• Document: Service. Self-Study Programme 237. Manual gearbox 02T. Design and Function
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Service. Self-Study Programme 237 Manual gearbox 02T Design and Function The 02T 5/6-speed manual gearbox 237_010 Gearbox design With the new 02T 5/6-speed manual gearbox of The type diversity within the gear and final drive the MQ200 series, Volkswagen has succeeded ratios allows an optimum compromise to be in developing an ultra-light twin-shaft gearbox. found between sporty and economical gearbox The housing is manufactured from magnesium. design for all automotive applications. The gearbox can transmit up to 200 Nm of torque and is used throughout the Group in The gearbox is operated by means of selector combination with various engines ranging from cables. The clutch control is hydraulic. the A00 class to the A class. The development goals for the new gearbox The final drive ratios and the ratios of the were as follows: individual gears can be matched to the power outputs of the various engines. – Easy and exact gear-changes – Optimal efficiency – Low weight – Modular technology – Standard cable-operated gearbox New Important Note The Self-Study Programme Please always refer to the relevant Service Literature is not a Workshop Manual! for all inspection, adjustment and repair instructions. 2 Table of contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Modular system Gearbox mechanicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Gearbox design Input shaft Output shaft Bearing support Double synchronisers Differential Force path Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Outer selector mechanism Inner gear change mechanism Selection movement Shift movement Reverse gear lock Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 6-speed-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Gearbox design Modifications to the 5-speed version Force path Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3 Introduction The modular system Clutch release lever Individual modules are assembled in modular form. This increases their functionality after assembly in series production and in the service workshop. The modules are: 237_040 Clutch release lever Selector shaft This module contains the clutch release lever, the release bearing and the guide sleeve. Selector mechanism cover Selector shaft with selector mechanism cover All blocking detent, spring and guide elements of Angle piece the selector mechanism, as well as the angle piece for adjustment of the selector mechanism are accomodated in this module. Shift finger 237_041 Inner selector mechanism The inner selector module with shift forks, selector plates and bearing. Bearing

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