09K TF-61SN Transmission Master Rebuild Kit VW T5

The 09K is the Aisin TF-61SN six-speed that VW put behind the 2.5 five-cylinder and the 2.0/2.5 TDI in the T5 Transporter, Multivan and Caravelle from 2003 through 2015. It is a solid unit, but the B clutch and the K1 pack cook after 120,000 miles of loaded van work, and once the frictions glaze you get a flare on the 2-3 and a shudder holding lockup on grade. Once you are that far in, you are pulling the unit anyway - so it gets everything new, not a filter and a prayer.

This is a master overhaul kit for that unit: friction plates, steel plates, the full seal and o-ring set, gaskets, and the bonded pistons and lip seals that harden and start bypassing. Cross-references 09K, TF-61SN, TF61-SN and the 09K321011H, 09K321015D, 09K321021R and 09K321025F casting and service numbers, so it covers the running changes VW made across the T5 and T5.1 build years.

On the bench: strip the unit, clean and air-check every drum before anything goes back together, and measure clutch pack clearance with a dial indicator as you stack - do not assume the new frictions land at the same height as what came out. Soak the frictions in fresh ATF for at least 20 minutes before assembly. The 09K is sensitive to valve body bore wear, so inspect the body while the case is apart; a fresh clutch pack will not fix a leaking pressure regulator or a worn TCC bore.

This is a rebuild kit, not a solenoid or valve body kit. It does not include the filter, the pan gasket, the torque converter, or hard parts. Fluid is separate - the 09K takes a specific Aisin-spec ATF and a level-set fill through the check plug at temperature.