Get Power transmission Guide for Volkswagen Multivan SUV Fifth Generation (2003-2015)

Power transmission

The gearboxes

Two manual gearboxes, the 02Z and the 0A5

gearbox, and the DSG automatic gearbox 0BT are

used in the T5 2010. They have been designed for

transverse installation in the vehicle.

5-speed manual gearbox 02Z

The 5-speed gearbox is already familiar from the

previous model, and is used with the 4-cylinder

85 kW petrol engine and the 4-cylinder TDI engines

with 62/75 kW. The gearbox can transmit torques up

to a maximum of 250 Nm.

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6-speed manual gearbox 0A5

The 6-speed gearbox is also familiar from the

previous model and is used in the 4-cylinder TDI

engines with 103/132 kW. It can transmit torques

up to a maximum of 500 Nm.

The compact design is convenient for transverse

installation, and has been achieved by structuring

it as a 4-shaft gearbox. In the 4-shaft concept, the

pinion shafts are permanently engaged with the

gear on the final drive.

Depending on which gear is engaged, the powerflow

is via the input shaft onto one of the pinion shafts.

The clutch bell housing has been adapted to the

modified installation situation in order for it to be

fitted on the 4-cylinder TDI engine.

S453_025

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7-speed dual clutch gearbox 0BT

The 7-speed dual clutch gearbox (DSG) 0BT is

being used in the T5 2010 for the first time in the

Volkswagen Group. From March 2010, it will be

possible to combine the DSG with four-wheel drive in

the T5 2010. It can also be used in heavy vehicles with

a gross vehicle weight rating of up to 3.2 t. The 0BT

gearbox is designed for input torques of up to

600 Nm.

The 7-speed DSG will initially only be used

in 103 kW and 132 kW TDI engines. In terms of its

mechanical and control systems, it represents a

significant further development on the previously

familiar dual clutch gearbox.

The 0BT gearbox has been developed entirely within

Volkswagen, and is also produced within the

company, to very high manufacturing standards.

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All-in-all, it represents a milestone in the gearbox strategy of the Volkswagen Group, which means it contributes to

a further expansion in the technological lead enjoyed by Volkswagen.

Advantages of the 7-speed DSG at a glance:

●

Reductions in fuel consumption and CO2 emissions

Expansion and further development of expertise

relevant for the competition in dual clutch

gearboxes

For further information about this

gearbox and its selector mechanism,

refer to self-study programme no. 454

"The 7-speed dual clutch gearbox 0BT".

●

This now permits four-wheel drive with an automatic

gearbox

●

Winning over manual gearbox customers

With the 7-speed DSG, Volkswagen is securing its

market leadership in the Transporter segment

Tachograph

In vehicles with a tachograph, it is a requirement to have a separate speed signal for recording the vehicle's speed

on the tachograph. The vehicle speed for the tachograph continues to be taken directly from the gearbox. It is now

possible to retrofit a speedometer sender on all gearboxes. There are two different gearbox-specific speedometer

senders for the T5.

21

Power transmission

The four-wheel drive

In the T5 2010, four-wheel drive is available in all vehicle variants in conjunction with the 2.0 l 103/132 kW TDI

engines.

It can be used with the 6-speed manual gearbox 0A5 and now, for the first time, also in conjunction with an

automatic gearbox - the 7-speed dual clutch gearbox 0BT.

A Haldex 4th generation coupling is used as the 4WD coupling.

Rear axle box

Haldex coupling

Rear axle box

The design of the rear axle box has been adapted for installation of the Haldex 4th generation coupling and for

the higher torque requirements in the T5 2010.

As an option, the T5 2010 is available with a mechanical differential lock comprising a dog clutch on the rear axle

box.

The picture shows the four-wheel drive system as an example in conjunction with

a dual clutch gearbox.

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Bevel drive

The bevel drive has been adapted for the higher torque requirements in the T5 2010.

Two different bevel drives are used, one of which is adapted for mounting on the manual gearbox and the other for

the dual clutch gearbox.

Propshaft

Bevel drive

Dual clutch gearbox 0BT

S453_043

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Power transmission

Bevel box

The housing structure, the bearings and the gears of the bevel box have been adapted for the higher torque

requirements in the T5 2010. At the same time, it has been possible to reduce the weight of the bevel box by 6.25 kg

compared to the previous type.

