SSP 237 Manual gearbox 02T [48s].pdf

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Service.
Self-Study Programme 237
Manual gearbox 02T
Design and Function
The 02T 5/6-speed manual gearbox
237_010
Gearbox design
With the new 02T 5/6-speed manual gearbox of
the MQ200 series, Volkswagen has succeeded
in developing an ultra-light twin-shaft gearbox.
The housing is manufactured from magnesium.
The gearbox can transmit up to 200 Nm of
torque and is used throughout the Group in
combination with various engines ranging from
the A00 class to the A class.
The final drive ratios and the ratios of the
individual gears can be matched to the power
outputs of the various engines.
The type diversity within the gear and final drive
ratios allows an optimum compromise to be
found between sporty and economical gearbox
design for all automotive applications.
The gearbox is operated by means of selector
cables. The clutch control is hydraulic.
The development goals for the new gearbox
were as follows:
–
–
–
–
–
Easy and exact gear-changes
Optimal efficiency
Low weight
Modular technology
Standard cable-operated gearbox
New
Important
Note
The Self-Study Programme
is not a Workshop Manual!
Please always refer to the relevant Service Literature
for all inspection, adjustment and repair instructions.
2
Table of contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Modular system
Gearbox mechanicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gearbox design
Input shaft
Output shaft
Bearing support
Double synchronisers
Differential
Force path
Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Outer selector mechanism
Inner gear change mechanism
Selection movement
Shift movement
Reverse gear lock
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-speed-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Gearbox design
Modifications to the 5-speed version
Force path
Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3
Introduction
The modular system
Individual modules are assembled in modular
form.
This increases their functionality after assembly
in series production and in the service workshop.
The modules are:
Clutch release lever
This module contains the clutch release lever, the
release bearing and the guide sleeve.
237_040
Clutch release lever
Selector shaft
Selector
mechanism cover
Selector shaft with selector mechanism cover
All blocking detent, spring and guide elements of
the selector mechanism, as well as the angle
piece for adjustment of the selector mechanism
are accomodated in this module.
Shift finger
237_041
Angle piece
Inner
selector mechanism
The inner selector module
with shift forks, selector plates and bearing.
Bearing
support
237_042
Input shaft
The bearing support
with the two grooved ball bearings and pre-
assembled powertrain and output shaft.
Output shaft
237_043
4
The housing
is made from magnesium and consists of 2 parts
(gearbox housing, clutch housing).
The gearbox housing is sealed off from the
exterior by a cover.
The fixing points for the left assembly mounting
bracket are located at the top of the gearbox
housing. The attachment points for the self-
aligning bearing support are located at the
bottom of the gearbox housing.
In comparison with aluminium, magnesium has a
lower density and therefore also lower strength.
This was compensated for by thicker ribbing and
increased wall thickness.
The result is a mass reduction of 2.5 kg
compared to the conventional aluminium
construction.
The lower material density of the
housing necessitates increased
bolt screw-in depths.
To protect the housing against
electrochemical degradation, the
bolts are coated (see SSP 192,
page 36/37).
Fixing points for
assembly mounting
Gearbox housing
cover
Clutch housing
Gearbox housing
237_039
5

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