6-speed Manual Gearbox 02M - VolksPage
Service.Self-Study Programme 2056-speed manual gearbox 02MDesign and Function
Adapting modern automobiles to meet therapidly growing demands on driving comfort,environmental compatibility and driving performance calls for advanced improvements in gearbox technology. Adding more gears meanssmoother running and enables the gearbox to beadapted better to the characteristics of thevarious engines; it also contributes indirectly toreducing exhaust emissions by enabling torqueto be utilised more effectively.6-speed manual gearbox 02 M is a newdevelopment. It is a compact gearbox with sixforward gears for A-platform vehicles with transversely mounted engine.A compact 6-speed gearbox was realised byusing two output shafts and one input shaft. Inthis booklet, we will explain to you the new gearbox and the technology used.205 052NEWThe Self-Study ProgrammePlease always refer to the relevant Service Literatureis not a Workshop Manual.for all inspection, adjustment and repair instructions.Service Literature.2ImportantNote
ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Gearbox mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . 7Installation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Power transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Cable-operated gearshift mechanism . . . . . . . . . . . . 14Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . 243
IntroductionHow many gears does a car need?There are many reasons for introducing gearboxes with more than five forward gears. Mostimportantly, it is a way to match the gearbox andthe engine even better than before. A secondmajor reason is that the gearbox can help makemodern vehicles more environmentally friendly.Why a 6-speed gearbox?Depending on the engine type used, a distinctionis drawn between two modes:- A sporty mode for engines with high poweroutput to quickly transfer high input torque,- A comfortable mode for exceptionally smoothrunning, which is achieved thanks to morebalanced and even transfer of input torque.6-speed gearboxes have the following advantages over 5-speed gearboxes:- More driving comfort (e.g. throughsmoother running),- Better environmental compatibility(low fuel consumption lowerexhaust emissions),- Better torque utilisation(the engine runs more in the “efficient torque”band),- 6-speed gearboxes allow engines with a highpower output to be driven sportily.What engines will be equipped with this gearbox in model year 1999?4-1.9-ltr. 66kW TDI engine1.9-ltr. 85kW TDI engine1.9-ltr. 110kW TDI engine-1.8-ltr. 132kW 5V turbocharged engine1.8-ltr. 165kW 5V turbocharged engine2.3-ltr. 125kW V5/4V engine2.8-ltr. 150kW VR6/4V engine
Specifications-Gearbox designation:Forward gears:Reverse gears:Maximum input torque:Method of installation:Gear oil:Weight:02 M61350 NmTransverse mountingDEA DES-508048.5 kg (front-wheel drive)68 kg with angle drive (four-wheel drive)Ratios and layoutsWe 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:Engine2.8-ltr. 150kW VR6 / 4VRatio1st gear/drive pinion set I41 : 12 3.4171.9-ltr. 85kW TDOverall ratioRatio14.35141 : 11 1 : 3.818Overall ratio12.3632nd gear/drive pinion set I40 : 19 2.1058.84140 : 19 1 : 2.1056.8163rd gear/drive pinion set I40 : 28 1.4296.00239 : 29 1 : 1.3454.3604th gear/drive pinion set I37 : 34 1.0884.47035 : 36 1 : 0.9723.1475th gear/drive pinion set II34 : 31 1.0973.64032 : 33 1 : 0.9702.5376th gear/drive pinion set II31 : 34 0.9123.02429 : 36 1 : 0.8062.108Reverse gear/drive pinion set II(30 : 12) * (23 : 14) 4.107Ratio, drive pinion set I63 : 15 4.20068 : 21 3.238Ratio, drive pinion set II63 : 19 3.31668 : 26 2.615ModesportcomfortFor a gearbox with two output shafts, the overallratio 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 thedifferential.13.620(31 : 11) * (23 : 14) 4.63012.108For reverse gear, the ratio of the reverse shaft muststill be taken into consideration, so the ratio comprises two values.The ratio for a particular gear multiplied by theratio for a particular drive pinion set gives theoverall ratio for the gear. This value is printed inbold in the table.5
IntroductionGearbox versionsThere are two different gearbox versions:- The version for vehicles with front wheel driveand- the version for vehicles with four-wheel drive.The 4-wheel-drive version of the gearbox has anadditional transfer case for driving both the frontand rear axles.Transfer case forfour-wheel drive205 0016
Gearbox mechanismThe installation angleof the gearbox is dependent on theengine type being used.Two different installation positions are possible:The term "installation angle" describes the angleat which the bolt holes on the engine flange areoffset to match the engine’s angle of tilt. Thegearbox itself is not tilted.- tilted back by 15 for 4-cylinder engines and- tilted forward by 8 for VR6 engines.Direction oftravel205 0324-cylinder engine205 031VR6 engine7
Gearbox mechanismDesignIn a conventional gearbox, an input shaft transfers drive force to an output shaft on which thevarious gears are positioned. The more gearsthere are lined in row on such a drive shaft, thelonger it will be.Selector shaftOutput shaft 1Input shaftOutput shaft 28For the so-called short gearbox, one of which ismanual gearbox 02 M, VW uses two outputshafts - on which the gears are arranged instead of one.This reduces the installation length considerably.
