Self-Study Program provides information regarding designs and functions. No part of this document may be reproduced, stored in a retrieval system, or transmitted. For maintenance and repair work, always refer to the current technical literature.
Self-Study Program provides information regarding designs and functions. No part of this document may be reproduced, stored in a retrieval system, or transmitted. For maintenance and repair work, always refer to the current technical literature.
Self-Study Program provides information regarding designs and functions. No part of this document may be reproduced, stored in a retrieval system, or transmitted. For maintenance and repair work, always refer to the current technical literature.
The 02E Direct Shift Gearbox Design and Function Volkswagen of America, Inc. Service Training Printed in U.S.A. Printed 05/2004 Course Number 851403 2004 Volkswagen 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 of America, Inc., its affiliated 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 modified 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 of America, Inc. Always check Technical Bulletins and the Volkswagen Worldwide Repair Information System 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. i Table of Contents The Self-Study Program provides you with information regarding designs and functions. The Self-Study Program is not a Repair Manual. For maintenance and repair work, always refer to the current technical literature. Important/ Note! New! Introduction...................................................................................1 Selector Lever................................................................................3 Direct Shift Gearbox Design.........................................................9 Basic Concept, Torque Input, Multi-disc Clutches, Driveshafts, Output Shafts, Reverse Gear Shaft, Differential Gear, Selector Lever Park Position Interlock, Synchronization, Torque Transfer in the Vehicle, Power Flow in the Transmission Mechatronics Module.................................................................26 Electro-hydraulic Control Unit ...................................................28 Transmission Lubrication System..............................................30 System Overview ........................................................................38 Sensors ........................................................................................40 Actuators .....................................................................................48 Functional Diagram.....................................................................54 CAN-Databus-Links.....................................................................56 Diagnostic....................................................................................57 Service..........................................................................................59 1 Introduction The current transm ission m arket in Europe is prim arily m anual transm issions. H ow ever, the m arkets in Japan and the U nited States use prim arily autom atic transm issions. Both of these transm issions have benefits and draw backs. M anual transm ission benefits: H igh efficiency Strength D river control Autom atic transm ission benefits: H igh com fort Ease of use Based on this inform ation, Volksw agen set out to design a transm ission that com bined the best characteristics of each of these transm issions. The result is the D irect Shift G earbox (D SG ). Transm ission Fluid Filter Transm ission Fluid C ooler Transm ission Fluid Pum p M echatronics M ulti-disc C lutch S308_014 The dual w et-clutch design and autom atic shifting program s of this transm ission w ill satisfy the autom atic transm ission drivers dem ands of high com fort and ease of use. The fast and sm ooth shifting capabilities, w hich can be controlled by the driver, satisfy the m anual transm ission drivers dem ands. A lso, this transm ission offers fuel consum ption characteristics as low as m ost vehicles w ith m anual transm issions. 