SSP 512 Automated 5 Speed Manual Gearbox 0CT
SSP 512 Automated 5 Speed Manual Gearbox 0CT
SSP 512 Automated 5 Speed Manual Gearbox 0CT
The idea of automating a manual gearbox is not new for Volkswagen. A 5-speed manual gearbox has already
been turned into an electronic manual gearbox with automatic shift function for the Lupo 3L by using
electrohydraulic actuators. Electromechanical actuators are used with the automated manual gearbox 0CT.
The automated manual gearbox 0CT is based on the manual gearbox 0CF.
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Important
note
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview of system components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Comparison of 0CT and 0CF gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Selector lever E313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Selector lever positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LED indicators in dash panel insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Gearbox mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of gearbox design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch actuator VX64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear actuator VX65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test Your Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Introduction
Overview of system components
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J514
E313
The new automated 5-speed manual gearbox 0CT will be introduced in the up!.
The automated manual gearbox system comprises:
-
The gearbox 0CT with electrical clutch actuator VX64 and gear actuator VX65
The electronic manual gearbox control unit J514 above the left-hand wheel housing liner
The selector lever E313 in the centre console with automatic and Tiptronic functions
Automated
5-speed manual gearbox 0CT
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Further information on the design of the manual gearbox 0CF can be found in self-study programme
509 Manual Gearbox 0CF.
Introduction
The differences between the automated 5-speed manual gearbox 0CT and the manual gearbox 0CF are:
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The automated 5-speed manual gearbox 0CT has additional components: the clutch actuator VX64 and the
gear actuator VX65.
The selector dome and the selector shaft have been integrated into the gear actuator.
The clutch release lever has been repositioned:
While the clutch release lever is almost vertical on the manual gearbox 0CF, the ball stud on the clutch release
lever for the 0CT had to be moved. This is a result of the clutch actuator being positioned on the gearbox to
save space. For the first time, the ball stud has been pressed into the clutch bell housing as a bearing for the
clutch release lever.
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When removing the clutch release lever, make sure you observe the manufacturer's information in
ELSA.
Technical data
Gearbox code
0CF
0CT
Gearbox type
Installation type
Front/transverse installation
356 mm/462 mm
120 Nm
Aluminium
Gearbox oil
G 052.527.A2
1.2 l / 1.1 l
26.7 kg with oil
Spread
Gear ratios
GT = gear transition
44 kW : 74 to 19
55 kW : 75 to 18
1st gear 3.643
2nd gear 1.955
3rd gear 1.270
4th gear 0.959
5th gear 0.796
Maximum speed
GT 12 1.86
GT 23 1.54
GT 34 1.32
GT 45 1.2
GT 12 1.7
GT 23 1.57
GT 34 1.42
GT 45 1.2
On the automated manual gearbox 0CT, the shorter gear jump from first to second gear increases gearshift
comfort.
A shift by wire concept has been created for the automated 5-speed manual gearbox 0CT, i.e. there is no direct
mechanical connection between the selector lever and the gearbox. The selector lever position is communicated to
the connected control units via the CAN data bus.
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While the vehicle is stationary, a gearshift request is only implemented by the control unit if you press
the brake pedal at the same time. The familiar rocking function is also possible here.
Design
Gearstick
Locking ring
Round shell
Sleeve
Gearshift
electronics
O-ring
Selector
finger
Detent
Guide tracks
Recesses
Locator
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Gearshift electronics
Guide plate
Slide
Gearshift electronics
Magnet
Housing
Hall elements
Circuit board
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Selector finger
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N position (neutral)
If you move the selector lever to the right, it is in
neutral. The recess in the locator holds the gearstick
in this position.
R position (reverse)
If you move the selector lever from the N to R
position, reverse gear will be engaged.
The detent moves from the recess for N to the recess
for R.
D/M position (automatic/manual mode)
If you push the selector lever briefly to the left, the
vehicle will switch to automatic or manual mode. If
you repeat this, the vehicle will change the mode
again.