Manual gearbox 02 M has one input shaft andthe two output shafts, TW1 and TW2.The gears are arranged on both output shafts asfollows:- TW1: Forward gears 1 to 4- TW2: 5th and 6th gear and reverseThe reverse gear comprises a reverse shaft withtwo gears via which the direction of rotation isreversed. (In the illustration below, the reverseshaft is hidden by the input shaft.)Transfer casefor four-wheel driveHousing205 0099
Gearbox mechanismDesign of input shaftThe gear wheels of the input shaft are designedas fixed gears, i.e. they are permanently linkedto the input shaft.Input shaftwith fixed gears205 047Design of output shafts TW1 and TW2The gear wheels run in needle bearings and canrotate on the output shaft. This is why they arealso known as sliding gears. Only when theappropriate gear has been selected is the slidinggear connected to the fixed gear of the outputshaft via a sliding sleeve and a synchromeshbody.The sliding gears of the output shaft arecontinuously in mesh with the matching fixedgears of the input shaft, i.e. the sliding gears alsorotate continuously. As the sliding gears - withthe exception of the idler of the engaged gear are not permanently linked to their output shaft,they transfer no torque to the output shaft in thisstate.Sliding gearsSliding sleeve with synchromesh bodyFixed gear to differentialOutput shaftTW2with sliding gearsInput shaftwith fixed gearsOutput shaftwith sliding gearsTW1Fixed gear to differentialSliding gears10205 048
Double gearingReplacing the conventional output shaft with twoshorter output shafts alone is not enough toachieve a short, compact design. It is still necessary to find a way to transfer torque to both output shafts without requiring more components.In the case of manual gearbox 02 M, this problem is solved by means of double gearing. In adouble gearing arrangement, a fixed gear of theinput shaft is linked to a sliding gear of TW1 anda sliding gear of TW2. In this way, two gears canbe driven by only one fixed gear on the inputshaft.To achieve different ratios, opposed sliding gearshave different diameters and therefore differentnumbers of teeth.Gears of the TW2 have a larger diameter thanthe gears of the TW1.This results in a 25% speed differentialbetween the output shafts.Manual gearbox 02 M has threedouble gearings:- Sliding gear wheel, 1st gear, on TW1 andreverse shaft with the the input shaft (red),- Sliding gear wheel, 4th gear, on TW1 andsliding gear 6th gear on TW2 with the inputshaft (blue) and- TW1 and TW2 with thedifferential gear (green).Differential gearOutput shaft 1205 030BReverse shaftInput shaftOutput shaft 2205 03011
Gearbox mechanismR205 010205 011Power transferSince gearbox 02M has two output shafts, poweris either transferred via the one shaft or via theother shaft to the differential, depending on whatgear is selected.Taking the selection diagram for the sake of clarity, the individual gears can be assigned to thepower transfers shown in the figure on the right.205 01212
205 013205 014205 015205 01613
Cable-operated gearshift mechanismThe two selector cables of the cable-operated gearshift mechanismestablish the connection between the gear lever and gearbox 02 M.Mechanism for transferring themotion of the selector cables to theselector shaft.Selector cableGear selector cable205 027205 028The two selector cables transmit the motions ofthe gear lever to the gearbox selector shaft. Themechanism shown above translates the movement of the selector cables into a movement ofthe selector shaft in the gearbox.14
Gear leverThe position of the gears is in accordance with the VW standard, except that an extra gearhas been added to fill a previously unallocated space.205 004Shift motionSelection motionThe gear lever can be moved in the direction ofthe three spatial axes. The mechanism of thegear lever splits the gearshift operation of thedriver.- A part of the mechanism transfers theright/left motion of the gear lever to theselector cable. With this operation, the driverselects the gate to be selected.205 029- The other part of the mechanism transfersthe forward/reverse motion to the gearselector cable. With this operation, the driverengages the desired gear.15
Cable-operated gearshift mechanismSelecting a gearIn essence, gear selection consists of three components of the selector mechanism and gearbox: The gear lever mechanism translates thedriver's operations. The selector cables transfer the operationof the selector lever mechanism to thegearbox selector shaft. The selector shaft mechanism on the gearbox.This mechanism selects and engages the gearwheel of the gear selected.We will explain to you the sequence of operations when selecting a gear by means of threeexamples.For the sake of clarity, we will split the selectionsequence into- operations outside the gearboxand- operations inside the gearboxGear leverBall jointSelector cableMechanism for transferring the motions of thecable pull to the selectorGear selector cableInterlockshaft.205 050Shift forkSliding sleeve with synchroniser ringSelector shaftOutput shaft 1Sliding sleeve with synchroniser ringOutput shaft 2Shift fork205 04916Shift finger
