TF-80 af-40 6 speed

AW 6 Speed FWD

Presented by Bob Warnke

ATRA Powertrain Expo 2009

© Sonnax 2009

AW 6 SPEED FWD

1 ©Sonnax Industries ATRA EXPO 2009

AW 6 Speed FWD Table of Contents

Topic Page/s

Features, Powerflow, Hydraulic Control and Adjustments

2-9

Exploded view, Vacuum test locations on TF-81SC (Ford/Mazda)

10-16

Exploded view, Vacuum test locations on AF-40 (Volvo, Opel, Saab)

17-26

Exploded view, Vacuum test locations on TF-60SN (VW 09G)

27-34

Pressure Testing

35-40

Common Complaints, Cause, Correction on AW6-FWD

41-50

Codes and Relearn Procedure

51, 52

AW 6 SPEED FWD


AW6 FWD & RWD TECHNICAL FEATURES

• AW55-50 was designed in ‘98 and went into production in ‘99. Torque capacity of

330 N.m. • AW/TF-60 was designed in ‘02 along with the rear wheel drive unit, the TR-60SN.

Both units use similar power flow & control. TF-60 went into production in the ‘03 Beetle (09G) with torque capacity of 280N.m. The later 09K has 400N.m. and 09M has a 450 N.m. torque capacity.

• Skip shift scheduling controls 4 clutches simultaneously. The units have the ability and programming for 2-4; 4-6 upshifts and 6-2, 2-1; 5-3, 3-1, 4-2 and 2-1 downshifts. This is accomplished by designing a compact hydraulic circuit that remains pre-charged. • Each clutch apply or release is controlled by one solenoid and valve circuit. • The control pressure curve of each circuit is affected by the adjustment screw on

the end of the bore opposite the solenoid. That feature is combined with fast adapts and CAN feedback.

• Software has been reduced by 45% over 5 speed and parts by 27% with a gain

of 5% fuel economy. • TF-80SC utilizes a brake band, TF-60SN uses a B1 clutch. The oil transfer

grooves in the band drum are critical to the timing for apply and to reduce heat. The double wrapped band has special oil grooves to reduce heat.

• Temperature sensor is extremely critical to proper shift strategy and adaption! TCM

has 3 distinct temperature modes of operation. 1. TCC apply & normal clutch apply release strategy. 2. Stage 1: 127°C (260°F) shifts become later and TCC remains applied longer. 3. Stage 2: Engine torque reduction.

AW 6 SPEED FWD


SO

LEN

OID

PO

WE

RFL

OW

A

W6

FWD

R

AN

GE

S

OLE

NO

ID

CLU

TCH

B

RA

KE

O

.W.C .

FOR

D/V

OLV

O/P

SA

S

SC

S

LC1

SS

D

SLC

2 S

SE

S

LC3

SS

F S

LB1

SS

A

S1

SS

B

S2

C-1

C

-2

C-3

B

-1

BA

ND

B

-2

CLU

TCH

F-

1

V.W

. N

92#5

N

282#

9 N

90#3

N

283#

10

N88

N

89

K-1

K

-2

K-3

B

-1

Clu

tch

B-2

C

LUTC

H

F-1

P

X X

X X

R

X X

X

X

X

N

X X

X X

Neu

tral C

ontro

l X

X

X

X

X

D S

1ST

X

X

X Z

Z X

Z

X

2ND

X X

X

X

3RD

X

X C

y C

y X

X

4TH

X

X C

y C

y X

X

5TH

X

X C

y C

y

X X

6TH

X

X

C

y C

y

X

X

S

SC

& S

SE

sol

enoi

ds h

ave

resi

dual

clu

tch

pres

sure

feed

ing

back

to th

e op

posi

ng c

lutc

h co

ntro

l val

e

Sol

enoi

d fo

r Clu

tch

C-1

C

-2

C-3

B

-1

RE

SIS

TAN

CE

-OH

MS

4.

0-8.

0 4.

0-8.

0 4.

0-8.

0 4.

0-8.

0 10

-16

10-1

6 Li

near

sol

enoi

ds o

pera

te a

t 300

Hz.

Sol

enoi

d Fl

ow

N.O

N

.O.

N.O

. N

.O.

N.C

N

.C

N91

/TC

C/S

LU is

N.C

.; N

93/E

PC

/SLT

is N

.O

X

=ON

=

OFF

Z =

ON

DU

RIN

G E

NG

INE

BR

AK

ING

C

y=C

YCLE

D

AW 6 SPEED FWD


K3 K1 F

B2 K2 B1

AF-40 - B1 is a Band

TF-60SN - B1 is a Clutch

K2 Case

sleeve

• Clutch piston travel is critical and set by selective flange/snap rings. • Split band has a print mark between the straps near the anchor. If the print mark is

worn away, band should be replaced. The C3 clutch drum onto which the B1 band applies, has a special surface finish and should not be altered. The B1 band should be pre-soaked with the correct fluid for 2 hours.

• Faced clutch plates have a print mark. OE suggests if the print mark is not legible the friction plate should be replaced and a new pre-soaked friction installed.