2 The D irect Shift G earbox has the follow ing features: Six forw ard gears and one reverse gear N orm al driving program , D Sport shifting program , S Selector lever and steering w heel Tiptronic sw itches (optional) M echatronics integrates electronic and electro-hydraulic controls into a single unit, located inside of the transm ission H illholder function: if a vehicle is brought to a stop by light braking, the clutch pressure rises and the vehicle rem ains m otionless C reep regulation: perm its creepingof the vehicle w hen the brake pedal is released and the accelerator pedal is not depressed Em ergency running m ode: w hen in em ergency running m ode, the vehicle can only be driven in either 1 st and 3 rd gears, or only in 2 nd gear Transm ission Fluid Filter Transm ission Fluid C ooler Electric C onnection w ith the Vehicle S308_003 Introduction Part num ber D SG 02E (D irect Shift G earbox Torque M axim al 258 lbs-ft (350 N m ) (engine dependent) C lutch Tw o w et m ulti-disc clutches G ear ranges Six forw ard gears, one reverse gear (all synchronized) O perating m ode Autom atic and Tiptronic m ode Fluid volum e 1.9 gallons (7.2 liters D irect Shift G earbox fluid G 052 182 W eight A bout 207 lbs (94 kg) in front drive vehicles, 229 lbs (104 kg) in 4M otion vehicles 3 Selector Lever Operation The selector lever operation is the sam e as in other autom atic transm ission vehicles. H ow ever, the D irect Shift G earbox also offers the possibility of being shifted w ith Tiptronic. This can be activated either through the selector lever or by using the optional steering w heel buttons. The selector lever controls the selector lever interlock and the ignition key interlock of the vehicles equipped w ith an autom atic transm ission. The interlock function operates the sam e as before, but the construction is different. The selector lever positions are: P - Park To shift the selector lever out of this position, the ignition m ust be O N and the brake pedal m ust be depressed. In addition, the unlocking button m ust be depressed on the selector lever. R - Reverse To shift into Reverse, the unlocking button m ust be depressed. N - Neutral In this position, the transm ission is idling. If the selector lever rem ains in N eutral for an extended period of tim e, the brake pedal m ust once again be depressed to change the lever position. D - Drive This position allow s for autom atic shifting of forw ard gears. U nlocking B utton Steering W heel Sw itches S308_004 S308_063 S - Sport This position allow s for autom atic shifting of forw ard gears but w ill hold each of these gears until a higher R PM before shifting. +and The Tiptronic functions can be controlled in the right cover plate of the selector lever and can also be controlled w ith the steering w heel sw itches. 4 Selector Lever Design The selector lever includes the follow ing com ponents: Selector Lever Sensor System Control Module J 587 The H all sensors in the selector lever input unit record the position of the selector lever and com m unicate this position to the M echatronics via the C A N -B us. Shift Lock Solenoid N110 This solenoid locks the selector lever in the Pand N positions. The solenoid is controlled by the Selector Lever Sensor System C ontrol M odule J587. F319 N 110 H all Sensors to identify the Selector Lever position Selector Lever Sensor System C ontrol M odule J587 Locking Pin H ole for N Locking Pin H ole for P S308_098 Selector Lever Park Position Interlock Switch F319 If the selector lever is in the Pposition, the sw itch sends the signal Selector lever in Ppositionto the Steering C olum n Electronics System C ontrol M odule J527. The control m odule requires this signal to control the ignition key interlock. Selector Lever 5 Selector Lever The Shift Lock Solenoid N 110 functions as follow s: Selector lever locked in P: W hen the selector lever is in P, the spring activated locking pin is in the locking pin hole P. As a result, it prevents the accidental shifting of the selector lever. Selector lever unlocked: O nce the ignition has been sw itched on and the brake pedal has been applied, the Selector Lever Sensor System C ontrol M odule J587 energizes the Shift Lock Solenoid N 110. As a result, the locking pin is pulled out of the locking pin hole P. The selector lever can then be m oved in other positions. Selector lever locked in N: If the selector lever rem ains in the N position for m ore than 2 seconds, J587 w ill energize N 110, allow ing the locking pin to engage in the N locking pin hole. This prevents accidental shifting of the selector