New Problems Facing the 09G
of the fill level pipe plug as the
transmission fluid temperature
reaches 35ºC (95ºF).
• If the transmission fluid doesn’t
start to drip out of the fill level
pipe plug, add fluid to the trans-
mission until it starts to run out of
the fill level plug (figure 1).
Other units require a similar meth-
od for filling and checking the fluid
level, so most R&R techs have devised
their own way of getting fluids into the
transmission through a small opening.
The critical step is to be sure that the
ATF is within the correct temperature
range.
Figure 3: Removing every valve from the valve body will make the
valve body easier to inspect.
Shifting Issues
As with most new transmissions,
it takes a few thousand miles of road
service for the troubles to show up.
There are some trouble spots you could
easily overlook that we’ve learned
about through experience. These spots
include the valve body, the case, and
some troubles you could cause your-
self.
These units are well behaved for
most of their road life. They start hav-
ing issues when the valve bodies start
wearing out. This can happen as early
as 20,000 miles. The shifting com-
plaints can range from clunky down-
shifts to a perceived slip or engine
flare. Too much torque converter slip
can also be a symptom of a worn out
valve body.
A shift to neutral on the 3-4 shift
Figure 4: An inexpensive LED pen works well to shed light on worn valve bores.
can be caused if the steel sleeve down Always remove every valve from every VW valve body.
in the case rotates. This cuts off the bore for easier inspection (figure 3). 2. Get a valve body repair kit
feed to the K2 clutch, which is needed Good lighting is critical; an LED pen from the aftermarket. These kits involve
to apply 4
th
, 5
th
and 6
th
gears (we’ll light is an excellent choice for this job boring the aluminum and installing
cover this in more detail later). (figure 4). sleeves and valves. Valve bore end
Another cause for a shift to neutral In this case, the Pressure Regulator plugs are also available.
on the 3-4 can be solenoid related. This Valve bore is in good shape; it’s a dull 3. Purchase a rebuilt valve body
typically happens after the valve body aluminum color (figure 5). On the other from a reputable rebuilder.
is replaced or the unit rebuilt. hand, the Lockup Clutch Control Valve The important thing to remember
The reason? The M1 solenoid bore is shiny and worn (figure 6). When is that these units are real hard on valve
(light gray wire) and the B2/4-6 sole- the bore becomes severely worn it may bodies; most of them are going to be
noid (black wire) have been crossed also exhibit visible ridges. damaged when they reach your bench.
(figure 2). Always mark the solenoids Okay, you’ve found a worn valve
harness or take a picture to make sure body. What are you going to do about Inside the Unit
you connect the harnesses to the cor- it? These days you generally have three The 09G has a Lepelletier gearset
rect solenoids. choices: (covered in the Nov/Dec 2006 GEARS)
1. Replace the complete valve in the front and a Ravigneaux gearset
Valve Body Inspection body with a new one from your local (think AOD) in the rear. Both seem to
When servicing the valve body, VW dealership. This used to be your be holding up extremely well.
pay close attention to the valve bores. only choice when you found a worn
6 GEARS January/February 2010
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