Self-Study Programme 386 6 speed twin clutch gearbox 02E (S tronic).pdf

(1881 KB) Pobierz
Service Training
6-speed twin-clutch gearbox 02E (S tronic)
Self-Study Programme 386
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Table of contents
Introduction
A new generation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gearbox concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gearbox periphery
Gearshift mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Shift lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Ignition key withdrawal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Gearbox subassemblies
Overview – 02E gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Twin clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Power flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Design features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Dynamic pressure equalisation in the clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Hydraulic clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Clutch cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Clutch functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Creep control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Microslip control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Clutch control adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Safety shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Power flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Synchromesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
gearshift sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
All-wheel drive - power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Hydraulic diagram of 02E gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
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Gearbox control unit
Gearbox control unit – mechatronic module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Electro-hydraulic control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Description of the valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electronic module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Mechatronic control unit J743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Function diagram of the Audi A3 (8P) and Audi TT (8J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Function diagram of the Audi TT (8N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CAN information exchange in the Audi A3 (8P) Audi TT (8J) . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CAN information exchange in the Audi TT (8N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Gearbox oil (ATF) temperature sender G93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Temperature sensor in control unit G510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Multi-plate clutch oil temperature sender G509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Gearbox input speed sender G182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Drive shaft 1 speed sender G501 (G502) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Gearbox output speed sender -1- (2) G195 (G196) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Automatic gearbox hydraulic pressure sender -1- (2) G193 (G194) . . . . . . . . . . . . . . . . . . . . . . 71
Gear selector travel sensor 1 (2, 3, 4) G487 (G488, G489, G490) . . . . . . . . . . . . . . . . . . . . . . . . 72
Selector lever sensor system E313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Gearbox functions
tiptronic steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
"Freeing vehicle by rocking back and forth" and drive-away in 2nd gear. . . . . 80
Launch Control Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
S - sport program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Downshifting with short intermediate throttle application
between gearshifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Software Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Starter inhibitor/starter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Activation of the reversing lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Selector lever position, gear and fault indication . . . . . . . . . . . . . . . . . . . . . . . . . 84
Kick-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SSP291, p. 62 . . XX
Emergency (limp-home) program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Index
Dear reader, to help you to find information, we have compiled for you an
index on the last page.
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Introduction
The S tronic 02E twin-clutch gearbox is also known as the Direct Shift Gearbox (DSG) 02E.
Given that Audi uses the name "-tronic" for its automatic gearboxes (tiptronic, multitronic),
the twin-clutch gearbox 02E has been named "S tronic" in keeping with
the Audi nomenclature system.
Is the S tronic a manual gearbox or an automatic gearbox?
It is both. The S tronic is an automatic sport gearbox with the emphasis on "Sport".
The technical basis of the S tronic is a 6-speed-manual gearbox which, as a special feature, has two clutches
(twin clutch).
Clutch control and gearshifts are performed by an electro-hydraulic control.
A twin multi-plate clutch and an intelligent electro-hydraulic control are used allowing two gears to be
selected simultaneously.
While driving, one gear is engaged and the matching gear is preselected.
During gearshifts, the clutch engaging the active gear opens while the other clutch of the preselected gear
closes. This is done under load and so quickly that power flow is virtually continuous.
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386_003
What are the customer benefits of the S tronic gearbox?
The S tronic 6-speed twin-clutch gearbox is more dynamic than a conventional manual gearbo x, because
it allows fast gear-shifting without any interruption in tractive power while affording the comfort of an
automatic gearbox.
In addition to the overtly sporty driving dynamics, the S tronic gearbox is highly efficient. This gives it an
advantage over the conventional manual gearbox with regard to fuel economy.
The self-study programme teaches the design and function of new vehicle models,
new automotive components or new technologies.
Reference
Note
The Self-Study Programme is not a Repair Manual!
The values given are intended as a guideline only and refer
to the software version valid at the time of publication of the SSP.
For maintenance and repair work, always refer to the current technical literature.
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