VW 01M Transmission

Article Title
65535 Error
By: Augie Ferron

Alternator connection

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Refer to the previous article “The VW 01M Speed Sensors” as The 65535 error is a “data corruption fault code” and can also
additional information. Consider this article as a resource and be attributed to a hardware malfunction. The list of possible
guide to test speed sensors, but equally an article as to “what causes is endless but for all intents and purposes, can narrow
can possibly go wrong.” For the learning and uninitiated techs, this fault down to these possibilities in the automotive field:
read the prior version.
Alternator/generator internal malfunction or harness damage.
On occasion there will be situations when a vehicle owner
requests help and/or repair that another repair facility has Vehicle harness/control unit malfunctions such as B+ or
previously diagnosed. This is one of those times when “a deeper B- connections.
look” leads to repairs beyond the scope of the original diagnosis.
Voltage spikes from vehicle boosting, reverse polarity, or stray
secondary ignition voltage.
Special tools used besides hand tools.
90 amp power supply Caution: Test/repair that assumption before installing any
Ross-Tech VCDS control units.
Fluke multi-meter
The 65535 error in most cases will never delete and if that fault
Wiring schematic
was previously recorded, will return quickly if deleted. In this
Additional hand-made harness attachments specific situation, the 65535 error will also mask other errors
Camera and lots of patience that would not be generally recorded. Consider 65535 as a
Force feed transmission oil fill fatal controller fault and requiring replacement. In some and
not all cases “Internal Control Module Memory Error” may
not even record any errors; therefore consider
65535 as one of multiple suspects.

Customer complaint: You may encounter a

situation where a previous shop diagnosed
the 65535 error but the owner noticed the
transmission not shifting correctly and stuck in a
higher gear when driving their Beetle.

Have a look first before any assumptions

65535 error Scan and save the entire network as a primary
baseline. Delete all faults and set basic settings
for throttle. Measure and test the alternator output
and perform an AC ripple test.

Road test if desired but contemplate the 65535

issues as described.

Give the customer the “what if” because of the

65535 issues.

Determine the correct model, transmission code

and sales code with the PR tag. The tag is found
the trunk and a copy is in the maintenance manual.

Identify the vehicle and look at the TCM data

within the scan (next page):
PR code

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01M Transmission 65535 Error

Address 02: Auto Trans Labels: User\01M-927-733.lbl the road test and record all faults. In this case you may note
TCM fault 00264 “solenoid 4 open circuit,” and fnote that
Part No: 01M 927 733 JF
the transmission does not shift correctly. This fault will delete
Component: AG4 Getriebe 01M 4833 with the TCM temperature far cooler than driving temperature.
Coding: 00000 Another road test may produce the same fault. The hotter the
Shop #: WSC 00000 transmission fluid, the longer the open circuit fault will remain.
VCID: 7DFA6B3E7785D9ADDE-0958
Is there another test? To test limp mode with VCDS and stopped
safely, look at the next image. Notice the relationship of where
2 Faults Found: the transmission will begin its driving range.
00300 - Transmission Fluid Temp. Sensor (G93)
34-00 - No Elaboration Available At 0.0 mi/hr, idle rpm and the Driving Mode in 3H with
65535 - Internal Control Module Memory Error NO throttle applied, is definitely Limp Mode. Apply this to
similar transmissions.
00-00 - What else might you find?
Another test can be accomplished by measuring the solenoid
You may find indications of previous sub-standard repair. For harness on top of the transmission case. Solenoid 4 measures
instance, here Marette connections were never used to attach open circuit when hot. Use this image with a schematic to
the harness to the voltage regulator. The possibility of the wires measure each solenoid. Refer to the 01M Speed Sensor article
connected to the incorrect positions was 50-50. The correct as well.
repair is performed by using “crimp and shrink” connectors.
Check Solenoid 4 at pins 1 and 6. Specification: 4.5 to 5.1 ohms.
The battery, alternator and
regulator tests typically prove
within specifications. The final
test is for a parasitic draw and is
also usually within specification.

The next step

The 65535 error will not offer
proper/correct/valued data
during a road test and the
possibility of “limp mode” can
also be quite high.
Solenoid 4 fault
A replacement TCM
(Transmission Control Module) is required to
achieve any form of proper diagnosis.

Cleaning of the inner plenum is vital only because

of the potential for rodents making a nesting bed.
So replace the cabin filter in these cases at all times
because of bacteria and other bodily fluids.

On to the road test.

Prepare the scan tool to either record or have
another technician drive the vehicle and get the
transmission to shift in city and highway driving.
Attempt to look at TCM and ECM faults during
Limp mode

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01M Transmission 65535 Error

Since 65535 errors

can mask other errors,
a working TCM is the
only option to move
forward. In this specific
situation, the working
TCM provides one more
piece to the complaint
of “not shifting” correctly
at times.