lever into a drive gear. This pin w ill be unlocked w hen the brake pedal is depressed. Shift Lock Solenoid N110 S308_101 S308_102 Locking Pin H ole for N Shift Lock Solenoid N 110 C om pression Spring Locking Pin H ole for P Locking Pin S308_103 6 Emergency release In case of a pow er supply failure to the Shift Lock Solenoid N 110, the selector lever can no longer be shifted because the shift lock Prem ains activated by spring tension. A pply m echanical pressure on the locking pin w ith a sm all object to disengage the shift lock. This releases the selector lever into the N position. S308_104 Selector Lever 7 + F319 J 527 - Selector Lever Ignition key interlock The ignition key interlock prevents the rem oval of the ignition key from the ignition assem bly if the selector lever is not engaged and locked in the Park position. It operates electrom echanically and is controlled by the Steering C olum n Electronics System C ontrol M odule J527. The interlock functions as follows: Selector lever in P; ignition sw itched O FF. If the selector lever is in P, the Selector Lever Park Position Interlock Sw itch F319 is open. The Steering C olum n Electronics System C ontrol M odule J527 recognizes that the sw itch is open. The Ignition Sw itch Key Lock Solenoid N 376 is not energized. The com pression spring in the solenoid presses the locking pin into the disengaged position. M agnet N 376 S308_093 Retaining Lug Ignition O FF Locking Pin C om pression Spring S308_092a 8 - + F319 J 527 The interlock functions as follows: Selector lever in D , the ignition is sw itched O N . W hen the selector lever is in D , the Selector Lever Park Position Interlock Sw itch F319 is closed. The Steering C olum n Electronics System C ontrol M odule J527 energizes the Ignition Sw itch Key Lock Solenoid N 376. The locking pin is pushed through the solenoids, against the strength of the com pression spring, and into the lock position. In the lock position, the locking pin prevents the ignition key from being turned back and rem oved. O nly w hen the selector lever is pushed in Pw ill the Selector Lever Park Position Interlock Sw itch F319 open w hile the control m odule deactivates the solenoid. The locking pin is then pulled back by the com pression spring. The ignition key can be rotated and pulled out. Ignition O n N 376 S308_091a Selector Lever 9 Direct Shift Gearbox Design Basic Concept The D irect Shift G earbox is basically a m anual transm ission designed to operate like an autom atic transm ission. In place of a dry clutch, tw o w et clutches are used. These w et clutches rotate in transm ission fluid. The M echatronics C ontrol M odule J743 controls clutch operation and gear selection. B asically, the transm ission is alw ays engaged. O uter D isc-C arrier K2 O uter D isc-C arrier K1 D ual-m ass Flyw heel Input H ub C lutch D riving D isc M ain H ub S308_007c 10 Direct Shift Gearbox Design Direct Shift Gearbox Schematic diagram Input Shafts O utput Shaft 2 Reverse G ear Shaft D rive G ear of the D ifferential S308_089b O utput Shaft 1 M ulti-disc C lutches Input from Engine 11 Torque Input The torque is transferred from the crankshaft to the dual-m ass flyw heel. The splines of the dual-m ass flyw heel on the entry hub of the dual clutch transfer the torque to the driving disc of the m ulti-disc clutch. The dual-m ass flyw heel transfers the torque to the input hub via splines. Therefore, the follow ing com ponents turn at the sam e speed as the dual-m ass flyw heel and input hub: C lutch driving disc M ain hub O uter disc-carrier K1 O uter disc carrier K2 O uter D isc-C arrier K2 O uter D isc-C arrier K1 D ual-m ass Flyw heel Input H ub C lutch D riving D isc M ain H ub S308_007a Direct Shift Gearbox Design 12 Direct Shift Gearbox Design Multi-disc Clutches The torque is transferred into the respective clutch through the outer disc-carrier. B y closing the clutch, the torque is transferred to the inner disc-carrier and then to the corresponding input shaft. There is alw ays one m ulti-disc clutch activated in all drive gears. Multi-disc clutch K1 C lutch K1 is the outer clutch and transfers the torque to Input Shaft 1 for 1 st , 3 rd , and 5 th gears and Reverse. Increasing the transm ission fluid pressure in the clutch K1 fluid pressure cavity w ill close the clutch. A s a result, piston 1 m