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SSP-850103-The 8-Speed Automatic Transmission Design and Function.pdf

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SSP 850103 THE SPEED AUTOMATIC TRANSMISSION DESIGN AND FUNCTION
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Service T raining Self Study Program 850103 The 8-Speed Automatic T ransmission 0C8 ?Design and FunctionVolkswagen Group of America, Inc. Volkswagen Academy Printed in U.S.A. Printed 08/2010 Course Number 850103 ?2010 Volkswagen Group of America, Inc. All rights reserved. All information contained in this manual ?is based on the latest information available at the time of ?printing and is subject to the copyright and other intellectual ?property rights of Volkswagen Group of America, Inc., its ?af? liated companies and its licensors. All rights are reserved ?to make changes at any time without notice. No part of this ?document may be reproduced, stored in a retrieval system, ?or transmitted in any form or by any means, electronic, ?mechanical, photocopying, recording or otherwise, nor ?may these materials be modi? ed or reposted to other sites ?without the prior expressed written permission of the ?publisher. All requests for permission to copy and redistribute ?information should be referred to Volkswagen Group of ?America, Inc. Always check Technical Bulletins and the latest electronic ?repair information for information that may supersede any ?information included in this booklet. Trademarks: All brand names and product names used in ?this manual are trade names, service marks, trademarks, ?or registered trademarks; and are the property of their ?respective owners.iii Contents This Self-Study Program provides information ?regarding the design and function of new ?models. This Self-Study Program is not a Repair Manual. ?This information will not be updated. For maintenance and repair procedures, ?always refer to the latest electronic ?service information. Note Important! Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 T ransmission Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T ransmission Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 T ransmission Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Page intentionally left blank1 Introduction S466_003 The 0C8 8-speed automatic transmission is based on the previous 09D automatic transmission. ?This transmission ?uses the same basic components and has added two more forward speeds, helping both performance and fuel ?consumption. ? All 2011 Touareg vehicles will have the 0C8 8-speed automatic transmission.2 Introduction T echnical Data Developer/ ?Manufacturer AISIN AW CO. LTD Japan Designation T ransmission ?Features ? Electrohydraulically controlled 8-speed planetary transmission with a simple primary planetary gear set ?and a Ravigneaux planetary gear set ?? Torque converter with slip-controlled torque converter lock-up clutch ? Designed for longitudinal installation in combination with a transfer case ? Automatic transmission 0C8 ? Hydraulic control unit (valve body) in the oil sump with external electronic control module ? Dynamic Shift Program DSP with separate sports program in “position S“ and “Tiptronic“ mode for ?manual gear changes ?? Special feature: Starting off in 2nd gear is possible in Tiptronic mode Control ?System T orque Service Depending on version, up to 737 lb/ft (1000 Nm) For ? uid maintenance and intervals, see ElsaWeb Depending on adaptation of the transmission to the engine, between 200 and 240 lb (91 and 108 kg) Weight Speed Depending on engine, the top speed can be achieved in 6th, 7th or 8th gear3 T ransmission Design S466_006 The 8-speed automatic transmission consists of : ? The torque converter with lock-up clutch ? The ATF pump ? The valve body ? The Lepellitier planetary transmission con? guration ? The transmission housing ? Auxiliary hydraulic pump for transmission oil ? ATF preheater Torque Converter Transmission Fluid Auxiliary Hydraulic Pump 1 V475 Housing Valve Body ATF Pre-heater Planetary ?Transmission ATF Pump4 T ransmission Design S466_042 S466_073 The T orque Converter Torque ?Converter Lock- up Clutch Torsional Damper Stator T uurbine Wheel Pump Wheel Transfer Case 8-Speed Automatic Transmission Engine Electric Motor/Generator The hydro-mechanical torque converter is a ? uid ?clutch. ?It is used both to transfer and multiply torque ?from the engine. ?It consists of a turbine, pump, ?stator and lock-up clutch. ? Torsional dampers are installed in all torque ?converters. ?This allows the engine’s torsional ?vibrations to be minimized. ? In hybrid vehicles with combined electric motor and ?combustion engine, the combustion engine drives ?the torque converter via a shaft. ?This shaft runs ?through the middle of electric motor (electric motor/ generator). ?If the electric motor is used to drive the ?hybrid vehicle, the torque converter is driven directly ?by the electric motor. Different torque converters will be used depending ?on the engine and drive characteristics.5 T ransmission Design S466_072 S466_216 The Connection between the Engine to the T orque Converter The torque converter is connected to the different ?engines via three lugs. ?Depending on the engine, ?3 or 6 bolts are required to connect the lugs to the ?engine. 