Self-Study Programme 512 Automated 5 speed manual gearbox 0CT.pdf

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Service Training
Self-study programme 512
Automated 5-speed Manual Gearbox 0CT
Design and function
The idea of automating a manual gearbox is not new for Volkswagen. A 5-speed manual gearbox has already
been turned into an electronic manual gearbox with automatic shift function for the Lupo 3L by using
electrohydraulic actuators. Electromechanical actuators are used with the automated manual gearbox 0CT.
The automated manual gearbox 0CT is based on the manual gearbox 0CF.
s512_001
The self-study programme presents the
design and function of
new developments!
The content will not be updated.
Current testing, setting and repair instructions can
be found in the provided service literature.
Important
note
2
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview of system components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Comparison of 0CT and 0CF gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Selector lever E313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Selector lever positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LED indicators in dash panel insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Gearbox mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of gearbox design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch actuator VX64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear actuator VX65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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14
15
21
Gearbox function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Basic adjustment of gear actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gearshifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Gearbox management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic manual gearbox control unit J514 . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox input speed sender G182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motors for clutch actuator and gear actuator . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
29
30
31
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test Your Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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Introduction
Overview of system components
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VX64 and VX65
J514
E313
The new automated 5-speed manual gearbox 0CT will be introduced in the up!.
The automated manual gearbox system comprises:
-
-
-
The gearbox 0CT with electrical clutch actuator VX64 and gear actuator VX65
The electronic manual gearbox control unit J514 above the left-hand wheel housing liner
The selector lever E313 in the centre console with automatic and Tiptronic functions
4
Comparison of 0CT and 0CF gearboxes
The automated 5-speed manual gearbox 0CT has, to a great extent, the same mechanical set-up as the manual
gearbox 0CF. The 0CT features fully automated gear selection and clutch operation. The shift point is determined
by the gearbox control unit and the gears are changed electromechanically by the clutch actuator and the gear
actuator.
Manual gearbox 0CF
Automated
5-speed manual gearbox 0CT
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Further information on the design of the manual gearbox 0CF can be found in self-study programme
509 “Manual Gearbox 0CF”.
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