The 02T 5/6-speed manual gearbox
Gearbox design
With the new 02T 5/6-speed manual gearbox of the MQ200 series, Volkswagen has succeeded in developing an 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 from the A00 class to the A class.
The final drive ratios and the ratios of the individual gears can be matched to the power outputs of the various engines.
The type diversity within the gear and final drive ratios allows an optimum compromise to be found between sporty and economical gearbox design for all automotive applications.
The gearbox is operated by means of selector cables. The clutch control is hydraulic.
The development goals for the new gearbox were as follows:
- Easy and exact gear-changes
- Optimal efficiency
- Low weight
- Modular technology
- Standard cable-operated gearbox
Chapters
- IntroductionThe modular system of the 02T gearbox (clutch release lever, selector shaft, inner selector module, bearing support) and its magnesium housing.
- Gearbox mechanicalsThe 02T as a compact twin-shaft gearbox with a separate reverse idler shaft: helical gears in needle bearings, synchronised forward gears.
- Input and output shaftsThe input shaft and the output shaft: bearings, gear wheels and change gears, synchromesh bodies, deep bore and hollow drilling for low weight.
- Bearing supportThe new bearing support with its two grooved ball bearings: pre-assembled shaft packet, form disk, sealing rings and six-bolt fixing.
- Double synchroniserThe double synchronisers of 1st and 2nd gear: three friction faces, about 50 % more synchroniser performance and almost half the shifting effort.
- DifferentialThe differential built into the gearbox: tapered roller bearings, oil seals, riveted final drive gear and axial adjustment with an adjusting disc.
- Force pathThe force path through the 5-speed gearbox in reverse and in 1st to 5th gear: from the input shaft over the gear pair to the final drive gear.
- Outer selector mechanismThe cable-operated selection: two selector cables, relay lever and lever for shift movement, the angle piece and the 4-gate pattern with reverse at the front left.
- Inner gear change mechanismThe selector shaft in the selector mechanism cover, selector plates and shift forks with their bearings, and the shift finger.
- Selection and shift movementHow the gear lever movements reach the gearbox: the selection movement over the gate selector cable and the gearshift movement over the gear selector cable.
- Reverse gear lockThe push lock in the selector housing that protects against unintentional engagement of reverse gear: pressure spring, interlock and locking cam.
- ServiceAdjusting the cable-operated gearbox in neutral: detaching the selector cables, arresting the selector shaft with the angle piece, arresting the gear lever with locating pin T10027.
- SensorsSpeedometer sender G22 (Hall sender on the differential housing) and reversing light switch F4, with their circuits.
- 6-speed versionThe 6-speed 02T: the same architecture with a longer magnesium gearbox housing cover, extended shafts and the 6th gear engaged by the 5th gear's synchromesh body.
- Test your knowledgeEight questions on the 02T gearbox: gear ratios, magnesium housing, modules, cable-operated selection, angle piece, locating pin T10027, road speed and bearing support, with the answers.