AW 6 SPEED FWD


Servo Actuating: • Reduces gear shift lag by prim-

ing circuit. • Uses temperature & pressure

to adjust. • Accurately times end of piston

stroke.

Torque Phase: • CAN & adaptive strategy timing

apply & release of exhausting clutch.

Inertia Phase:

• After initial apply, RPM vs. torque vs. slippage is monitored. Pressure is adjusted to eliminate the slip at the end of the shift.

Skip Shift: • Four elements controlled • Controls the apply & release

to reduce overlap without bind or flare.

SLIP SHIFT 6-3

UPSHIFT

UPSHIFT

SLIP SHIFT 6-3

AW 6 SPEED FWD


A balance area opposes clutch apply pistons. These are fed from lubrication oil. The valve body damper/accumulators pre-charge all circuits.

A:

Piston Hydraulic Pressure Chamber

B:

Centrifugal Hydraulic Pressure Control

Chamber

C-1 = 1.2 to 1.4mm 2.8-3.5mm

C-2 = .045 to .065mm 2.5-3.2mm

C-3 = 0.6 to 0.8mm 2.8-3.5mm

B-2 = 1.2 to 1.4mm 47-53mm

Clutch Piston Stroke (use selective flanges)

AW 6 SPEED FWD


Adjuster: By sealing this with Loctite or

cutting o-ring groove. Both the vacuum test and clutch

control improve.

Vacuum Test Example 3”=Poor 7”=Poor

12”=Normal 11”=Normal 14-18” =Post repair 14-18”=Post repair

Refer to vacuum test locations on all covers.

AW 6 SPEED FWD


(3) a

lignm

ent h

oles

EXA

MP

LE:

C

-3 a

djus

ter:

Tur

n sc

rew

out

-w

ard

to in

crea

se C

-3 c

lutc

h pr

essu

re.

1/

4 tu

rn is

abo

ut 4

psi

. di

ffere

nce.

W

ould

sug

gest

1/2

turn

firs

t at

tem

pt.

Hill

hol

d, N

-D, 4

-5, 5

-4

3-4,

4-3

Rev

s.

2-3,

4-5

3-

2, 5

-4

3-4

4-3,

6-5,

6-3

1-2,

3-2

5-

6, 6

-5

Line

rise

& s

hift

qual

ity

TCC

sol

enoi

d

Incr

easi

ng c

lutc

h pr

essu

re w

ill re

duce

slip

dur

ing

upsh

ift.

Incr

easi

ng p

ress

ure

will

slo

w c

lutc

h ex

haus

t dur

ing

rele

ase.

FOR

D-M

AZD

A P

ICTU

RED

HE

RE

(U

se o

ther

Illu

stra

tions

and

app

licat

ion

char

t on

pg. 3

to m

atch

AW

6 D

esig

n)

You

Can

Alte

r Driv

e-ab

ility

by a

djus

ting

clut

ch p

ress

ure

cont

rol o

n A

LL A

W6!

Rem

embe

r! C

lutc

h ov

erla

p re

quire

s tim

ing

or a

djus

tmen

t of t

he a

pply

and

/or t

he re

leas

ing

clut

ches

. A

lway

s m

easu

re th

e ad

just

er o

r not

e th

e tu

rns

to re

gain

OE

, if r

equi

red.

SS

C

SS

D

SS

E S

SF

AW 6 SPEED FWD


Tips Regarding Clutch Control Adjustment 09G

When adjusted properly: • Hill hold will not allow vehicle to roll back nor move forward with foot off accelerator. • Smooth engagement into Fwd-Revs. Not more than 1.5 second delay or double

bump into reverse. To Isolate proper drive-ability & shift quality: • Suggest graphing engine RPM & transmission ISS #182. When correct, they follow

each other with slight delay/lower ISS. • Flare & harsh shifts show up on graphs as spikes or square wave shift transitions. • Drive monitoring TCC slip RPM. Verify TCC stages: off, on, modulated slip mode. • When K-3 is too far out of adjustment, a cut-loose will occur on 2-3 or harsh 3-2

downshifts. It is likely the B-1 will have to be adjusted at the same time. • Drive and adjust in city driving conditions first. Once acceptable, drive it harder with

elevated upshifts and coast down. Testing on hydraulic test stand. • Strongly suggest the solenoid cover with control valves be tested independent of

the rest of the valve body. • Compare OE duty % and clutch control output, then adjust your rebuild to match.

AW 6 SPEED FWD


IDENTIFICATION OF VALVE BODY CORES

AF/AWF-21; TF-81SC; AW6A-EL FORD LINCOLN

Year Vehicle Engine Year Vehicle Engine 05-07 Five Hundred 3.0L 07-09 MKX, MKZ 3.5L

06-09 Fusion 3.0L 06-07 Zephyr 3.0L

LAND ROVER MERCURY 07 Freelander II 1.8/2.5L 06-09 Milan 3.0L

07 LR2 3.2L 05-07 Montego 3.0L

07-08 CX7 2.3L

07-08 CX9 3.5L

06-07 6S 3.0L

MAZDA

Side mount valve body & pan.