Structure and function

The bevel box is driven via a hollow shaft with inner spines. This hollow shaft is a component of the bevel box and

is positively connected to the housing of the differential via its splines. The spur gear on the hollow shaft transmits

the torque onto the intermediate shaft with hypoid gearing and subsequently to the propshaft via the pinion. The

stub shaft for the right front wheel runs inside the hollow shaft. This stub shaft is driven by the shaft bevel gear of

the differential.

The bevel boxes for the manual gearbox and the dual

clutch gearbox differ in the area of the attachment to

Powerflow

Haldex coupling/final drive

Differential

housing

the differential.

The picture shows a bevel box combined with a dual

clutch gearbox.

Hollow shaft with inner spines

Hollow shaft spur gear

to wheel

front left

to wheel

front right

Final drive

Front axle differential

Intermediate shaft with

hypoid and spur gearing

Shaft bevel gear

Stub shaft for

right front wheel

Pinion with hypoid gearing

to

rear final drive

S453_027

24

Rear final drive

The design of the rear final drive has been adapted for installation of the Haldex 4th generation coupling and for

the higher torque requirements in the T5 2010, as far as the housing and the bearings are concerned.

The reservoir tank for the Haldex oil is an integral component of the final drive housing. This means it is protected

against mechanical damage from the outside.

The Haldex 4th generation coupling is similar in design to the Haldex coupling in the Caddy and Tiguan.

Optionally, the rear axle drive is available with a mechanical differential lock.

More information about the Haldex 4th generation coupling is available in self-study programme

no. 414 "4MOTION with generation IV 4WD coupling".

Rear axle box

Ventilation

Rear axle box

Haldex coupling

Ventilation

Haldex coupling

Mounting frame

S453_132

Output flange

left

Reservoir

Haldex oil (metal)

Drive flange

Four-wheel drive control unit J492

When service work is carried out on the rear axle box, refer to the information in ELSA (Electronic

Service Information System) or in the technical product information documents. This applies to the oil fills

in particular. Never mix up oils for the rear axle box and for the Haldex coupling with one another!

If oils are mixed up or there is no oil fill, there will be massive damage to the final drive and/or the

Haldex coupling.

25

Power transmission

Ventilation

Rear axle box

Cutaway view – rear axle box

Ventilation

Haldex coupling

The rear final drive of the four-wheel drive T5 2010

consists of the Haldex 4th generation coupling, the

final drive and the optionally available differential

lock. The transmission ratio is 2.466.

Drive

to left wheel

The Haldex coupling is integrated into the final drive

and can be renewed separately.

Differential

The oil supply to the Haldex coupling and the final

drive comes from two different oil circuits. Two oils

adapted to the particular requirements are used for

lubrication and cooling.

The two oil circuits are sealed off from one another

internally by a double oil seal.

This separates both the oil circuits from one another.

There is a spacer between the two halves of the

double oil seal, in order to guarantee that there will

be a narrow gap. The gap is connected to the

atmosphere by means of a breather hole in order to

equalise the pressure.

In the event of a leak of the pinion, it is possible for

leaking Haldex or final drive oil to reach the outside

via the breather hole.

The double oil seal prevents any mixing between the

two oils.

Crown wheel with

hypoid gearing

Mixing would impair the lubrication properties of

both oils, and could result in malfunctions in the final

drive or in the Haldex coupling.

Operating lever for

dog clutch

Drive to

right wheel

Pressure unit for

differential lock

Reed contact switches 1-3 for

differential lock F360-F362

For more information about the

differential lock, refer to self-study

programme no. 333 "4MOTION with

Haldex coupling".

For more information about the Haldex

4th generation coupling, refer to self-study

programme no. 414 "4MOTION with

Haldex 4th generation coupling".

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Four-wheel drive control unit J492

Pinion

Torsional vibration damper

Drive from

propshaft

S453_130

Multi-disc pack of the

Haldex coupling

Oil space

Haldex oil

Pump for

Haldex coupling V181

Double oil seal

Oil space

final drive oil

Double oil seal

Breather hole

27

Power transmission for Your Volkswagen Multivan SUV Fifth Generation (2003-2015)

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