oves and presses the m ulti-discs of clutch K1 together. The torque is transferred to Input Shaft 1 by the m ulti-disc clutch. W hen the clutch opens, the spring w asher pushes piston 1 back into its initial position. Inner D isc-C arrier K1 O uter D isc-C arrier K1 Piston 1 Transm ission Fluid Pressure C avity K1 Input Shaft 1 Spring W asher C lutch K1 S308_039 13 Multi-disc clutch K2 C lutch K2 is the inner clutch and transfers the torque to Input Shaft 2 for 2 nd , 4 th , and 6 th gears. Increasing the transm ission fluid pressure in the clutch K2 fluid pressure cavity w ill close the clutch. The piston K2 closes the pow er flow to Input Shaft 2 through the m ulti-disc clutch. W hen the clutch opens, the coil springs push piston 2 back into its initial position. C lutch K2 Piston 2 Fluid Pressure C avity K2 Inner D isc-C arrier K2 C oil Spring Input Shaft 2 S308_040 Direct Shift Gearbox Design 14 Drive Shafts The engine torque is transferred to the input shafts by the m ulti-disc clutches K1 and K2. Input Shaft 2 Input Shaft 2 is a hollow shaft and is coupled to the m ulti-disc K2 by external splines. The helical gear w heels for 6 th , 4 th and 2 nd gears are on Input Shaft 2. A com m on gearw heel is used for 6 th and 4 th gears. The D riveshaft 2 Speed Sensor G 502 is located next to the second gear w heel. This sensor m easures the speed of Input Shaft 2. Input Shaft 1 Input Shaft 2 S308_010 Im pulsion W heel 6 th /4 th G ears 2 nd G ear S308_084 Direct Shift Gearbox Design The Input Shafts m ay be referred to as D riveshafts in the repair inform ation. 15 Input Shaft 1 Input Shaft 1 rotates inside of Input Shaft 2, w hich is hollow . It is connected to the m ulti-disc clutch K1 by external splines. The helical gear w heel for 5 th gear, the com m on gear w heel for 1 st gear and Reverse, and the gear w heel for 3 rd gear are located in Input Shaft 1. The D riveshaft 1 Speed Sensor G 501 is located betw een 1 st , Reverse and 3 rd gear w heels. This sensor m easures the speed of Input Shaft 1. A strong m agnet can destroy the im pulsion w heels! Im pulsion W heel 5 th G ear 1 st G ear/ Reverse 3 rd G ear S308_085 Direct Shift Gearbox Design 16 Direct Shift Gearbox Design Output Shafts Just as there are tw o input shafts, there are tw o output shafts in the D irect Shift G earbox. Stretched representation 1 st G ear 3 rd G ear 4 th G ear 2 nd G ear O utput G ear W heel Sliding C ollar Mounting position in the transmission D rive Shafts S308_086 S308_105a The follow ing are located on the O utput Shaft 1: The triple synchronized control w heels for 1 st , 2 nd and 3 rd gears The single synchronized control w heel for 4 th gear The output gear w heel for engaging the differential gear The output shaft m eshes in the gear w heel of the differential gear final drive. The overall length of the transm ission w as shortened by using a com m on gear w heel on the input shafts for 1 st gear and Reverse, as w ell as a com m on gear w heel for 4 th and 6 th gears . Output Shaft 1 17 Output Shaft 2 Stretched representation Mounting position in the transmission Im pulsion W heel for G 195 and G 196 5 th G ear 6 th G ear Reverse O utput G ear W heel S308_87 S308_105b The follow ing are located on the O utput Shaft 2: A n im pulsion w heel for the transm ission output R PM The control w heels for 5 th and 6 th gears as w ell as the gear w heel of the reverse gear The output gear w heel for engaging the differential gear B oth output shafts provide the torque to the differential gear through their output gear w heel. Direct Shift Gearbox Design 18 Direct Shift Gearbox Design Reverse Gear Shaft The R everse G ear Shaft changes the direction of rotation of O utput Shaft 2 and, as a result, changes also the direction of rotation of the gears for the final drive of the differential gear. It is m eshed w ith the 1 st gear and R everse com m on gear w heel on Input Shaft 1, and w ith the Reverse control w heel on O utput Shaft 2. Stretched representation Mounting position in the transmission G ear W heel for 1 st G ear and R everse Reverse G ear Shaft S308_105c S308_088 19 Differential Gear Both output shafts transfer the torque to the differential drive gear. The differential gear transfers the torque through the drive train to the w heels. The park position lock w heel is integrated into the