Description

Aisin Warner Touareg, Q7, Cayenne 2010 Service Manual – Factory-Level Rebuild Guide for the TR60SN/09D

You pull a TR60SN out of a Cayenne, valve body is fried, solenoids are full of debris. The local parts store hands you a universal manual that says “typical values are…” That’s not acceptable. You need the factory spec for line pressure, clutch clearances, and solenoid resistance. This Aisin Warner Touareg, Q7, Cayenne 2010 Service Manual gives you exactly that – 136 pages of data from the people who built the transmission. Aisin Warner designed this six-speed for the Volkswagen Group, and ATSG printed it with full cooperation from Volkswagen. If you want to rebuild it right the first time without chasing ghosts, this is the document you want on your bench.

What This Manual Covers: From Application Chart to Torque Converter

The first six pages lay out the basics you’d expect: general description, vehicle application chart (page 3), component application chart (page 4), and identification tag location (page 5). These are not filler – they tell you which clutch pack count and planetary setup your specific application uses. The Touareg, Q7, and Cayenne all use the same basic gear train, but the number of friction plates varies with engine torque. Skip the identification step and you could end up with wrong parts. The manual also covers fluid type and check procedure (page 6). Use the spec listed there – don’t guess with aftermarket fluid.

Pressure Specs and Tap Locations – Page 26 and 27

Line pressure is everything in a TR60SN. Page 26 has the exact pressure specifications for each gear range in psi. Page 27 shows the pressure tap locations on the case. I’ve seen guys use generic pressures from the internet and wonder why the shift quality is garbage. This manual gives you the numbers for the specific valve body version. You’ll also find oil passage identification on page 28, which helps when you’re chasing a clogged feed.

Solenoid Identification and Failure Modes

This transmission uses a bunch of solenoids, and they’re not all the same. Pages 10 through 13 cover solenoid locations, individual function, failure results, and application chart. The resistance charts on pages 17 and 18 – case connector and TCM connector – are gold. Test every solenoid with a DVOM before reassembly. I’ve been burned by one dead shift solenoid that passed a visual check. Factory ohms values here are dead accurate.

Rebuilding the TR60SN: Case, Clutches, and Planetary Assemblies

Starting on page 31, the manual walks through complete transmission disassembly. Then it goes into component rebuild sections: case assembly (page 52), K2 clutch housing (57), output shaft and rear ring gear (62), rear planetary (65), F1 sprag (66), sun gears and thrust bearings (68), K1 clutch housing (71), K3 clutch housing (75). Even the torque converter operation differences between 2-port and 3-port are explained on page 79 – that’s critical if you’re ordering a replacement converter. Oil pump differences (page 80) and turbine shaft differences (page 81) prevent mix-ups. The front planetary assembly (page 82) and valve body assembly (page 91 onward) are covered with the same level of detail. You get the OEM clearances and snap ring thicknesses – no aftermarket guessing.

Who Needs a Factory-Level Rebuild Manual?

If you’re a home garage enthusiast with a lift and a transmission jack, and you’ve done a couple of front-wheel-drive units, this one is a step up. The TR60SN is big and heavy – about 200 lbs with fluid. You need a solid bench, a dial indicator, and a torque wrench that reads to 10 ft-lb increments. Professional shop owners should have this on the shelf for the Cayenne and Q7 jobs that roll in. DIY mechanics who want to save the $4,000 rebuild cost – read every page. Then read it again. This manual does not hold your hand through basic tool use, but it gives you the numbers. That’s what you’re paying for.

Source Authenticity: ATSG and Volkswagen Cooperation

This is not a random aftermarket PDF. It’s the 1st printing from September 2010 by Automatic Transmission Service Group (ATSG), with technical input from Volkswagen engineers. The copyright page credits Wayne Colonna, Peter Luban, and ten other consultants who know this gearbox inside out. You get the same data that dealer techs used. Automotive Industry Overview sources like this confirm that OEM cooperation produces reliable documentation. Compare that to a third-party reprint with blurry diagrams and speculative torque values. Automotive Industry Overview also notes that factory-sourced manuals reduce comeback rates. I trust ATSG because they’ve been around since the 80s and they don’t print fluff.

Page 79. That’s where you find the torque converter differences. Don’t skip it.

If you’re working on other Aisin transmissions, the Aisin Warner 50-42LE 2004 Service Manual – Factory Specs for Volvo, Saab, Daewoo covers a different family. For VW Transporter applications, the Aisin Warner Golf Touran New Beetle Transporter Passat Training Manual 72 Pages provides supporting training material. And for non-transmission jobs, the White Outdoor LT-5 700 Series 2005 Service Manual – OEM Factory Specs is an example of proper documentation.

Frequently Asked Questions

Does this manual include the torque converter lockup clutch clearance specs?

Yes. Page 79 covers the “Torque Converter Operation, 2-Port and 3-Port Differences” including lockup clutch specifications. Use those numbers.

Are the solenoid resistance values given in the manual?

Yes, pages 17 and 18 provide case connector and TCM connector internal component resistance charts. You get exact ohm values for every solenoid and sensor. Do not trust aftermarket charts – they often get pinouts wrong. This manual lists the exact resistances for each circuit, so you can verify with a DVOM before bolting the valve body back in. If a solenoid reads out of spec, replace it. No guesswork.

Can I use this manual for a 2011 Audi Q7?

This manual is specifically for the 2010 model year. Later years had running changes. Use it as a baseline, but cross-reference with updated bulletins.

What specialty tools are required for the rebuild?

You’ll need a transmission jack, snap ring pliers, a dial indicator with magnetic base for endplay checks, a torque wrench that reads in inch-pounds and foot-pounds, and a press for bushing and bearing replacements. The manual does not list tool part numbers, but it shows where each tool is used. For clutch pack clearance you need feeler gauges. For oil pump alignment, a straightedge and feeler gauge set. This is not a beginner job without proper tools.

You can spend a week chasing down the right specs from forum posts and questionable PDFs, or you can have this manual open on the bench while you work. The factory data is here – pressure specs, solenoid tests, clutch clearances, and every step of the rebuild. If you’re ready to get this transmission on the bench and open it up with manufacturer-sanctioned numbers in hand, access the factory manual.