大眾自學(xué)手冊02t手動(dòng)箱

1、Service.Self-Study Programme 237Manual gearbox 02TDesign and FunctionThe 02T 5/6-speed manual gearbox237_010Gearbox designWith the new 02T 5/6-speed manual gearbox of the MQ200 series, Volkswagen has succeededThe type diversity within the gear and final drive ratios allows an optimum compromise to b

2、e found between sporty and economical gearbox design for all automotive applications.in develoan 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 fro

3、m the A00 class to the A class.The gearbox is operated by means of selector cables. The clutch control is hydraulic.The development goals for the new gearbox were as follows:The final drive ratios and the ratios of the individual gears can be matched to the power outputs of the various engines.Easy

4、and exact gear-changes Optimal efficiencyLow weight Modular technologyStandard cable-operated gearboxNewImportant NoteThe Self-Study Programmeis not a Workshop Manual!Please always refer to the relevant Service Literaturefor all inspection, adjustment and repair instructions.2Table of contentsIntrod

5、uction4Modular systemGearbox mechanicals6Gearbox design Input shaft Output shaft Bearing supportDouble synchronisers DifferentialForce pathSelector mechanism16Outer selector mechanism Inner gear change mechanism Selection movementShift movement Reverse gear lockService . . . . . . . . . . . . . . .

6、. . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246-speed-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gearbox designModifications to the 5-speed version Forc

7、e path26Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303IntroductionThe modular systemClutch release leverIndividual modules are assembled in modular form.This increases their functionality after assembly in series production and in the service workshop.The mo

8、dules are:237_040Clutch release leverSelector shaftThis module contains the clutch release lever, the release bearing and the guide sleeve.Selector mechanism coverSelector shaft with selector mechanism coverAll blocking detent, spring and guide elements of the selector mechanism, as well as the angl

9、e piece for adjustment of the selector mechanism are accomodated in this module.Angle pieceShift finger237_041Innerselector mechanismThe inner selector modulewith shift forks, selector plates and bearing.Bearing support237_042Input shaftThe bearing supportOutput shaftwith the two grooved ball bearin

10、gs and pre- assembled powertrain and output shaft.237_0434The housingisfrom magnesium and consists of 2 partsIn comparison with aluminium, magnesium has a lower density and therefore also lower strength. This was compensated for by thicker ribbing and increased wall thickness.(gearbox housing, clutc

11、h 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.The result i

12、s 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 electrochemical degradation, the bolts are coated (see SSP 192, page 36/37).Fixing points for assembly mountin

13、gClutch housingGearbox housing coverGearbox housing237_0395Gearbox mechanicalsGearbox designReverse idler gearGearbox housing coverThe 02T manual gearbox is a compact gearbox for 5-speed front wheel drive.It is a twin-shaft gearbox with an additional axle for reverse gear.The gears on the input and

14、output shafts are helical-cut and continously in mesh.All change gears run in needle bearings to ise smoothness.Gearbox housingThe reverse gear is straight-cut.The 1st and 2nd gears are engaged on the output shaft and the 3rd, 4th and 5th gears are engaged on the input shaft.6When reverse gear is se

15、lected, the reverse idler gear is engaged on a separate shaft between the input and output shaft, and the direction of rotation the output shaft is changed.All forward gears are synchronised. 1st and 2nd gears have double synchronisers.Torque is transmitted to the final drive gear, and therefore als

16、o to the differential, via the output shaft gear.Clutch housingClutch release leverInput shaftOutput shaftOutput shaft gearDifferentialFinal drive gear237_0047Gearbox mechanismThe input shaftis mounted in a bearing assembly in the gearbox housing together with a cylindrical roller bearing in the clu

17、tch housing (loose bearing) and with a grooved ball bearing (fixed bearing).For mass reduction, the input shaft has a deep bore.237_031Change gear, 5th gearSynchromesh body, 5th gearChange gear, 3rd gearGearing, 1st gearGearing, 2nd gearChange gear, 4th gearDeep bore for mass reduction237_032Gearing

18、, reverseCylindrical roller bearingLocking ringBearing support with grooved ball bearingSynchromesh body, 3rd/4th gearThe 1st, 2nd and reverse gear wheels are connected positively to the input shaft.The synchromesh body of 3rd/4th gear and 5th gear are connected positively to the input shaft via a l