differential gear. Stretched representation Mounting position in the transmission D rive G ear of the D ifferential Parking Lock W heel S308_089 S308_105d Direct Shift Gearbox Design 20 Direct Shift Gearbox Design Parking Lock A parking lock is built into the differential gear assem bly to help ensure a com plete stop of the vehicle and prevent the vehicle from unintentionally rolling aw ay w hen the hand brake is not activated. The parking lock is m echanically controlled by a connecting cable betw een the selector lever and the parking position lock lever in the transm ission. The only function of the connecting cable is to operate the parking lock. Parking Lock Parking Lock W heel S308_023 Function The parking lock is engaged by shifting the selector lever in the Pposition. As a result, the parking lock engages into the teeth of the parking lock w heel. A detent spring locks the lever in place and sets the parking lock in its position. If the parking lock does not lock into a gap betw een the teeth of the parking lock w heel, the spring w ill be com pressed. If the vehicle m oves, the parking lock w ill lock into the next gap of the parking lock w heel. The park position lock is disengaged by shifting the selector lever out of the P position. The slider is pushed back to the right into its initial position and the com pression spring 2 pushes the parking lock out of the gap of the parking lock w heel. Lever C onnecting C able to the Selector Lever Slider C om pression Spring 1 D etent Spring C om pression Spring 2 Parking Lock W heel Parking Lock S308_079a 21 Synchronization To change gears w ithout interference or noise, the D irect Shift G earbox uses synchronization on each gear. The purpose of a synchronizer is to bring to the sam e speed the gears to be m eshed and the selector sleeve. This allow s for easy shifting. The synchronizer rings are m ade of brass that is coated in m olybdenum . The m olybdenum allow s for long life. G ears 1, 2 and 3 are equipped w ith triple synchronization. This triple synchronization provides a larger heat transfer surface. The larger heat surface is needed because the rotation speed differences are higher in the low er gears. G ears 4,5 and 6 have sim ple cone synchronization. Since the speed differences are not as high, the larger surface area of the triple synchronizers is not needed. Interm ediate R ing Inner R ing O uter R ing Friction C one Friction C one Synchronization R ing S308_022 S308_078 Direct Shift Gearbox Design The reverse gear has a double-cone synchronization. The sim ple synchronization is m ade of: The synchronizing ring The friction cone of the shifting gear w heel The triple synchronization is m ade of: A n outer ring (synchronization ring) A n interm ediate ring A n inner ring (2 nd synchronization ring) The friction cone of the shifting gear w heel Triple Synchroniser Simple Synchroniser 22 Direct Shift Gearbox Design Torque Distribution The engine torque is transferred from the dual-m ass flyw heel to the transm ission. For front-w heel drive vehicles, this torque is transferred to a drive shaft on either side, w hich allow s the w heels to turn. For all-w heel drive vehicles, there are drive shafts for the front w heels and a drive shaft going to the rear differential to drive the rear w heels. D irect Shift G earbox D ifferential G ear H aldex C oupling Rear D ifferential S308_020 S308_021 Vehicles equipped w ith the D irect Shift G earbox have a H aldex coupling to distribute the torque to the rear w heels. W hen the H aldex coupling locks, torque is passed from the input shaft to the rear differential and out through the rear input shafts to the rear w heels. 23 Transmission Power Flow The engine torque is transferred to the transm ission either through clutch K1 or K2. Each of these clutches drives a separate shaft. Input Shaft 1 is driven by the K1 clutch Input Shaft 2 is driven by the K2 clutch There are tw o additional shafts needed to transfer the pow er to the differential: O utput shaft 1 for gears 1, 2, 3, and 4 O utput shaft 2 for gears 5, 6 and Reverse 1 st Gear K1 C lutch Input Shaft 1 O utput Shaft 1 D ifferential S308_055_1 Direct Shift Gearbox Design 24 Direct Shift Gearbox Design 2 nd Gear K2 C lutch Input Shaft 2 O utput Shaft 1 D ifferential 3 rd Gear K1 C lutch Input Shaft 1 O utput Shaft 1 D