Note: Any vehicle of this TCM connection

vintage and with many
miles should be suspect to oil, harness, and solenoid degradation.

A replacement solenoid pack, harness kit, with gasket and filter

is recommended in this case.

Drain and fill

Onward and upward!
The harness connections to the solenoids will self destruct
of oil is a good idea and saved for later inspection with
with plastic particles jammed within the solenoid attachment.
the customer.
Therefore a new kit supplied includes:
• Filter If the decision is to remove the valve body, remember to set
• Solenoid kit (7 solenoids in total) the manual valve. If the decision is to replace the solenoids
in-vehicle, either way make sure there are photo images and
• Harness
place the correct valve in the correct bore.
• Gasket
Install the new harness and route it correctly, install the
transmission cooler with new seals and finish by installing the oil
Not so fast! pan with a new seal.
Solenoids 4 and 6 are measured at 4.5 to 5.1 ohms.
Thread the oil spill port gently and attach the plug. The oil fill
Solenoids 1, 2, 3, 5 and 7 are measured at 55 to 65 ohms. tube can be gently unlocked for access to fill the transmission.

Paying attention now? That is why the fluid is measured; the correct volume can be
The transmission cooler requires added quickly.
removal/lifting off the portion
of the hidden harness. Four
seals are required to remount
the cooler.

Draining and
keeping clean.
On this type of system, the drain
plug can be removed (replace
the gasket) and the plastic
spill port is removed as well.
Generally, measuring the volume Solenoid 7 fault

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Proper filling is with VCDS and measuring the fluid temperature Back to step one
at 95 degrees F (35 degrees C) maximum (check your specs) Pin 1 = B+ supply to solenoids 1, 2, 3, 4, 5, 7 and
while the engine is running and drain plug removed. When the Temperature Sensor
fluid spills/drips from the open port, the level is correct. Insert the
plug. Simple enough? Not quite! Pin 2 = B+ supply to solenoid 6
Pin 3 = B- signal to solenoid 1
What if the car is still on the hoist and solenoid 7 has an Pin 4 = B- signal to solenoid 2
open circuit? Pin 5 = B- signal to solenoid 3
Pin 6 = B- signal to solenoid 4
Pin 7 = B- signal to solenoid 5
Pin 8 = B- signal to solenoid 6
Pin 10 = B- signal to solenoid 7
Pin 12 = Temperature signal return

Pins 1 and 10 are measured and the value is open circuit, so a

replacement harness and solenoid are the fix here.

The tests and learning lesson – for the uninitiated.

Measure twice, cut once!

1. The drain plug and spill port is removed, capturing the fluid.
2. Pan removed and harness disconnected at solenoid 7.
3. Measured from the transmission end harness to the
solenoid harness.
4. Found an open circuit in new harness.
5. Solenoid 7 is the one in white. (See image Solenoid 7
on the left.)
Solenoid 7

Harness test 2 Harness test one

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01M Transmission 65535 Error

Note the temperature sensor attached to the foil strip below the ball valves control the volume of fluid when force feeding
solenoid 7. through small ports.

The control of each ball valve also allows the fill side to remain
Double check closed but the spill side open to watch for the drip at the
Measure the replacement harness and ensure connectivity by temperature with VCDS. n
using a snug fitting pair of wires (female) and correctly sized
male end to the solenoid ends of replacement harness.

Using the TCM Connection image and PIN location description,

the harness and solenoids can be measured in-vehicle to
determine if all the solenoids are connected and the harness
is intact. Follow the next series of steps to double check the
replacement components before assembly.

Using a high quality multi-meter, measure the entire harness

according to the wiring schematic to confirm that the
replacement harness passes the continuity test.

Since the two blue female wires fit the round pins, the next test
is after the assembly onto the valve body. The test can be done
in-vehicle using the same pin layout described earlier. Measure
with an ohmmeter or with 12 volts.

Note: These are 12 volt solenoids and can be tested with a

voltage supply to the correct B+ and B- connections. Audible
clicking should be heard by applying power or ground
intermittently to the individual solenoids.
Harness test two
Hint: By increasing or decreasing resistance with a decade box,
the TCM can be fooled into different temperature
variances at pins 12 and 2. That test would prove out
a defective transmission oil temperature sensor within
the transmission strip harness.

Replacement harness under test with made up

harness to fit both ends.

Install in the reverse order and ensure the harness

is tight and routed correctly. Refill the transmission
again and, with VCDS, setting the correct oil level,
against transmission oil temperature.

How many ways to fill transmissions of this style?

Gravity feed tends to be a bit slow, a hand pump is
too much work but this one is air regulated with two
ball valves.

That will also mean that, with the correct adapter

and coupler, different styles of fill ports can be fitted
Transmission filler
to one basic tool. 5 psi is enough pressure and

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