AW 6 SPEED FWD


Ford

/Maz

da-F

ront

Cov

er

TCC

SSE

SSF

PC

A

SS

D

SS

C

C3

Clu

tch

Con

trol

B1

Ban

d C

ontro

l

Mai

n P

ress

ure

Reg

.

1 B

oost

Ass

embl

y

C1

Clu

tch

Con

trol

B1

Ban

d A

ccum

ulat

or

C2

Clu

tch

Con

trol

2 1

3

AW 6 SPEED FWD


Ford

/Maz

da M

iddl

e C

astin

g -F

ront

Sid

e 7

4 V

acuu

m m

arks

at v

alve

s, n

ote

test

ed fr

om

circ

uit o

n op

posi

te s

ide

of c

astin

g.

B1/

C3

cont

rol Lo

ckup

Rel

ay

B1/C

3 R

elay

12

B1/

C3

Shi

ft R

estri

ct

B1/

C3

Sw

itch

8 5

6

C1

Shi

ft

B2/

C2

Sw

itch

C2

Rel

ay C

3 Si

gnal

B1

Sig

nal

Seco

ndar

y Pr

ess

Reg

.

Sequ

ence

Cut

back

15

14

13

11

10

3

4

5

6

7

8

9

AW 6 SPEED FWD


Ford

/Maz

da R

ear C

over

, Fro

nt S

ide

10

11

9

12

L/U

Con

trol

L/U

Con

trol P

lung

er

Ass

embl

y

Sole

noid

Mod

ulat

or #

1

C1

Rel

ay

C2

Tim

ing

Sole

noid

Mod

ulat

or #

2

Engi

ne B

rake

En

gage

men

t

20

21

18

19

17

16

AW 6 SPEED FWD


FORD/MAZDA

AW 6 SPEED FWD


FORD AW6 SPRING I.D. Bore # Identification Color Wire dia. Spring OD Free Length

SOLENOID/FRONT COVER 1 Main Pressure regulator Plain .047” .541” 1.472” SSD-C2 Plain .032” .253” .740” SSC-C1 Pink .032” .324” .762” SSE-C3 Plain .032” .253” .740” SSF-B1 Blue .030” .253” .675” Accumulator inner Lt. blue .061” .430” 1.089” Accumulator outer Plain .082” .631 1.085” Relief. 0.392 diameter White .023” .249” .593” Relief.314 dia. x2 Orange .014” .161” .368”

MIDDLE CASTING 3 C1 Shift Lt. brown .026” .252” 1.126” 4 B2/C2 Switch White .028” .297” 1.131” 5 C2 Relay Pink .024” .275” 1.071” 6 C3 Signal Lt. brown .026” .252” 1.126” 7 B1 Signal Pink .024” .275” 1.075” 8 Secondary regulator Plain .039” .413” 1.582” 9 Sequence White .026” .325” 1.038”

10 Cut back White .026” .325” 1.038” 11 B1-C3 Switch Pink .024” .275” 1.074” 12 B1-C3 Check ball 13 B1-C3 Relay Pink .024” .275” 1.074” 14 Lock-up Relay Lt green .020” .275” 1.054” 15 B1-C3 Control Lt brown .026” .252” 1.126”

REAR CASTING 16 Engine brake 17 Solenoid modulator 2 Plain .052” .389” 1.207” 18 C2 Timing White .028” .295” 1.130” 19 C1 Relay Pink .024” .271” 1.075” 20 Lock-up Control Plain .026” .382” .781” 21 Solenoid modulator 1 Plain .050” .389” 1.207

(4 lower accumulator)

Accumulator diameter .627” Red .040” .308” .921” Red .061” .479” .923”

Accumulator diameter .627” Red .040” .308” .921” Red .061” .479” .923”

Accumulator diameter .785” Lt. blue .062” .430” 1.090” Plain .080” .630” 1.088”

Accumulator diameter .785” Lt. blue .062” .430” 1.090” Plain .080” .630” 1.088”

Large accumulator end diameter .942” Plain .0772” 3.045”

Upper Accumulator dia.785” Plain .080” .635” 1.085” Blue .060” .428” 1.085”

Lower Accumulator diameter .785”

Green .053” .416” 1.056” Green .076” .618” 1.045”

(Inch x 25.4=mm)

