SSP 390 - EN - The 7-speed Double-clutch Gearbox 0AM.pdf

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Service Training
Self-study Programme 390
The 7-speed Double-clutch Gearbox 0AM
Design and Function
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The new 7-speed double-clutch gearbox from Volkswagen
The 7-speed double-clutch gearbox 0AM is a further development of the very successful direct-shift
gearbox 02E from Volkswagen.
In terms of comfort and shifting without interrupting drive, it offers the same as the direct-shift
gearbox 02E.
It has been designed for engines with a torque of up to 250 Nm in the Polo, Golf, Passat and Touran.
Whilst the direct-shift gearbox is on a par with vehicles with manual gearbox in terms of fuel
consumption, the double-clutch gearbox has succeeded in reducing fuel consumption below that of
manual gearboxes by means of certain technical innovations in the gearbox.
This reduction in fuel consumption makes a significant contribution towards lowering emissions and
safeguarding the environment.
In this self-study programme, you can find out how the new double-clutch gearbox functions and which
technical highlights have helped to reduce fuel consumption.
We hope you enjoy reading it.
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Make use of the available range of training courses
for training…
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NEW
Attention
Note
The self-study programme shows the design and
function of new developments.
The contents will not be updated.
For current testing, adjustment and repair
instructions, refer to the relevant
service literature.
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Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Design of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mechatronic module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Electrohydraulic control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Oil circuit – hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Gearbox management system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Test yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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Introduction
With the new double-clutch gearbox 0AM, Volkswagen is presenting two world premieres:
The first 7-speed gearbox for mounting transversely at the front and
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The first double-clutch gearbox with dry double clutch
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Mechatronic unit
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Double clutch
As a design feature, the dry double clutch has an extensive impact on the entire gearbox concept. In comparison
with the direct-shift gearbox 02E, efficiency has once again been considerably improved thanks to the new
gearbox concept.
This improved efficiency makes a significant contribution towards lowering consumption and emissions.
The 7-speed double-clutch gearbox 0AM is a further milestone in the Volkswagen Group's gearbox strategy,
and therefore extends Volkswagen's technological advantage still further.
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Design features
Modular design of the gearbox:
The clutch, mechatronic unit and gearbox each form one unit
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Dry double clutch
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Separate oil circuit, mechatronic unit and mechanical gearbox, with lifetime fillings
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7 gears on 4 shafts
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Oil pump driven subject to requirements
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No oil/water heat exchanger
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Mechatronic unit
Double clutch
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Technical data
Designation
0AM
Weight
Approx. 70 kg including clutch
Torque
250 Nm
Gears
7 forwards gears, 1 reverse gear
Spread
8.1
Operating mode
Automatic and Tiptronic modes
Gearbox oil volume
1.7l - G 052 171
Mechatronic unit oil volume
1.0l central hydraulic/power steering box oil G 004 000
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