Self-Study Programme 507 Amarok 8 speed Automatic gearbox 0CM.pdf

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Service Training
Commercial
Vehicles
Self-Study Programme Technology 507
Amarok 2012
The 8-speed automatic gearbox 0CM
Design and function
The 8-speed automatic gearbox in the Amarok
With a combustion engine, it is necessary to have a moving-off element that permits rotation speed differences
between the engine speed and drivelines speed. In contrast to manual gearboxes and increased gearboxes, a
converter operates with almost no wear, because the powerflow is only via the gearbox when moving off. The
advantages of the converter are thus its low wear and the fact that its design causes the torque to be boosted
beyond the engine torque. Specifically for the Amarok, the converter therefore represents the ideal moving-off
element, because the very low ratio and torque increase provide a significant improvement in off-road and towing
properties. This is in comparison to the Amarok with a manual gearbox, without step-down box. After the moving-
off phase, the hydraulic slip of the converter is eliminated by the controlled lock-up clutch. This improves efficiency
significantly.
S507_003
Key data
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Engine: 2.0 l bi-TDI with 132 kW
Gearbox: 0CM
can be combined with start/stop system
The automatic gearbox in the Amarok is a completely newly developed 8-speed automatic gearbox, in which the
greatest importance has been placed on efficiency, gearshift comfort and speed, low weight and reliability.
The gearshifts are performed without interruption in traction, and the gearshift speeds are at the level of a DSG.
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
At a glance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
The driveline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
The transfer box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Design features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
The 8-speed automatic gearbox 0CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
The new 2.0 l 132 kW TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
The selector lever module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
The selector lever actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
The selector lever emergency release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gearbox structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
The overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
The torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
The oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The planetary gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gearbox management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
The mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
The sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
The actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gearbox function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
The hydraulic interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
The start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
The hydraulic pulse accumulator (HPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
The special tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
The gearbox adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3
Introduction
The driveline
The Amarok has a modular driveline in which the individual components such as automatic gearbox, front final
drive, transfer box and rear final drive are each independent modules. The drive combination designed especially
for the Amarok comprising permanent four-wheel drive and an automatic gearbox is configured for ideal traction
on any surface.
Connection of transfer box to automatic gearbox
Transfer box with self-locking centre differential and variable torque
distribution.
The ATF drain plug is located at the bottom of the oil pan made from sheet
steel. The ATF filler and inspection plug is located on the side of the housing
(ATF = Automatic Transmission Fluid).
The intermediate plate prevents dirt from getting in between the automatic
gearbox and the transfer box.
Automatic gearbox
Intermediate plate
Electrical
connector
ATF drain plug
ATF filler and inspection plug
Transfer box
4
The transfer box
The design of the transfer box installed in the Amarok with a self-locking centre differential is based on the transfer
box in the Audi Q7 and the Touareg 2011. It has been adapted for use in the Amarok.
Characteristics
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Modern "four-wheel drive" technology in the Amarok
Sturdy system that operates purely mechanically
Suitable for onroad and offroad use
Permanent four-wheel drive
Differential compensation between the front and rear axles
Full ESP suitability in four-wheel drive and locked-up rear axle differential
For more information, refer to SSP 464.
Gearbox ventilation
S507_005
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