AW 6 SPEED FWD


VALVE RELIEF CUP & SPRING REFERENCE

Valve #

Relief Cups & Springs Specification

Valve #

Relief Cups & Springs Specification

1 .392”O.D. White

.247” O.D. .022”wire

.597” free length 10.5 coils

7

Opposite side

TEE relief No color

.370” O.D. .050” wire


2 .312” O.D. Orange

.161” O.D. .015” wire


8

Opposite side

.392” O.D. No color

.203” O.D. .018” wire

.448” free length 9 coils


.161” O.D. .015” wire


9 .393” O.D. White

.247” O.D. .022” wire


4 .392” O.D. White

.246” O.D. .025” wire

.600 free length 10.5 coils

10 .393” O.D. White

.247” O.D. .022” wire


5 .392 O.D. Light Blue .250” O.D. .040” wire



.162” O.D. .014” wire



.250” O.D. .034” wire


12 .393” O.D. White

.247” O.D. .022” wire


TF-81SC FORD/MAZDA

AW 6 SPEED FWD



AF40/AM6; AW TF-80SC VOLVO CITROEN

Year Vehicle Engine Year Vehicle Engine 07-09 XC90 3.2L 06-07 C4

06-09 XC90 4.4L 06 on C5 1.8/2.0L 2.2dsl

08-09 XC70 3.2L 05-07 C6

09 XC60 3.0L 05-07 C8

07-09 580 3.2L 02 on Synergie Transit

07-09 580 4.4L OPEL

SAAB 06-07 Vectra C 2.2/3.2L

06-07 9-3 2.0/2.8L 05-07 Zafira 2.2L

06-07 Axtra G 2.0/2.2L

PEUGEOT 06-07 607 2.2/2.9L FIAT

07 407 06-07 Croma

06-07 307 1.7/2.2L

AW 6 SPEED FWD


TF-80SC; AF-40/AM6

33

31

32

30 SLT

SLC1

SLC2

S1-S2

TCC

SLC3

SLB1

29

Ports in middle check control valve to solenoid. Outside ports check control valve to adjuster. Don’t be surprised at 5” or less on a vacuum test!

AW 6 SPEED FWD


4

3

2

1

TF80SC; AF-40/AM6

AW 6 SPEED FWD


TF-80SC; AF-40/AM6

AW 6 SPEED FWD


5

8

6

7

.392 TEE pink .350” O.D. .042” wire


.392” cup white .246” O.D. .024” wire


.312” cup red .160” O.D. .015” WIRE


TF-80SC; AF-40/AM6 9

AW 6 SPEED FWD


Acc

umul

ator

2

red

sprin

gs

.392

” cup

O

rang

e .2

48” O

.D.

.036

” wire

.6

15 fr

ee

leng

th

7 co

ils

.392

” cup

whi

te

.246

” O.D

. .0

24” w

ire

.595

” fre

e le

ngth

10

.5 c

oils

Acc

umul

ator

2

red

sprin

gs

.392

” cup

whi

te

.246

” O.D

. .0

24” w

ire

.595

” fre

e le

ngth

10

.5 c

oils

TF-80SC; AF-40/AM6

AW 6 SPEED FWD


18A

17

16

15

13

14A

12

11

A=Accumulators. Can be vacuum tested through the cover as well.

19A

No

20

21

22A

23

24

25

TF-80SC ; AF-40/AM6

AW 6 SPEED FWD


.312

” cup

red

.161

” O.D

. .0

16” w

ire

.363

” fre

e le

ngth

.468

” cup

whi

te

.275

” O.D

. .0

18” w

ire

.655

” fre

e le

ngth

26

27

TF-80SC; AF-40/AM6

AW 6 SPEED FWD


TF-80SC; AF-40/AM6

AW 6 SPEED FWD


VOLVO AW 6 SPEED SPRING I.D. Bore # Identification Color Wire dia Spring OD Free Length

MIDDLE CASTING 1 Main pressure regulator Plain .050” .551” 1.495” 2 Sequence valve Lg. blue .028” .326” 1.021” 3 B2/C2 Switch White .030” .299” 1.127” 4 C1 Shift Red .028” .254” 1.100” 5 B1/C3 Control Orange .028” .255” 1.131” 6 B1/C3 Relay Pink .026” .278” 1.055” 7 B1/C3 Check ball 8 B1/C3 Switch Valve Pink .026” .281” 1.075” 9 Manual Valve

REAR BODY WITH 1 ACCUMULATOR 26 Accumulator C1 Plain .087” .771” 3.051” 27 Lock-up control Plain .028” .382” .800”

TOP COVER WITH SOLENOIDS 29 Cut back Lt. blue .028” .322” 1.015” 30 SLB1-B1 Control Plain .034” .258” .739” 31 SLC2-C2 Control Blue .032” .258” .663” 32 SLC3-C3 Control Plain ..034” .258” .739” 33 SLC1-C1 Control Pink .034” .327” .752”

REAR CASTING WITH ACCUMULATORS & END PLATES 11 C2 Relay Pink .026” .283” 1.064” 12 C2 Timing White .029” .298” 1.132” 13 B1 Signal Pink .026” .280” 1.071”

14 Accumulator Outer Plain .083” .633” 1.094” Accumulator Inner White .063” .433” 1.089”

15 Engine brake engagement No spring 16 Accumulator 17 Secondary Regulator Plain .041” .416” 1.595” 18 Accumulator Inner Plain .083” .633” 1.094” 19 Accumulator Outer White .063” .433” 1.089” 20 Solenoid Modulator Plain .052” .393” 1.195” 21 Relay Valve Pink .027” .279” 1.069”

22 Accumulator Outer Green .079” .618” 1.040” Accumulator Inner Green .055” .414” 1.068”

23 Shift Valve Orange .029” .254” 1.130” 24 Solenoid modulator Plain .052” .393” 1.200” 25 TCC Lock up relay Lt. green .023” .273” 1.025”

Note: Valve terminology may differ!