19、ongitudinal grooved spline.The 3rd, 4th and 5th gear wheels are loose and run in needle bearings.After one of the gears is engaged, the corresponding idler gear is also connected to the input shaft.Locking rings hold the gears in position.8The output shafthas a fixed / idler bearing.As with the inpu

20、t shaft, the output shaft runs in bearings in the gearbox housing together with a cylindrical roller bearing (idling) in the clutch housing together with a grooved ball bearing (fixed) which is mounted together with the input shaft in the bearing assembly.For mass reduction, the output shaft is holl

21、ow- drilled.237_033Change gear, 1st gearChange gear, 2nd gearGear wheel, 3rd gearGear wheel, 5th gearGear wheel, 4th gearBore for mass reduction237_034Locking ringBearing support with grooved ball bearingFinal drive gearSynchromesh body, 1st/2nd gearCylindrical roller bearingThe 1st and 2nd gear whe

22、els are idler gears and run in needle bearings on the output shaft.The 3rd, 4th and 5th gear wheels and the synchromesh body for 1st/2nd gear are positively connected to the output shaft in thedirection of rotation by means of gear teeth.-spacedLocking rings hold the gears in position.9Gearbox mecha

23、nismThe bearing supportNewThe modular design is a new feature of the gearbox layout.A module of this type is the bearing support with the two grooved ball bearings.The grooved ball bearings are not mounted directly in the gearbox housing, they are seated in a separate bearing support.237_035Bearing

24、supportInput shaft The complete shaft and gear packet of the input and output shaft is pre-assembled outside the gearbox housing in the bearing support and, thus, can easily be installed in the gearbox housing.237_036Output shaftFor repair work, the bearing support together with the two grooved ball

25、 bearings is replaced completely.See also the instructions in the Workshop Manual.10Bearing supportForm diskGrooved ball bearingSealSealCollar237_037237_038The two grooved ball bearings for the fixing the input and output shafts are an integral part of the compact bearing support and are press- fitt

26、ed in it.The grooved ball bearings are protected abrasion residues in the gearbox oil by separate radial sealing rings.The bearing support, with its spectacle type collar, is press-fitted in the gearbox housing and secured to the gearbox housing with six bolts.The grooved ball bearings are located i

27、n the design position using a form disk. The form disk is welded onto the bearing support.11Gearbox mechanismDouble synchroniser for 1st/2nd gearBefore a gear on the input shaft is engaged with a gear on the output shaft through the synchromesh body and the sliding sleeve, it is first of all necessa

28、ry to synchronise the gears.The gears are synchronised during the gearshift via a taper on the gear and on the sliding sleeve of the synchromesh body.237_023This near-doubling of the area of the tapered friction face increases synchroniser performance by approx. 50 % and almost halves the shifting e

29、ffort required.The result is an improvement in operating comfort during down-changes from 3rd gear into 2nd gear and from 2nd into 1st gear.237_021Change gear, 2nd gearSliding sleeveChange gear, 1st gearSynchromesh bodyfor 1st and 2nd gearThe double synchronisers for each gear consist ofa synchronis

30、er ring (inner) a tapered ringa synchroniser ring (exterior).237_022Inner synchroniser ringOuterChange gearInner taper fortapered ringOuter synchroniser ringsynchronisation12The differentialIs combined with the manual gearbox to form a unit.It is mounted in two optimised tapered roller bearings in t

31、he gearbox and clutch housing.Two oil seals with different diameters seal the housing off from the exterior at the flange shafts.The final drive gear is riveted to the differential housing and paired with the output shaft gear.237_027After replacing components, the differential is required to bejust

32、ed axially in the clutch housing with an adjusting disc. Refer to the relevant Workshop Manual for instructions!Output shaft gearFinal drive gearClutch housingGearbox housingDifferential housingAdjusting discFlange shaft, right237_028Flange shaft,leftOil sealTapered roller bearingsOil sealSegments for speed reductionTapered roller bearings13Gearbox mechanismForce path1R237_011237_0052237_019237_0061435237_007237_009The force path in the gearboxEngine torque is transferred to the gearbox via the input shaft.In accordance with the gear selected, the torque is transferred via the relevant