Self-Study Programme 509 Manual gearbox 0CF.pdf

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Service Training
Self-study Programme Technology 509
Manual Gearbox 0CF
Design and function
The launch of the up! sees Volkswagen offer a new 5-speed manual gearbox.
The manual gearbox 0CF features a compact, lightweight design. It thus meets the main requirements that have
been set for the up!.
The following goals were achieved during the development of the gearbox:
- Greater efficiency
- Reduction in weight by optimising all gearbox components
- Simple design
- Simplification of assembly steps
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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
Volkswagen manual gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Design and Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview of gearbox design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Input shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reverse gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gearshift components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gearbox Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Gearshifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Transmission of power between input shaft and output shaft . . . . . . . . . . . . . 16
Gearbox Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3
Introduction
Volkswagen manual gearboxes
Even though they have been around for a long time, manual gearboxes are not outdated technology. They have
been adapted to new requirements over and over again. Consequently, manual gearboxes have had a decisive
influence on aims such as reducing fuel consumption and noise.
Manual gearboxes are and will remain a worthwhile
addition for the task of transmitting power from the
engine to the drive wheels.
Manual gearbox 02T
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Manual gearbox 08D
5-speed manual gearbox 0CF
4
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In Volkswagen's gearbox development department,
manual gearboxes for a wide range of conditions
and requirements in vehicle use have been planned.
The spectrum ranges from the manual gearbox 02T
for engines that deliver low torques and for compact
installation spaces to the manual gearbox 08D for
engines that deliver high torques. The manual
gearbox 0CF as featured in the up! has now been
added to the range. This gearbox covers the needs of
the small car segment in particular.
Technical data
Gearbox code
Gearbox type
Installation type
Installation length/installation width
Max. input torque
Material used for gearbox and clutch housing
Gear oil
Initial fill/oil change quantity
Weight
Spread
Final drive ratio
Gear pairs
Top speed
0CF
5-speed manual gearbox; 2-shaft manual gearbox
with additional shaft for reverse gear
Front/transverse installation
356 mm/462 mm
120 Nm
Aluminium
SAE 75 W
1.2 l / 1.1 l
26.7 kg with oil
4.57 both with 44 kW and 55 kW
44 kW: 74 to 19
55 kW: 75 to 18
Identical for 44 kW and 55 kW
Reached in 4th gear
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