AW 6 SPEED FWD



TF-60SN, 09G, 09M, 09K V.W. AUDI

Year Vehicle Engine Year Vehicle Engine 07 Eos 2.5L 03-06 A3 2.0/3.2L

06-07 Golf 1.9L dsl 06-07 A4 2.0/3.2L

06-07 Golf 2.5L 04-06 Avant, S4 4.2L

06 GTI 2.0L 03-06 TT 1.8/3.0L

05-06 Jetta 1.9L dsl

05-06 Jetta 2.5L SEAT 03-07 Multi-van 2.5/3.2L 06-07 Altea

03 Beetle 1.8/1.9L 06-07 Leon

06-07 Passat 2.0/3.6L 05-07 Toledo

06-07 Polo

05-07 Touran BMW 04 Transporter 06-07 Mini’s 1.6L

Pressure switches used until ‘04.

There are external & case mounted cooler

designs!

The separator plate must match the type of cooler. A7/A6 plate code is case mounted.

F0 is external cooler.

AW 6 SPEED FWD


primary pressure regulator –1

2-secondary pressure regulator

3 G 193

N88

N 89

G 194

N 91 TCC N 93

EPC

7 N 90 K3

6 N 283

B1

5 N 282

K2

4 N 92 K1

8

TF-60SN

Align. pin

Align. pin

Control valve index: Min. .187”-4.74mm Max. .220”-5.58mm From end of casting

Use 2 alignment pins of.238” diameter

AW 6 SPEED FWD


.293” cup red; .160” O.D. .015” wire; .374” free length

.392” cup orange; .249” O.D.; .035 wire;

.694” free length; 6.5 coils

.392” cup white; .246” O.D.; .024” wire;

.595” free length

.312” cup red; .160” O.D.; .015” wire;

.374” free length .392” cup orange; .249” O.D.; .035” wire; .624” free length;

6.5 coils

Relief is not in all TF60 units. No hole in plate=no relief.

Key: Vacuum test location

TF-60SN

AW 6 SPEED FWD


9 10 11 12 13 14 15

19 18 17 16

Rubber check ball .210-.218”

.375” cup white .246” O.D. .024” wire


TF-60SN

AW 6 SPEED FWD


26 27

25

24

23 22

21

20

4 Accumulator pistons on back side. .392” TEE no color; .374” O.D.;

.050” wire; .428” free length

3 coils Line relief at B1/C3 control valve.

25

24

20

21

.392” cup white; .245” O.D. .024” wire


TF-60SN

AW 6 SPEED FWD


.392” cup white .245” O.D. .024” wire

.598” free length

Rubber

.392” TEE green .334” O.D. .030” wire

.793” free length

30

28

29

AW 6 SPEED FWD


Plate ID and

cooler hole area

Main separator plates vary. A6/A7 (pictured above) are used with case mounted cooler FO code has external cooler.

AW 6 SPEED FWD


09G AW6 SPRING I.D. Bore

# Identification Color Wire dia. Spring OD Free Length

SOLENOID/FRONT COVER 1 Primary Regulator Pink .043” .519” 1.450” 2 Secondary Regulator White .046” .410” 1.485” 3 Solenoid Modulator #2 No color .040” .315” 1.00” 4 N-90 K3 Control Pink .036” .325” .800” 5 N-283 B1 Control White .034” .256” .740 6 N-282 K2 Control Dark Red .034” .250” .746” 7 N-92 K1 Control Dark Green .040” .326” .805” 8 Manual Valve

MIDDLE CASTING 9 B2-C2 Switch White .028” .290” 1.140” 10 B1-C3 Switch Pink .024” .270” 1.080” 11 C1 Shift Brown .026” .250” 1.135” 12 B1 Signal Pink .024” .275” 1.075” 13 C1 Relay Pink .024” .275” 1.075” 14 B2 Switch Lt. Green .026” .322” 1.010” 15 Engine Brake No Spring 16 Lock up Relay Lt. Green .022” .275” 1.010” 17 Cut back Lt. Green .026” .322” 1.010” 18 C2 Signal Brown .026” .250” 1.135” 19 C2 Timing White .028” .290” 1.135”

UPPER/FRONT 4 ACCUMULATOR PISTON BODY 20 Check ball 21 B1 Signal Pink .024” .278” 1.085” 22 K3 Accumulator No/Lt. Green .076/.053” .621/.412” 1.050/1.055” 23 B2 Accumulator Lt. Green/Pink .089/.060” .620/.400” 1.0/1.036” 24 B1-C3 Relay Pink .024” .278” 1.073” 25 B1-C3 Control Brown .026” .248” 1.146” 26 K1 Accumulator No color .076” .620” 1.055” 27 K2 Accumulator No color .076/.055” .620/.410”. 1.055/1.046”

UPPER/REAR TCC CONTROL BODY

28 Solenoid modulator Lt. Brown 29 TCC Control Dk. Green 30 Line Pressure Accumulator -

Sm diameter Lg. diameter

No paint No paint

.053” .077”