ifferential 4 th Gear K2 C lutch Input Shaft 2 O utput Shaft 1 D ifferential S308_055_2 S308_055_3 S308_055_4 25 5 th Gear K1 C lutch Input Shaft 1 O utput Shaft 2 D ifferential 6 th Gear K2 C lutch Input Shaft 2 O utput Shaft 2 D ifferential Reverse K1 C lutch Input Shaft 1 Reverse G ear Shaft O utput Shaft 2 D ifferential S308_055_6 S308_055_R The change of rotation direction for Reverse is perform ed through the reverse gear shaft. Direct Shift Gearbox Design S308_055_5 26 Mechatronics Module Mechatronics The M echatronics assem bly is located inside of the transm ission and im m ersed in transm ission fluid. This assem bly is m ade up of both the transm ission control m odule and electro-hydraulic controls. The M echatronics is the central control m odule of the transm ission. A ll sensor signals from the transm ission and other relevant areas of the vehicle are sent to the M echatronics assem bly. As a result, the M echatronics assem bly can m onitor the operation of the transm ission and regulate output correctly. Electro-hydraulic C ontrol U nit S308_095 S308_097 C entral C onnector to the Vehicle. Tw elve sensors are located w ithin the M echatronics assem bly. These sensors regulate eight hydraulic gear actuators, six pressure m odulation valves, five control valves and the pressure and cooling of both clutches. The M echatronics assem bly can adapt to learn the positions of the clutches, the positions of the gear actuators for each specific gear and the m ain transm ission fluid pressure. 27 The benefits of this assem bly are: Integrated sensors Actuators located directly on the M echatronics assem bly A ll interaction w ith the rest of the vehicle is done through a single connector These features reduce the num ber of connectors and w ires, providing better electrical reliability and low er w eight. H ow ever, this also m eans that the transm ission control m odule electronics are exposed to higher therm al and m echanical loads. The M echatronics assem bly has been engineered to easily w ithstand these conditions. Electronic C ontrol M odule S308_096 Mechatronics Module 28 Electro-hydraulic Control Unit Electro-hydraulic Control Unit The electro hydraulic control unit is integrated to the M echatronics m odule. A ll the solenoid valves, pressure control valves, the hydraulic slider and the m ultiplexer are located inside the control unit. N 88 Solenoid Valve 1 (G ear actuating valve) N 89 Solenoid Valve 2 (G ear actuating valve) N 90 Solenoid Valve 3 (G ear actuating valve) N 91 Solenoid Valve 4 (G ear actuating valve) N 92 Solenoid Valve 5 (M ultiplexer valve) N 215 Pressure Control Valve 1 (Clutch valve K1) N 216 Pressure Control Valve 2 (Clutch valve K2) A pressure relief valve is located outside of the hydraulic m odule. This valve prevents high internal pressures that can dam age the hydraulic valves. N 217 Pressure C ontrol Valve 3 (M ain pressure valve) N 218 Pressure C ontrol Valve 4 (C oolant valve) N 233 Pressure C ontrol Valve 5 (Safety valve 1) N 371 Pressure control valve 6 (Safety valve 2) A Pressure Relief Valve B Printed C ircuit Board S308_033 N 215 N 218 N 371 B N 88 N 233 N 217 A N 92 N 216 29 Valves have different shifting characteristics according to their function. The tw o function types are: Yes/N ocontrol valves M odulation valves The Yes/N ocontrol valve type includes: The gear selector valves and The m ultiplexer valve The M odulation valve type includes: The m ain pressure valve The cooling fluid valve The clutch valves The safety valve The gear actuator valves N 89, N 90 and N 91 can be seen by rem oving the printed circuit board. N 89 N 92 N 90 N 91 S308_034 Electro-hydraulic Control Unit 30 Transmission Lubrication System Transmission Fluid System The D SG transm ission has a fluid capacity of 7.2 liters. This fluid m ust m eet the follow ing requirem ents: Ensure clutch regulation and hydraulic control H ave a stable viscosity through the entire tem perature range W ithstand and lubricate the dual-clutch, w heels, shafts, bearings and synchronizer rings under high m echanical loads N o foam A llow for sm ooth operation of all valves A llow for correct operation of the dual- clutch and gear control piston A separate transm ission fluid cooler prevents the transm ission fluid tem perature from rising above 135C (275F). This cooler uses