3.6L V6 FSI Engine ?3.0L V6 TDI 3.0L V6 FSI S466_215 S466_214 The T orque Converter Lock-up ?Clutch The torque converter lock-up clutch is a hydraulic ?multi-plate clutch. ?It locks the torque converter’s ?pump and turbine to eliminate slip. Depending on the vehicle operating status, this can ?be carried out at any time at engine speeds of over ?1000 rpm. ? Torque ?Converter Lock- up Clutch Torque ?Converter6 T ransmission Design S466_007 Oil Supply to the Valve Body ATF Pump Converter Housing with Converter Hub The Oil Supply The A TF Pump Depending on drivetrain, the 8-speed automatic transmission is equipped with the following oil pressure pumps: ? Combustion Engine: ?The ATF pump inside of the transmission ? Hybrid Drivetrain: ?The ATF pump inside of the transmission and the Transmission Fluid Auxiliary Hydraulic ?Pump 1 V475 In vehicles with combustion engine, the mechanical ?ATF pump (Automatic Transmission Fluid) is ?responsible for supplying the transmission with oil. ? It draws the ATF out of the oil pan, builds up the ?oil pressure and supplies the valve body with the ?hydraulic oil required for changing gears. The oil pump is a crescent pump (duocentric oil ?pump). ?It is driven directly by the engine via the ?converter housing and the converter hub. ?When ?driven, the ATF pump’s pinion drive plates engage in ?two grooves on the converter hub. In hybrid vehicles, this ?pump is driven by either ?the combustion engine and/or the electric motor/ generator.7 T ransmission Design s466_046 Auxiliary ?Hydraulic Pump T ransmission Fluid Auxiliary Hydraulic Pump 1 V475 Hybrid vehicles do not always run the combustion ?engine. ?However, it is still necessary for the ?automatic transmission to have oil pressure for ?normal operation. ?The Transmission Fluid Auxiliary ?Hydraulic Pump 1 V475 is responsible for supplying ?oil pressure to the transmission when the engine is ?not running and the vehicle is stationary. ?It is located ?under the bell housing. Function The V475 is an electric motor which drives the ?hydraulic pump. ?The electric motor is a brushless DC ?motor that is made up of a stator and a rotor. The pump is a crescent pump (duocentric pump) that ?draws the ATF ? uid out of the oil pan to pressurize ?and supply to the rest of the transmission. ?The oil ?enters the pump through a one-way check valve ? The one-way check valve in the V475 prevents the oil ?pumped by the mechanical ATF pump from ? owing ?back into the oil pan. Oil Temperature Sensor 2 G664 is located inside ?of the auxiliary hydraulic pump. ?This provides the ?Transmission Control Module J217 with the operating ?temperature of the pump. Effect in the event of failure Based on the rotational speed of the DC motor, ?the position sensors detect whether a malfunction ?is present. ?The malfunction is reported to the ?transmission control module. ?J217 tells the ECM to ?start the mechanical ATF pump via the combustion ?engine or the electric motor. s466_030 Brushless Electric Motor Duocentric Hydraulic Pump s466_066 Non-return valve8 T ransmission Design s466_011 s466_002 The Planetary T ransmission Design The Lepellitier planetary gear set concept is based on a single planetary gear set (primary planetary transmission) ?and a downstream, double planetary gear set (Ravigneaux) with freewheeling capability. The special feature of the Lepelletier planetary transmission is the fact that the double planetary gear set's sun ?gears and planet carrier are driven at different rotational speeds. ?These different input speeds create a large ?number of possible gear ratios. In this transmission, the double planetary gear set's sun gears can be driven by the output speeds of the planet ?carrier or the annulus (sun gear) of the single planetary gear set. ?At the same time, the double planetary gear ?set's planet carrier runs at the transmission input speed. ?This con? guration enables the use of two additional ?forward gears. Four multi-plate clutches, two multi-disc brakes and the freewheel are used to operate the eight forward gears ?and one reverse gear.9 T ransmission Design The Single Planetary Gear Set The single planetary gear set is located in front of the ?double planetary gear set. The single planetary gear set consists of: ? The stationary sun gear S1 ? The planetary gears P1 ? The planet carrier PT1 ? The annulus H1 ? The multi-plate clutches K1, K3 and K4 ? The multi-disc brake B1 Either four or ? ve planetary gear pairs are installed ?depending on the engine. ?These gears make the ?connection to the S1 and the H1 . ?The engine torque ?is transmitted