.412” .618”

1.058” 1.045”

Note: Valve terminology may differ! (Inch x 25.4=mm)

AW 6 SPEED FWD


TC Release on Ford/Mazda

C1

C3

C2

B2 on AF-40, lube on TS80

B2

AF-40 B1

AF-40 TC Re-lease

Pressure Tap Location Ford/Mazda Type Similar in location to AF-40

Cooler return

AW 6 SPEED FWD


PRESSURE TAP IDENTIFICATION 09G

K3

K1

K2 Lube B2 TCC Release

B1

AW 6 SPEED FWD


TYP

ICA

L C

-1 C

LUTC

H P

RE

SS

UR

E (T

ypic

al o

f all

FWD

AW

6)

P, N

19-2

0 C

-1 e

ngag

es

PA

RK

TO

DR

IVE

Poi

nt o

f E

ngag

emen

t, 1.

2 se

cond

s.

Driv

e ac

cele

ratio

n to

1-

2 sh

ift

2-3

SH

IFT

& 3

-4

4-5

5-4,

6-4

4-

3-2

190,

180

ju

st p

rior t

o do

wns

hifts

Am

ount

of l

ine

rise

is to

rque

pro

porti

onat

e.

58-6

1 D

/Idle

225

Stal

l D

rive

AW 6 SPEED FWD


TYP

ICA

L C

-3 C

LUTC

H P

RE

SS

UR

E (A

ll AW

6 FW

D)

PA

RK

P

TO

RE

VS

.75

SE

CO

ND

S

Idle

R

evs.

.

RE

VS

ST

ALL

1ST-

2ND

2-

3, 1

.2 S

EC

ON

DS

3-

4, 1

.2 S

EC

ON

DS

4-

5, 1

.2 S

EC

C-3

pre

ssur

e sp

ikes

to a

ppro

xim

ate

170-

180

on a

ll do

wn

shift

s.

334

max

.

88

AW 6 SPEED FWD


AW6

TYP

ICA

L LU

BE

PR

ES

SU

RE

PA

RK

, RE

V, N

, ID

LE

DR

IVE

EN

GA

GE

1.

5 S

EC

C

OO

L TE

MP

DR

IVE

IDLE

A

T H

WY

S

PE

ED

S H

OT

1-2.

2-3

RIS

E

AT

EA

CH

S

HIF

T

3-4

SH

IFT

NO

RM

AL

5-

8 ps

i TC

C

AP

PLI

ED

AW 6 SPEED FWD


#6-N

93

EP

C L

INE

AR

SO

LEN

OID

(Typ

ical

TF-

60S

N)

PA

RK

-N, R

-N, N

-D

RE

V. S

TALL

TY

PIC

AL

UP

SH

IFT

4TH

CR

UIS

E,

4-5,

5-6

Low

am

pera

ge=

Hig

h pr

essu

re o

r inv

erse

pro

porti

onal

#5 N

92 L

INE

AR

SO

LEN

OID

(Typ

ical

TF-

60S

N)

PA

RK

P

-R

N-D

1,

2, 3

, 4

5-4

FOR

CE

D D

OW

NS

HIF

T 5T

H &

6TH

C

ontro

ls K

-1/C

-1 c

lutc

h.

L

ow A

mp=

Hig

h cl

utch

pre

ssur

e.

AW 6 SPEED FWD


COMMON COMPLAINTS WITH AW 6 SPEED FWD

NOTES:

AW 6 SPEED FWD


Complaint: • Harsh up or downshifts. • TCC slip, fluid overheat • RPM cycling at low speed or coast Cause: • TCC clutch is not releasing or loss of TC modulation control. • Torque converter clutch control valve bore worn and/or secondary regulator valve

bore worn. Diagnostic Procedure: • Monitor converter release pressure to verify the clutch is being controlled. If re-

lease psi remains low (see chart) during up/down shift, the control valve is not stroking. Compare the release pressure to TCC solenoid amperage. For overheated conditions, also monitor cooler flow (see chart).

AW 6 SPEED FWD


Not

e: T

appi

ng re

leas

e pr

essu

re is

a g

ood

met

hod

to v

erify

ope

ratio

n of

#4-

N 9

1 so

leno

id.

T

CC

mod

ulat

es o

ff-on

dur

ing

4-5-

6 ge

ar s

hifts

. Th

is ta

p is

a m

etho

d to

ver

ify T

CC

is a

ffect

ing

shift

qua

lity.

TC

C m

odul

ates

on

afte

r 1-2

shi

ft.

T

CC

cut

off

durin

g Ti

p-Tr

onic

up

& d

owns

hifts

TC

C re

mai

ns o

n du

ring

coas

t dow

n.

If

coo

ler r

elea

se p

ress

ure

is lo

w, c

heck

flui

d le

vel!

AW6

CO

NV

ER

TER

RE

LEA

SE

PR

ES

SU

RE

(Typ

ical

)

STA

RT,

PA

RK,

RE

VS

, N, D

RIV

E ID

LE

RE

VS

. STA

LL

DR

IVE

HA

RD

AC

CE

L.