engine coolant to reduce tem perature. . G ear Actuator Transm ission Fluid C ooler Transm ission Fluid Filter Transm ission Fluid Spraying Tube for C ooling the G ear W heels Valve Body Transm ission Fluid Pum p Transm ission Fluid Sum p S308_019 31 Transmission Fluid Pump A crescent shaped pum p draw s the transm ission fluid and produces the m ain pressure required for the hydraulic parts to operate. It produces up to 26.4 gal/m in (100 l/m in) and a m axim um pressure of 20 bar (290 psi). The transm ission fluid pum p supplies fluid for: The m ulti-disc clutches The clutch cooling The gear shift hydraulic pressure The gear w heel lubrication The transm ission fluid pum p is driven by the pum p shaft rotating at engine R PM . This pum p shaft is a third shaft located inside Input Shaft 1, w hich rotates w ithin Input Shaft 2. C rescent Pressure Side Suction Side Return Pipe to Suction Side S308_018 Pum p Shaft D ual-M ass Flyw heel Transm ission Fluid Pum p Input Shaft 1 Input Shaft 2 S308_036 Transmission Lubrication System 32 Transmission Lubrication System Schematic Diagram Transm ission Fluid Pum p Transm ission Fluid C ooler Suction Filter Transm ission Fluid Filter Transm ission Fluid Spraying Tube Transm ission Fluid Sum p Pressure R elief Valve M ain Pressure Slide Valve Pressure C ontrol Valve 3 O il Pum p Return Pipe C lutch C ooling Fluid Slide Valve C ooling Fluid tow ard the C lutches Lubrication/C ooling of G ear W heels To M ulti- D isc C lutch K2 To M ulti-D isc C lutch K1 G ear Actuator Color Coding Regulated pressure, w ork pressure U ncontrolled pressure C ontrolled pressure, clutch cooling Transm ission fluid sum p return circuit S308_017a 33 Transmission Lubrication System Description The transm ission pum p draw s the transm ission fluid from the sum p, through the filter, pressurizes it and sends it to the m ain pressure slider valve. The M ain Pressure Valve N 217 controls the m ain pressure slider valve. This regulates fluid pressure inside of the transm ission. A transm ission fluid channel from the m ain pressure slider valve directs extra fluid back to the transm ission pum p suction side. Pressurized fluid from the m ain pressure slider valve branches off into tw o channels. O ne channel directs the fluid to the transm ission fluid cooler, cooling the fluid and returning it to the sum p. The other channel directs the fluid to the clutch cooling fluid slide valve. O ther features of the fluid circuit: The transm ission fluid cooler is in the engine cooling circuit and uses engine coolant to control tem perature The transm ission fluid filter is located outside of the transm ission housing The pressure relief valve lim its the fluid pressure to 32 bar (464 psi) The individual gears are lubricated by fluid spray from directional nozzles Transmission Lubrication System 34 Transmission Lubrication System Schematic Diagram of Hydraulic Elements in the Transmission Lubrication System Pressure R elief Valve U V M ain Pressure Slide Valve M ain Pressure Valve N 217 Safety Valves N 233 and N 371 Pressure Accum ulator C heck Valve Pressure Sensor G 194 C lutch Valve N 216 M ultiplex valve N 92 M ultiplex Pressure Accum ulator Pressure Sensor G 193 C heck Valve C lutch Valve N 215 G ear Actuator To K2 To K1 N 88 N 89 N 90 N 91 S308_017b Color Coding Regulated pressure, w ork pressure U ncontrolled pressure Transm ission fluid sum p return circuit 35 Electro-hydraulic Control of the Transmission Fluid System. Pressure Control Valve 3 for Automatic Transmission N217 The Pressure C ontrol Valve 3 for Autom atic Transm ission N 217 controls the m ain pressure valve. This controls the m ain pressure for all of the transm ission com ponents including: Pressure C ontrol Valve 1 N 215 Pressure C ontrol Valve 2 N 216 C lutch K1 C lutch K2 Solenoid Valve 1 N 88 Solenoid Valve 2 N 89 Solenoid Valve 3 N 90 Solenoid Valve 4 N 91 In addition to controlling the m ain supply pressure, N 217 also controls: The transm ission fluid return through the transm ission fluid cooler, transm ission fluid filter and spray nozzle Transm ission fluid pum p return circuit Multiplexer valve Solenoid Valve 5, N 92, operates the m ultiplexer in the transm ission. The m ultiplexer is a slide valve that allow s four solenoid valves to have the control of eight solenoid valves. The m ultiplexer