into the single planetary gear set via ?the transmission input shaft. The Sun Gear S1 This is ? rmly joined to the mechanical ATF pump via a ?splined connection. ?As a result of this joint, the S1 is ?unable to rotate. s466_013 s466_014 s466_015 Splined Connection Sun Gear S1 B1 K4 K1 K3 S1 H1 P1 PT110 T ransmission Design The Double Planetary Gear Set The double planetary gear set is attached to the ?single planetary gear set. The engine torque is transmitted into the double ?planetary gear set via two routes: The S2 and S3 transfer the torque via the single ?planetary gear set via K2 to PT2. ?The output to the ?transfer case goes from the H2 via the transmission ?output shaft. ?The double planetary gear set consists ?of: ? The sun gears S2 and S3 ? The planetary gear sets P2 and P3 ? The planet carrier PT2 ? The annulus H2 ? The multi-plate clutch K2 ? The multi-disc brake B2 and ? The freewheel F The Sun Gears S2 and S3 Both S2 and S3 can be rotated independently of each ?other. The axle of S3 runs through S2. Both sun gears ?can be driven at different rotational speeds. s466_012 s466_022 s466_035 s466_034 P3 S3 PT2 P2 S2 K2 B2 F Connection to the Single Planetary Gear Set Sun Gear S2 Sun Gear S3 H211 T ransmission Design Sun Gear S2 Section 1 Section 2 Sun Gear S3 Outer Planetary Gears P3 Inner Planetary Gears P3 Annulus H2 Planet Carrier PT2 Planet Carrier PT2 Annulus H2 Planetary Gears P2 Section 1 Section 2 Planet Carrier PT2 Outer Planetary Gears P3 Planetary Gears P2 s466_038 s466_049 s466_051 s466_050 The Planetary Gears P2 and P3 Planetary gears P2 and outer planetary gears P3 are ?? tted together on one single shaft. The torque from sun gear S2 is transferred to P2 ?and to the P3. ?Only the P3 are joined to annulus H2. ? These transfer the torque from S2 to H2. The torque from S3 to the H2 is ? rst transmitted to ?the P3. The P3 transfer the torque to the P3 and to ?the H2. Depending on the engine, three or four P2 plus P3 ?planetary gears are used.12 T ransmission Design Brake B1 Brake B1 is keyed to the transmission housing. ?If the ?Automatic Transmission Pressure Regulating Valve ?N216 is supplied with current, the brake's discs are ?pressed together with hydraulic oil pressure. Under ?these conditions, the sun gear S2 is held. Brake B2 B2 is keyed to the transmission housing. ?It is ?actuated via the valve body. ?No pressure regulating ?valve is required to control B2. When closed, it holds the planet carrier PT2. The engine type determines the number of discs in the brakes. ?The number of discs can vary between 4 and 7 per brake. T ransmission Housing with the Discs of Brakes B1 and B2 Brake B1 Brake B2 s466_21813 T ransmission Design Clutch K2 s466_060 Clutches K1, K2, K3 and K4 The clutches are opened or closed via the solenoid ?valves within the valve body. ?The following list shows ?the function that each clutch performs in its closed ?position: 1 . K1 connects annulus H1 to sun gear S3. 2. K2 connects the turbine shaft to planet carrier PT2. 3. K3 connects annulus H1 to sun gear S2. 4. K4 connects planet carrier PT1 to sun gear S2.14 T ransmission Design s466_005 The V alve Body The valve body is mounted to the bottom of the ?transmission housing. ?The clutches and brakes are ?controlled by the valve body using sliding valves. ?The slide valves are controlled by solenoid valves ?which are actuated by the Transmission Control ?Module J217 . In addition to the clutches and brakes, the valve body ?controls the torque converter clutch and the various ?pressures throughout the entire transmission (ex. ?main pressure, control pressure, converter pressure, ?lubrication pressure, etc.). The valve body is responsible for the entire oil supply. ?The valve body contains the following components: ? The mechanically actuated spool valve ? The hydraulic selector valves ? Two electrically controlled solenoid valves ? ? ? ? (3/2-way directional control valves) ? Seven electric pressure regulating valves ?(modulation valves) and ? The transmission oil temperature sensor15 T ransmission Design The V alves The valve body contains three different types of solenoid valves. Pressure Regulating Valve with ?Ascending Characteristic Curve The more the pressure regulating valve is supplied ?with current, the higher the hydraulic pressure. ?If the ?pressure regulating valve is not supplied with current, ?no hydraulic pressure is present. Pressure Regulating Valve with ?Descending Characteristic Curve The more the pressure regulating valve is supplied ?with current, the lower the hydraulic pressure. ?If the ?pressure regulating valve is not supplied with current, ?full hydraulic pressure is present. Pressure regulating valves with ascending characteristic curve Pressure regulating valves with descending characteristic curve Selector valves (ON/OFF valves) Automatic Transmission Pressure Regulating Valve 7 N443 Solenoid Va

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