TCC

AP

PLY

AW 6 SPEED FWD


AW6

CO

NV

ER

TER

RE

LEA

SE

PR

ES

SU

RE

PA

RK

TO

RE

VS

1-

2 U

PS

HIF

T 2-

3 U

PS

HIF

T 3-

4 U

PS

HIF

T 4-

5 S

HIF

T 5-

6 SH

IFT

TO

FULL

TC

C O

N

TC

C s

trate

gy o

f par

tial s

lip b

etw

een

upsh

ifts.

TCC

may

rem

ain

appl

ied

on c

oast

dow

n fo

r eng

ine

brak

ing.

Whe

n co

nver

ter i

s fu

lly a

pplie

d, re

leas

e w

ill b

e –0

-

All

Con

verte

r app

ly &

rele

ase

flow

& p

ress

ure

is c

ontro

lled

by lo

ck-u

p co

ntro

l val

ve a

nd fe

d by

sec

onda

ry re

gula

tor v

alve

,

limiti

ng it

to 1

25 p

si.

AW 6 SPEED FWD


#4-N

91

TCC

LIN

EA

R C

ON

TRO

L S

OLE

NO

ID (T

ypic

al T

F-60

SN

)

PA

RK

, RE

V.,

DR

IVE

1-2

P

OS

T 1-

2 S

HIF

T C

ON

TRO

L S

LIP

FU

LL O

N

DR

OP

DU

RIN

G 2

-3, 3

-4, 4

-5 U

P O

R D

OW

NS

HIF

T

Not

es:

0.2

Am

p =

off

.9/1

.0am

p =

full

on

(E

xam

ple)

; ‘07

TF-

60 J

etta

N

o m

odul

atio

n up

on e

ngag

emen

t int

o P

-R o

r R-D

; can

sta

rt m

odul

atio

n or

con

trol s

trate

gy ju

st a

fter 1

-2 s

hift.

H

ot c

ontin

uous

mod

ulat

ion

durin

g m

aneu

vers

of u

p &

dow

n sh

iftin

g. H

ot c

ontin

uous

mod

ulat

ion

durin

g lif

t thr

ottle

rele

ase.

R

etur

ns to

1.0

Am

p po

st s

hift.

Cut

bac

k to

0.2

(app

roxi

mat

e) in

man

ual T

ip-T

roni

c co

ntro

l shi

fts.

TC

C s

lip v

ery

activ

e at

spe

eds

35-5

0 K

. D

oes

not c

ance

l with

bra

ke p

edal

.

Rem

ains

at 1

.0 A

mp

durin

g co

ast d

own

5, 4

, 3, 2

, 1 fo

r eng

ine

brak

ing.

All

linea

r sol

enoi

ds fo

llow

N 9

1 A

mp

spik

e.

Sug

gest

mon

itor s

lip R

PM w

ith a

mpe

rage

nor

mal

, tra

nsm

issi

on te

mp

is 8

7C a

t 0.7

0 vo

lts.

Max

imum

sta

ll R

PM

, 278

5 in

reve

rse,

bu

t sta

ll te

stin

g is

not

sug

gest

ed.

AW 6 SPEED FWD


AF-

21 ‘0

9 Fu

sion

10K

Coo

l

Hot

Par

k R

ever

se

Idle

R

ever

se

stal

l D

rive

Id

le

Driv

e S

tall

Driv

e 1-

3 TC

C

Can

cel

TCC

Ap

plie

d

Med

. Acc

eler

atio

n

Har

d ac

cele

ratio

n

2.8

TCC

app

lied

on h

ard

ac

cele

ratio

n

Even

t: N

orm

al o

pera

tion

____

____

____

____

____

____

____

____

____

____

____

____

____

____

__

Not

es:

Top

hose

coo

ler r

etur

n___

____

____

____

____

____

____

____

____

____

____

____

____

___

AW 6 SPEED FWD


Complaint: • Flare on 2-3 shift • Harsh engagement • Delay forward or reverse Cause: • Clutch control valves (at solenoid bore) are out of adjustment. Primarily K3/C3 and

or B1. • K3 valve is most active and bore wears quickly. Correction & Diagnosis: Must repair K3/C3 clutch control valve body, then: • Remove oil pan and adjust clutch control valves. Always measure & record the OE

position. • To overcome a flare on 2-3, back out the K3 adjuster which increases apply psi.

You may have to turn in the B1 adjuster to slow down its exhaust rate. Suggest 1/2 to 3/4 turn per test.

• Suggest use of graphing scanner to monitor engine RPM vs. ISS RPM. Should not have spikes in engine RPM during down shift. Engine RPM and ISS #182, sensors should parallel each other. If the engine RPM has spikes at the beginning of shift, clutch pressure is not high/fast enough. If the engine RPM sensor appears to be a square form or dips down during shift, there is a bind up and the opposing clutch (probably B1) may have to be adjusted as well!

