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Technical Service Information

AUDI/PORCHE/SAAB/VOLVO/VW
AISIN 09G, 09D, TF80, AW 55-50SN WITH VARIOUS SHIFT COMPLAINTS
COMPLAINT: Before or after overhaul, vehicles equipped with Aisin transmissions may exhibit various shift complaints such as harsh 2-3, 3-5 and N-R, or a harsh N-D and 5-4, or a harsh 3-4 and/or coast downshift clunks. CAUSE: The cause may be a loss of lube pressure due to worn pressure regulator valve bores (primary/secondary), worn bushings, excessive end play and/or failed bonded balance pistons. The K1, K2 and K3 clutch assemblies are equipped with these bonded counter balance pistons. Using K3 as an example from an 09G transmission (figures 1 and 2), the balance piston function is to hold "counter" or "back" pressure on the K3 apply piston. The balance piston is fed from the lube circuit, and its purpose is to provide a small amount of pressure to assist the release of the K3 clutch. It also acts as an accumulator during application of the K3 clutch (figures 3 and 4). The bonded piston has three notches where the retaining snap ring is located allowing a controlled leak of this pressure, and when the bonded rubber is worn this will allow a larger volume of pressure loss which can cause the harsh applications. The K1 can cause a harsh N-D and 5-4 shift, the K2 can cause a harsh 3-4 shift and the K3 can cause a harsh 2-3, 3-5 and N-R shift.

CORRECTION: Most Aisin Seiki transmissions utilize a primary and secondary pressure regulator valve from which lube originates and has its pressure control. Should either one of these valves wear into the bore it can drop lube pressure (figure 5). Check lube pressure with a pressure gauge. There should be approximately 6 to 10 psi of lube during operating temperature. If pressure runs close to zero psi, these regulator valve bores will need to be inspected. Bushing wear and loose end play can also cause a loss of lube pressure in addition to failed counter balance bonded pistons. All of which will need to be either repaired or replaced restoring circuit integrity. Refer to figure 6 for the TF80- SC pressure tap locations Refer to figure 7 for the TF81-SC pressure tap locations Refer to figure 8 for the TF60-SN pressure tap locations Refer to figure 9 for the TR60-SN pressure tap locations Refer to figure 10 for the AW55-50SN pressure tap locations

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Technical Service Information


K3 CLUTCH DRUM EXPLODED VIEW

K3 BALANCE PISTON

K3 CLUTCH ASSEMBLY

K3 RETURN SPRING

K3 CLUTCH PISTON

K3 CLUTCH DRUM

Copyright 2012 ATSG

Figure 1

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Technical Service Information


K3 CLUTCH CROSS-SECTIONAL VIEW
Pump K3 Clutch Drum

K3 Clutch Apply Piston K3 Clutch Balance Piston K3 Clutch Balance Piston Controlled leak K3 Clutch Balance Piston Feed (Lube circuit)
Copyright 2012 ATSG

Stator Support

K3 Clutch Piston Feed Figure 2

K3 CLUTCH "OFF"
Pump K3 Clutch Drum

K3 Clutch Apply Piston K3 Clutch Balance Piston K3 Clutch Balance Piston Controlled leak K3 Clutch Balance Piston Feed (Lube circuit) Copyright 2012 ATSG

Stator Support

K3 Clutch Piston Feed Figure 3

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Technical Service Information


K3 CLUTCH "ON"
Pump K3 Clutch Drum

K3 Clutch Apply Piston K3 Clutch Balance Piston K3 Clutch Balance Piston Controlled leak K3 Clutch Balance Piston Feed (Lube circuit)
Copyright 2012 ATSG

Stator Support

K3 Clutch Piston Feed Figure 4

09G LUBE CIRCUIT


To Cooler .058

Secondary PR
To Rear Trans Lube .032 .032

To Front Trans Lube

To Diff. Lube

.045 .076 .032 TFT

.032
x

Pump

Primary PR

Copyright 2012 ATSG

Figure 5

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Technical Service Information


TF80-SC AM6 AF40 TF-80 AF40/6
TCC Apply

C1 TCC Release C3

Line C2 Lube B2

B1

Copyright 2012 ATSG

Figure 6

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Technical Service Information


TF81-SC AF21 AW6A-EL

TCC Apply

Line C3 C2 Lube

B2

Copyright 2012 ATSG

Figure 7

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Technical Service Information


TF860-SN 09G 09M 09K
Lube
(Some Models)

09 G 30 00 0C 3 3

40 5 10 1 - 1 04 -1

GG 03 Z 09 C2T 280 3 57 G 30 021 03 34 0 68 4 - 03 02 5H

W V G A

SG F
2T 0 2 5H 16 8
O Z

AU FA

TCC Release B-2 Clutch Lube

B-1 Clutch K-3 Clutch


In Case Below Fluid Fill Device

Note: All Transaxles Are Not Equipped With Fluid Fill Device

K-2 Clutch K-1 Clutch Figure 8

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Technical Service Information


TR860-SN 09D

B2 Clutch "Small" Cavity B2 Clutch "Large" Cavity

Lube K1 Clutch "From Cooler" "To Cooler"

K3 Clutch

Copyright 2012 ATSG

Figure 9

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Technical Service Information


AW55-50SN RE5F22A AF23/33-5

4-5 Clutch (C3) 1-2/Reverse (B5) Forward Clutch (C1) Lube Direct Clutch (C2)

Copyright 2012 ATSG

Figure 10

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