Solution – This issue may be caused by fuse S7, S15 and/or S231 being open, missing or not properly seated. There could also be a poor or corroded power and/or ground connection. If no issues are found, the shift interlock system should be considered.
TSB 37 07 18 – Transmission knocking noise under load – 09G transmission
2005 – 2007 Volkswagen Jetta – 2006 – 2007 Volkswagen Passat – 2006 – 2007 Volkswagen Rabbit – 2006 – 2007 Volkswagen Golf GTI – 2006 – 2007 Volkswagen Eos
Problem – Drivers may notice a pronounced knocking noise coming from the transmission when the engine is under load.
Solution – The connection/bolts between the pendulum support and the gearbox may have come loose because of engine vibrations.
Solving 09G valve body problems
The problem with repairing a 09G valve body is that you don’t really know what kind of stress and extreme temperature changes they have been subjected to. This is why many people simply install a remanufactured 09G valve body, to eliminate the threat of the unknown. Companies like Street Smart Transmission use state of the art equipment to completely remanufacture the valve body. This is not like rebuilding, where new components are simply installed into the existing valve body. They use specialized equipment to analyze each valve body to see if it has been cracked or warped. A mechanic does not just simply eyeball it, a machine does the inspection, and even checks the tensile strength of the metal to make sure that it meets the original OE specification.
Once a casting has been selected for the build, all of the bores are modified, to make sure that the valves will function the way they were intended to. Then every single component from the check balls, to the valves, pistons and springs are tested and/or replaced. After that process is complete and quality inspected, they install all new solenoids (they also bench test them prior to installation), speed sensors and pressure switches. The finished product is then put on a Superflow AXILINE Valve Body Tester, which can simulate actual road conditions. This allows their ASE certified techs to verify the functionality, and make any adjustments or fixes before they ship it out to the customer. Street Smart Transmission also gives it a 1-Year/No Hassle Warranty, which makes getting a remanufactured 09G valve body almost a no-brainer. To learn more about the remanufactured 09G valve body and the remanufacturing process that Street Smart Transmission uses
Post time: Jan-10-2022