6-speed manual gearbox 02M - VolksPage.Net

Service.

Self-Study Programme 205

6-speed manual gearbox 02M

Design and Function

Adapting modern automobiles to meet the rapidly growing demands on driving comfort, environmental compatibility and driving performance calls for advanced improvements in gearbox technology. Adding more gears means smoother running and enables the gearbox to be adapted better to the characteristics of the various engines; it also contributes indirectly to reducing exhaust emissions by enabling torque to be utilised more effectively.

6-speed manual gearbox 02 M is a new development. It is a compact gearbox with six forward gears for A-platform vehicles with transversely mounted engine.

A compact 6-speed gearbox was realised by using two output shafts and one input shaft. In this booklet, we will explain to you the new gearbox and the technology used.

NEW

The Self-Study Programme is not a Workshop Manual.

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Please always refer to the relevant Service Literature for all inspection, adjustment and repair instructions. Service Literature.

205_052

Important Note

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Gearbox mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Power transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cable-operated gearshift mechanism . . . . . . . . . . . . 14 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Introduction

How many gears does a car need?

There are many reasons for introducing gearboxes with more than five forward gears. Most importantly, it is a way to match the gearbox and the engine even better than before. A second major reason is that the gearbox can help make modern vehicles more environmentally friendly.

Why a 6-speed gearbox?

6-speed gearboxes have the following advantages over 5-speed gearboxes:

- More driving comfort (e.g. through smoother running),

- Better environmental compatibility (low fuel consumption = lower exhaust emissions),

- Better torque utilisation (the engine runs more in the "efficient torque" band),

- 6-speed gearboxes allow engines with a high power output to be driven sportily.

Depending on the engine type used, a distinction is drawn between two modes:

- A sporty mode for engines with high power output to quickly transfer high input torque,

- A comfortable mode for exceptionally smooth running, which is achieved thanks to more balanced and even transfer of input torque.

What engines will be equipped with this gearbox in model year 1999?

- 1.9-ltr. 66kW TDI engine - 1.9-ltr. 85kW TDI engine - 1.9-ltr. 110kW TDI engine

- 1.8-ltr. 132kW 5V turbocharged engine - 1.8-ltr. 165kW 5V turbocharged engine - 2.3-ltr. 125kW V5/4V engine - 2.8-ltr. 150kW VR6/4V engine

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Specifications

- Gearbox designation: - Forward gears: - Reverse gears: - Maximum input torque: - Method of installation: - Gear oil: - Weight:

02 M 6 1 350 Nm Transverse mounting DEA DES-5080 48.5 kg (front-wheel drive) 68 kg with angle drive (four-wheel drive)

Ratios and layouts

We do not intend to present all the possible variants here, as this would be beyond the scope of this booklet. Instead, we will explain the principle by which the gearbox ratio is calculated using two examples:

1st gear/drive pinion set I 2nd gear/drive pinion set I 3rd gear/drive pinion set I 4th gear/drive pinion set I 5th gear/drive pinion set II 6th gear/drive pinion set II Reverse gear/drive pinion set II Ratio, drive pinion set I Ratio, drive pinion set II Mode

Engine

2.8-ltr. 150kW VR6 / 4V

Ratio

Overall ratio

41 : 12 = 3.417

14.351

40 : 19 = 2.105

8.841

40 : 28= 1.429

6.002

37 : 34 = 1.088

4.470

34 : 31 = 1.097

3.640

31 : 34 = 0.912

3.024

(30 : 12) * (23 : 14) = 4.107

13.620

63 : 15 = 4.200

63 : 19 = 3.316

sport

1.9-ltr. 85kW TD Ratio 41 : 11 = 1 : 3.818 40 : 19 = 1 : 2.105 39 : 29 = 1 : 1.345 35 : 36 = 1 : 0.972 32 : 33 = 1 : 0.970 29 : 36 = 1 : 0.806 (31 : 11) * (23 : 14) = 4.630 68 : 21 = 3.238 68 : 26 = 2.615 comfort

Overall ratio 12.363 6.816 4.360 3.147 2.537 2.108 12.108

For a gearbox with two output shafts, the overall ratio comprises two factors: firstly, the ratio of the input shaft to the output shaft (you will find this value in the table under Ratio). Secondly, the ratio between the output shaft and the differential.

For reverse gear, the ratio of the reverse shaft must still be taken into consideration, so the ratio comprises two values.

The ratio for a particular gear multiplied by the ratio for a particular drive pinion set gives the overall ratio for the gear. This value is printed in bold in the table.

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