+/- (shift up/shift down):
If you push the selector lever briefly to + or -, the
gearbox will temporarily switch to manual mode.
The desired gear can be selected for approximately 8
seconds.
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Shift lock
Apply
handbrake
Selector lever in
neutral position
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Clutch temperature warning
Multifunction display
There are several new LED indicators in the dash panel insert for the up!:
- Clutch temperature warning
- Apply handbrake
- Selector lever in neutral position
- Gear indicator in the multifunction display
The temperature warning for the clutch has two stages. For reasons of safety, the clutch functions are still available
even when the second temperature warning stage has been reached.
You will find further information on the different dash panel inserts used in the up! in self-study
programme 500 The up!.
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Flashes
Possible cause
Together with the flashing indicator in the instrument cluster display: the selector lever for the
automated manual gearbox is not in N position;
instruction to start the engine.
Possible cause
Apply handbrake.
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Gearbox mechanics
Overview of gearbox design
Gearbox case
Gear actuator VX65
Gear actuator
motor 2 V529
Clutch housing
Clutch actuator
motor V530
Gear actuator
motor 1 V528
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Clutch actuator
motor V530
Plunger with boot
Plastic cover
Aluminium housing
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Gearbox mechanics
Design
Gear segment, main section
Aluminium housing
Upper stop
Coil spring
Compensating spring
Gear segment,
cover
Plunger with boot
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Lower stop
Locking wedge
Pressure spring
Wedge carrier
Boot
Inner part
Outer housing
Roller freewheel
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Clutch operation
Clutch is closed
The gear segment is resting against the lower stop of the housing.
Upper stop
Clutch
Gear segment
Compensating spring
Plunger
Lower stop
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Clutch opens
The motor V530 is energised and turns the gear
segment to the upper stop.
The compensating spring supports the motor in this
movement in order to reduce the energy requirement
of the motor.
The gear segment presses the plunger against the
release lever. This force acts on the diaphragm spring
of the pressure plate via the release bearing and the
clutch opens.
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Gearbox mechanics
Clutch is open
The gear segment is resting against the upper stop of
the housing.
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Clutch closes
If the motor V530 is energised again, the gear
segment turns back to the starting position against the
lower stop. The motor works against the
compensating spring at first. It is supported by the
diaphragm spring on the pressure plate. If the pivot
point of the gear segment and the axis of the springs
are aligned, the compensating spring will support the
movement of the motor from this position.
The plunger will be pulled back into the aluminium
housing by the turning motion of the gear segment.
The clutch closes.
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Balance of forces
A large amount of force is required to open the
clutch.
The compensating spring was added so that the
clutch actuator motor V530 does not have to apply
the force on its own. It helps the motor open the
clutch.
This combination has allowed us to optimise the size
of the motor.
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Compensating wear
The clutch is subject to mechanical wear during usage. The clutch actuator therefore has a mechanical wear
compensation system.
Starting situation
The plastic shoulders of the inner part rest against the
stop walls of the aluminium housing.
The wedge carrier moves into the rest position with
the locking wedge and releases the rollers. The inner
part can slide within the outer housing.
The pressure spring pushes the inner part and the
outer housing apart until the plunger is resting on the
release lever.
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Stop wall
Plastic shoulder
Wedge
carrier
Inner part
Pressure
Locking
spring
wedge
Rollers
Outer housing
Compensating wear
When the clutch actuator is operated, the inner part
moves towards the clutch. The locking wedge is
pushed between the rollers of the roller freewheel
and pushes them outwards. The rollers are then
jammed against the outer housing.
The gear segment together with the plunger pushes
the release lever and the clutch opens.