Note: On the TF-60SN (VW 09G/09K/09M), the Ross-Tech performs well for this diagnosis. (www.Ross-Tech.com)

AW 6 SPEED FWD


Complaint: • Slippage or loss of 3-4, K-2 clutch failure Cause: • TF-60 series commonly have a cross leak under the case sleeve which feeds

the K-2 clutch. Correction: • Replace the sleeve with an aftermarket with improved retention. Complaint: • Loss of lubrication • Transmission temperature codes • Enable of shift mode I or II Cause: • Incorrect valve body and separator plate for case lube design. • Remote heat exchanger and case mounted cooler use different separator plates. Correction: • Install matching parts. To isolate this (prior to road test) check for cooler flow and

release pressure on the lift. Refer to Sonnaflow® charts. Complaint: • (09M, 09G) Harsh reverse, 3rd or 5th. • Bind up on 3-4 or 3-2. Cause: Damaged K-3 clutch balance piston. This piston acts as a return and accumulator counter acting upon the K-3 apply piston. Correction: • Need to replace the K-3 drum assembly unless pistons are available. • Aftermarket pistons are now available with tabs to eliminate the radial piston move-

ment.

AW 6 SPEED FWD


Complaint: • Post overhaul, flare upshifts or bumpy downshifts Cause: • Failure to reset adapts or relearn strategy has not been completed. Correction: • Reset all control modules. • Perform a drive cycle relearn of 15 shift cycles. Complaint: • Fluid discoloration • TCC clutch failure Cause: • Improper fluid will not control TCC clutch slip rate and dissipate heat. Correction: Suggested fluids • T-IV or 1161540 for Volvo • XT-8QAW-Ford • JW53309-Mazda • 9986195-GM • Mobile 1, ESSO or Castrol full synthetic are aftermarket alternatives Complaint: • No reverse, Loss of gear • Low fluid level Cause: • Solenoid wiring may be incorrect. VW Fill adapter: Some VW applications use a plastic fill elbow that enters above the pan and to the left of front. The number on the part is VW AG-JP57344-02. The case could be bored to accept this fill adapter. It would require drilling the case to .517” ID (13.1mm) to a depth of .487” (12.3mm). At the base of the first bore is a stepped transition to a final bore of .412” (10.4mm)

AW 6 SPEED FWD


Complaint, Cause, Correction Issues

Complaint: • Harsh coast downshifts, harsh upshifts. Cause: • TCC control valve bore and sleeve wear. Bore wear reduces the hydraulic control

of release pressure on the converter piston. The piston remains applied during the shift.

Correction: • Service TCC control bore and sleeve. Complaint: • Flare/long upshifts, gear ratio codes, loss of gear. Cause: • Bore wear at a specific clutch control valve. • Solenoid modulator valve bore worn. • Clutch circuit, relay valve sticking. • SL clutch control solenoid defective or contaminated. • Main pressure regulator bore and/or boost sleeve worn. • Incorrect fluid level. Correction: • Inspect and service in order of above. Complaint: • Delayed forward engagement Cause: • Valve body temperature sensor not registering properly. (Will also affect TCC ap-

ply) • Fluid level incorrect’C-1/ K-1 clutch control valve bore worn or defective solenoid. Correction: • Service C-1/K-1 valve and test thermal element.

AW 6 SPEED FWD


PO 602 Control module programming error PO 710 Oil temperature sensor P0 715 Input revolution sensor PO 720 Output revolution sensor PO 729 Gear ratio 6th PO 731 Gear ratio 1st PO 732 Gear ratio 2nd PO 733 Gear ratio 3rd PO 734 Gear ratio 4th PO 735 Gear ratio 5th PO 736 Gear ratio reverse PO 743 SLU Linear solenoid fault PO 748 SLT Linear solenoid fault PO 753 S2 solenoid fault PO 773 S1 solenoid fault PO 780 Unusual shift, (valve stuck) PO 1743 TCC stuck on or off PO 1981 SLC1 Linear solenoid fault PO 1982 SLC2 Linear solenoid fault PO 1983 SLC3 Linear solenoid fault PO 1984 SLB1 Linear solenoid fault

PO U2100 Series– CAN communication errors

Common Codes

AW 6 SPEED FWD


Relearn

Initial Relearn: If transmission or TCM is repaired or replaced, delete the learned data and perform both Neutral and Initial Learning. If the TCM has been overwritten (reflashed), perform relearn process! 1. Warm up ATF to minimum of 66°C (151°F) and maximum of 110C (230°F). 2. Garage shift:

Brake applied, select N for 3 seconds. Then N to D and allow engagement of C1 for 3 seconds. Repeat 5 times for D-Reverse.

3. Gear shift: Drive 25-35% throttle to obtain 6th gear and hold 80 Kmh. Then coast to a stop within a minimum of 60 seconds. Repeat this cycle 10 times.

Note: Spec for maximum N-D engagement is 1.0, N-Rev is 1.5 sec. Neutral Position Relearn: 1. Vehicle running in Park 2. Release & shift to Neutral 3. Verify N is recognized by TCM on dash & scanner. 4. If not recognized, adjust shifter & input Neutral gear with scan tool.

Documents

TF-80 af-40 6 speed