Left/right motion of the gear lever205 045Gear leverSelector cable205 024The gear lever mechanism transfers the right/left motion of the gear lever to the selectorcable. The gearbox mechanism translates themotion of the gear selector cable into an up/down movement of the selector shaft.In the gearbox, this up/down motion causesthe shift finger on the selector shaft to moveupwards or downwards. The shift finger forthe selected gear pair then reaches into thecutout in the relevant shift fork.Selector shaft205 02217
Cable-operated gearshift mechanismForward and reverse motion of gear lever.205 044Gear leverGear selector cable205 025The forward and reverse motions of the gear lever istransferred to the shift cable. The gearbox mechanismtranslates the motion of the gear selector cable into arotational motion of the selector shaft.In the gearbox, this rotational motion of the selectorshaft causes the shift finger which has engaged in thecutout in the shift fork to move the shift fork and gearchange sleeve sideways.The gear change sleeve links the gear wheel of the selected gear to the output shaft. The selected gear isthen selected.Selector shaft205 02318
Selecting reverse gearGear lever205 046205 026SpringSelecting reverse gear represents a special case,since an interlock must first be cancelled in orderto engage this gear.Ball jointGear leverInterlock205 040Press down the interlock against the force of thespring and the gear lever will slide down throughthe ball joint.205 041Only then can the interlock be cancelled in orderto engage reverse by moving the gear lever tothe left and forwards.205 042A spring pulls the gear lever back up.205 04319
ServiceAdjusting the cable-operated gearshift mechanismThe procedure for adjusting the cable-operatedgearshift mechanism has been simplified:- Pull the spring at both ends of the cable pullback.- Fix the springs by a rotational motion with theplastic nuts (arrows).205 034- Attached to the gearbox housing is an adjusting pin which fixes the selector shaft in apredefined position. Move the selector shaftby hand into the gate of first and second gearand then press the adjusting pin into thegearbox housing. The gearbox pin latcheshome in this position and locates the selectorshaft.205 036205 020Push in the setting pin20
- You still have to move the gear lever intothe first and second gear positions. In thefigure, you can see two guide holes: one onthe gear lever and one in the housing.205 021- To fix the gear lever in place, pass locatingpin T10027 through bore A into bore B whenthey are exactly one above the other.AB205 035- Now you can let the springs on the selectorcables snap back into place. Detach the adjusting pin from the gearbox hou
6-speed manual gearbox 02 M is a new development. It is a compact gearbox with six forward gears for A-platform vehicles with trans-versely 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 gear-box and the technology used. 205_052
REDUCTION GEARBOX FINNØY REDUCTION GEARBOX The gearbox range covers input powers from 250 kW and up to 12 000 kW. They are divided into 3 model types: - SINGLE STAGE REDUCTION GEARBOX, with vertical or horizontal offset - GXU REDUCTION GEARBOX - TWIN
Field test: torque and modal characterization. Planet bearing calibration. Trunnion stiffness characterization. Phase 1. Dyno Gearbox 1: run-in and instrumentation checkout. Field Gearbox 1: loads, responses, events. Dyno Gearbox 2: run-in, limited non-torque loading. Phase 2. Dyno Gearbox 2: extensive Non-Torque Loads (NTL), dynamics, HSS .
Harmonic gearbox have smaller backlash but a very high price, while a planetary gearbox have a higher load carrying capacity, a better coefficient of efficiency and a significantly lower price, all for the same overall dimensions. Because of this, it would be reasonable to use a planetary gearbox instead of a harmonic gearbox. Figure 5.
speed of the grinding table. As only standard motors with a horizontal shaft are used in today’s mills, the gearbox needs a horizontal input shaft and a vertical output shaft. The gearbox therefore always includes a bevel stage. The output shaft of the gearbox is designed as a
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II. Weak acid- strong base titration In this part of the experiment you will do weak acid strong base titration. 0.05M, 20 mL CH 3 COOH is titrated with 0.05M NaOH. perform same procedure mentioned above. III. Mixture of weak acid, strong acid and strong base titration 0.02M, 10 mL HCl and 0.02M, 10 ml acetic acid mixture is titrated with 0.05 .
1 (fixed speed-induction generator) through Type 4 (variable speed-full-conversion system). Types 1 through 3 are based on an induction generator; they require a gearbox to match the generator speed (high-speed shaft) to the turbine speed (low-speed shaft). Type 4 may be with or without a gearbox, depending on the type of the generator.
An API (US) nationally adopted standard, either modified from or identical to the ISO standard, may include the API Monogram Program requirements. This shall be noted on the front cover as to be evident to the reader. Both modified and identical adoptions which include the API Monogram should be designated as follows: API Title . ANSI/API XX . Edition, Month/Year . Effective Date: (minimum of .
