Self-Study Programme 37 5 speed manual gearbox 02T and 002.pdf

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New manual gearboxes in
the
Š
koda Fabia
New
5-Speed Gearbox 02T
Evolution
5-Speed Gearbox 002
02T
What's the reason for new gearboxes?
The consequent further development of the
platform strategy with the modular principle on
which this is based, has also necessitated
developing new variably designed assem-
blies, which also fit well into this concept.
It was an obvious step to employ modern
computer technology in the development
phase to achieve an optimum design of the
gearboxes to match the needs of the strategy
and also in terms of weight, performance and
environmental friendliness.
What are the applications of gearbox 02T?
What are the applications of gearbox 002?
To begin with the Fabia, the gearbox will be
employed for universal applications within the
Group.
It is intended for model ranges with a
maximum transmitted torque of 200 Nm.
002
SP37_04
This gearbox is intended for use in model
ranges with a torque of up to 150 Nm.
Development work has aimed at optimising
the shift mechanism, which included
harmonising it with the modular system, and to
produce a component which supplements the
modules of the platform strategy.
This Self-Study Programme will provide
you with further information relating to
design and function of these two
gearboxes.
2
GB
Contents
Part I – 5-Speed Gearbox 02T
Introduction
Gearbox Mechanical Components
Gearbox design
Input shaft
Output shaft
Bearing mounting
Double synchromesh
Differential
Power flow
Shift Mechanism
External shift mechanism
Internal shift mechanism
Selection movement
Shift movement
Reverse gear lock
Service
Setting cable shift
The material magnesium
Sensors
Indicating vehicle speed
Reversing light switch
4
8
18
24
28
Part II – 5-Speed Gearbox 002
Gearbox
002
The evolution
Shift pattern
Engine mounting – gearbox mounts
Test Your Knowledge
30
34
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You will find notes on inspection and maintenance,
setting and repair instructions in the Workshop
Manual.
GB
3
Introduction
The 5-Speed Manual Gearbox 02T
New!
SP37_12
The gearbox design
The new 5-speed manual gearbox MQ200/02T is
used for the first time in the
Š
koda Fabia.
It has proven possible with the new 5-speed
manual gearbox 02T in the MQ200 series, to
develop an extremely lightweight two-shaft
gearbox. The housing is manufactured from
magnesium. The gearbox is able to transmit
torques of up to 200 Nm and will be used through-
out the Group in combination with various
engines, from the A00 up to the A class.
The final ratios and the ratios of the individual
gears can be matched in terms of their gear steps
to the various power outputs of the engines.
As a result of the wide range of versions available
within the gear ratios and final drive ratios, it is
possible to achieve an optimal compromise for all
vehicle applications between a gearbox design
aimed at a sporty style of driving as well as one
with the accent on good fuel consumption.
The gears within the gearbox are shifted by
means of cables. The clutch control is performed
hydraulically.
Development objectives of the new gearbox
were:
–
–
–
–
–
smooth and exact gearshifts
highest possible efficiency
low weight
modular design
standardised cable shift mechanism
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Engine/gearbox combinations (examples)
Manually operated
5-speed manual
gearbox
Gearbox code letter
Engine assignment
Teeth of driven gear z
2
Ratio i =
Teeth of driving gear z
1
EYW
1.4-ltr./74 kW
z
2
z
1
17
11
21
30
38
46
24
11
i
3.882
3.455
2.095
1.433
1.079
0.891
3.182
z
2
66
38
44
43
40
39
35
24
EYX
1.4-ltr./55 kW
z
1
17
11
21
31
39
48
24
11
electronic
1.9 litre
G50 SAE 75 W 90
(synthetic oil)
filled for life
hydraulic
i
3.882
3.455
2.095
1.387
1.026
0.813
3.182
z
2
64
38
43
41
38
37
35
24
EYY
1.9-ltr./47 kW
z
1
19
11
22
32
41
50
24
11
i
3.368
3.455
1.955
1.281
0.927
0.740
3.182
Final drive
1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse
Speedometer
Gear oil capacity
Gear oil specification
Gear oil change
Clutch control
66
38
44
43
41
41
35
24
The gearbox can be used with engines of greatly
differing type and power output (spark ignition
and diesel engines). The gear steps of the
gearbox are matched to the particular type of
engine.
The wide range of versions available makes it
possible to fully exploit the available engine
torque in the different driving conditions.
It is possible to achieve improved fuel consump-
tion when driven in 5th gear at a uniform constant
speed.
Note:
The code letters of the gearbox are
also contained in the data stickers of
the vehicle.
GB
5
Introduction
The modular engineering
Individual components are combined in a modular
technology.
This enhances the functionality following
assembly, both in series production as well as in
the service sector.
The components are:
Clutch release lever
This module contains the release lever, the
release bearing and the guide sleeve.
SP37_40
Clutch release
lever
Shift shaft
Shift cover
Shift shaft with shift cover
All the detent, spring and guide elements of the
shift mechanism, as well as the angle for setting
the shift mechanism, are housed in this module.
Shift finger
Angle
SP37_41
Internal shift
mechanism
Internal shift mechanism
with the shift fork, the shift rails and the mounting.
Bearing
mount
SP37_42
The bearing mount
with the two grooved ball bearings and
preassembled input shaft and output shaft.
Input shaft
Output
shaft
SP37_43
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