Vehicles Affected





-> Replacing the Valvebody on JF011E

-> Audi RS6 fitted with a ZF 5HP24 FLA

-> Range Rover fitted with GM 5L40E

-> Double Clutch Transmission

-> Malfunctions on the Direct Shift Transmission


 

Replacing the Valvebody on JF011E

Fitted to Nissan, Mitsubishi and Dodge Vehicles

The JF011E valvebody has a calibration (ROM) chip fixed to the side. This ROM has information that is recognised by the TCM and needs to be replaced by the ROM from the original valvebody from the car or, if damaged, the new one can be programmed by Chrysler. However, if you are working on a Nissan or Mitsubishi you will need to order a new ROM from the dealer using the VIN.

 

Audi RS6 fitted with a ZF 5HP24 FLA

Take extra care when replacing the transmission oil filter. The pick-up spout is slightly shorter than the standard filter. If the filter with the slightly longer spout is fitted it may cause loss of drive and torque converter trouble codes.

 

Range Rover fitted with GM 5L40E

Total loss of drive because transfer unit has gone into failsafe mode.

If a vehicle comes in with no drive and the "Hill descent light is on" check fuse number 37 (Passengers side). These should have been removed after their PDI check but some vehicles slipped the net.

With ignition off:

  • Remove fuse no 37
  • Start engine (foot on brake)
  • Flick Transfer unit switch to low and then to high
  • Move gear lever into gear
  • This should re-set the transfer unit .
  • Discard the fuse (this mode was only used to transport the new vehicles).

 

Double Clutch Transmission

What is a Double Clutch Transmission?

For several years the double clutch transmission (DCT) has been used in volume production at the Volkswagen Group. Since 2003 a number of successive models have been equipped with the 6-speed version which features a wet double clutch. Since 2008, models with engine torque of up to 250 Nm have been equipped with the new 7-speed DCT with dry double clutch.

State-of-the-art transmission concepts are designed to incorporate the advantages of automatic manual gearboxes. Automatic transmissions offer superb driving comfort thanks to automated gear shift and uninterrupted traction while manual transmissions are sporty, fun and economical. Both the 6-speed and 7-speed versions of the DCT offer these benefits. The DCT is an automated shift gearbox featuring two gear sets which operate independently of each other, thereby enabling fully-automatic gear shift without traction interruption. There is no clutch pedal, and the conventional gear lever has been replaced with a lever with integrated Tiptronic function.

How it works.

Both the dry and wet versions have two gear sets and two clutches. Each of the clutches is assigned a gear set. They are operated alternately when changing gears, making traction interruption a thing of the past.

The 6-speed gearbox uses a wet double clutch which is immersed in the gearbox oil. This design offers excellent cooling performance as the transmission oil immediately absorbs heat. Additionally, it requires little installation space and is able to transmit higher engine torque. This is why the wet double clutch is predominantly used with high-torque engines. But there are also drawbacks: high drag losses due to the wet clutch, a requirement for high-capacity hydraulic pumps and time-consuming repairs.

 

Malfunctions on the Direct Shift Transmission

7-Speed Transmission with Dry Double Clutch

Manufacturer: VW

Models:

Scirocco(137)

Passat CC(357)

Golf Plus(5M1/521)

Golf/Jetta(1K/5K1)

Touran(1T)

Transmission:

0AM


 

In the direct shift transmission, the gear is changed by the mechatronics. The mechatronics consist of a control unit and an electrohydraulic control unit. The integrated hydraulic pump is electrically driven and provides an operating pressure of 70 bar. As a result of the increased power required by the hydraulic pump, a fuse must be used that is designed for a high continuous load.

A 30A fuse is installed ex works for the power supply to the mechatronics. In individual cases, it is possible that an incorrectly dimensioned 15A fuse may have been installed, which could cause a range of malfunctions on the direct shift transmission.

The following error memory entries may have been stored in the transmission control unit:

  • P0562/21148
    Supply Voltage for the electric motor is too low
  • P177F/21065
    Unacceptable high voltage drop in the electric motor
  • P175F/21098
    No valid basic calibration for the transmission
  • P189C/21247
    Accumulator diagnosis not possible
  • P174A/21108
    Valve open load coupling

In the event of malfunctions on the direct shift transmission, first check whether a functioning 30A fuse has been installed for the power supply to the mechatronics. The precise installation location of the fuse depends on the vehicle and can only be located using the current flow diagram or the on-board literature. Faulty or incorrectly dimensioned fuses must be replaced.

A 30A fuse is essential for the direct shift transmission to operate without any malfunctions.
Observe the specifications of the vehicle manufacturer.