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Pressure
spring
Wedge
carrier
Inner part
Locking
wedge
Outer housing
Rollers
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Gearbox mechanics
Upper stop
Gear segment
Plastic shoulder
Plunger
Compensating spring
Lower stop
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Gear actuator
VX65
Selector dome
Selector shaft
Gear actuator
motor 2 V529
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Gear actuator
motor 1 V528
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Gearbox mechanics
Design
Gear actuator
VX65
Selector fork
mechanism
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Output shaft
Input shaft
Selector segment of
selector shaft
Reverse
gear lock
Gear actuator
motor 1 V528
(selector motor)
Gear actuator motor 2 V529
(shift motor)
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Selector
finger
Selector shaft
Further information on the design and function of the manual gearbox 0CF can be found in self-study
programme 509 Manual Gearbox 0CF.
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Locking pawl
Locking finger
Selector finger
Selector shaft
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Gearbox mechanics
Function
Rack
Shaft for shift motor
Shaft for selector
motor
Gear segment
Selector
finger
Selector shaft
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Gearbox function
Basic adjustment of gear actuator
During the basic adjustment, the selector finger travels through the shift gates and the selection gates several times.
The position of the selector finger and both the length and the width of the respective gates are thus determined.
The calculated width and length of the selection and shift gates allow the motors V528 and V529 to be activated
almost simultaneously. The selector finger therefore does not collide with the walls of the shift gates. As a result, the
gearshift operations are shortened.
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Measuring gears:
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Gearbox function
Gearshifts
The values calculated in the basic adjustment are used to activate the shift motor and the selector motor
simultaneously at times.
Prerequisites:
- The gearshift electronics has transferred the driver's request to the electronic manual gearbox control unit.
- The clutch actuator has opened the clutch.
V530
E313
J514
VX64
VX65
V528
V529
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E313
Selector lever
J514
VX64
Clutch actuator
VX65
Gear actuator
V528
V529
V530
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J514
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VX65
V528
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V529
J514
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VX65
V528
V529
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J514
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VX65
V528
V529
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Gearbox management
System overview
Sensors
Actuators
Gear actuator
VX65
Gear
actuator
motor 1
(selector
motor)
V528
Gear
actuator
motor 2
(shift motor)
V529
Engine control
unit J623
Data bus diagnostic
interface J533
Clutch actuator
VX64
ABS control unit
J104
Clutch actuator
motor V530
Legend
Input
Output
CAN data bus
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The control unit J514 can be accessed by removing the left-hand front wheel and the wheel housing
liner.
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Gearbox management
Gearbox input speed sender G182
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Hall elements
Drive shaft
Aluminium housing
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Sender ring
Design
Function
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Service
Service information
For the clutch actuator
No grease may be applied in the vicinity of the ball
and the ball socket for the release lever.
Reason:
The combination of grease and dust from the clutch
lining increases wear and causes noise.
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Ball
Ball socket
Positioning marks
Gear segment
Make sure you observe the latest repair instructions in ELSA when installing and removing the gear
actuator.
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Pressure compensation
The clutch and the gear actuators have a drilled hole in the housing that allows pressure compensation between
the inside and the surrounding atmosphere. Pressure compensation is necessary because the movement of the
mechanical parts and temperature variations can cause pressure fluctuations inside the components. The hole is
sealed with a GoreTex membrane so that moisture cannot get inside the housing. Air can pass through the
membrane in both directions and thus compensate for pressure fluctuations.
Plastic cover
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Membrane
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Membrane
Fitting
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1.
What are the special features of the 0CT gearbox compared with the 0CF?
2.
3.
In which selector lever position can the vehicle be started while pressing the brake pedal?
a) In selector position R.
b) In selector position N.
c) In selector position P.
d) In selector position D.
4.
a) The V529 motor is energised and the selector shaft moves up and down.
c) The V528 motor is energised and the selector shaft moves up and down.
5.
b) The spring on the gear segment pushes against the clutch pressure plate.
c) The movement is transferred to the clutch pressure plate by the release lever.
6.
What effect would clutch wear have if the clutch actuator did not have a
wear compensation system?
c) The constant pressure on the diaphragm spring could destroy the release bearing and the clutch.
Answers:
1. b), c); 2. b); 3. b); 4. b), c); 5. c); 6. a), c)
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