has tw o positions, hom e and w ork. The default position is the hom e position and it is held in that position by a spring w hen N 92 is not energized. In this position, gears 1,3,6 and Reverse can be selected. W hen N 92 is energized, pressure is applied to the m ultiplexer and the spring is com pressed. In the w ork position, gears 2,4,5, and N eutral can be selected. A lso, in the w ork position, the m ultiplexer spring is com pressed. Safety valve A safety valve for clutches K1 (N 233) and K2 (N 371) allow s a quicker opening of the respective clutch. This is necessary w hen the actual clutch pressure is above the rated pressure. Pressure sensors G193 and G194 Pressure sensors G 193 and G 194 control the clutch pressure of clutches K1 and K2. A pressure relief valve prevents an increase of the m ain pressure that could result from a defective m ain pressure slide valve. Transmission Lubrication System 36 Transmission Lubrication System Clutch Cooling Lubrication System The m echanical friction in the m ulti-disc clutches increases the tem perature of the dual clutch. To cool dow n the clutches, the transm ission fluid circulation system includes a separate clutch cooling system . The coolant slide valve and the Pressure C ontrol Valve 4 N 218 (clutch cooling valve) belong to the clutch cooling system . The m ulti-plate clutches oil tem perature sensor G 509 m easures the fluid tem perature directly at the m ulti-disc clutchesfluid discharge. D epending on the m easured tem perature, the pressure control valve either increases or reduces the fluid pressure to the clutch cooling fluid slide valve. The clutch coolant slide valve opens or closes the fluid pressure for the fluid channel to the m ulti- disc clutches. The m axim um cooling fluid flow is 20 liters per m inute. The m axim um cooling fluid pressure is 2 bar (29 psi). C lutch C oolant Slide Valve Pressure Accum ulator M echatronics Transm ission Fluid Tem perature Sensor for the M ulti-D isc C lutches S308_061 N 218 37 Shifting Gears G ear shifting is based on m anual transm ission gearshift forks. Each fork shifts 2 gears. The operation of the gearshift forks is perform ed hydraulically in the D irect Shift G earbox, instead of w ith a cam m echanism like the one used in com m on m anual transm issions. The gearshift forks are set in cylinder ball bearings, for sm ooth operation. To shift a gear, the M echatronics fluid is sent to the left cylinder. Since the right cylinder pressure is open, the gearshift fork m oves and activates the selector sleeve. As a result, the gear is engaged. O nce the gear is engaged, the gearshift fork pressure is sw itched off. The gear is stopped by a detent in the shift tooth system and by the indexing socket of the gearshift fork. W hen the gearshift fork is not activated, it is held in the neutral position by a detent in the transm ission housing. O n each gearshift fork, there is a perm anent m agnet. W ith this m agnet, the position sensor in the M echatronics can identify the exact position of the individual gearshift forks. Fluid Pressure from the M echatronics Indexing Sleeve Piston Cylinder Position Sensor M agnet G earshift Fork Sliding C ollar S308_047 S308_048 Transmission Lubrication System 38 System Overview M ulti-Plate C lutch O il Tem perature Sensor G 509 Sensor for Transm ission R PM G 182 Senders for Transm ission O utput R PM G 195 and G 196 D riveshaft 1 Speed Sensor G 501 and D riveshaft 2 Speed Sensor G 502 Sender 1 G 193 and Sender 2 G 194 for H ydraulic Pressure, Autom atic Transm ission Transm ission Fluid Tem perature Sensor G 93 Tem perature Sensor (in C ontrol M odule) G 510 G ear Position D istance Sensors 1 to 4, G 487, G 488, G 489, G 490 Tiptronic B uttons (on the Steering W heel) E438 and E439 Sensors D irect Shift G earbox (D SG ) M echatronics J743 39 Selector Lever Sensor System C ontrol M odule J587 CAN Actuators Shift Lock Solenoid N 110 Pressure C ontrol Valves N 215, N 216, N 217 Solenoid Valves N 88, N 89, N 90, N 91, N 92, N 218, N 233, N 371 D iagnostic C onnector S308_024 System Overview 40 Sensors Sensor for Transmission RPM G182 The sensor for transm ission R PM is positioned inside the transm ission housing. It electronically senses the outside of the double coupling and records the input transm ission R PM . The transm ssion input R PM is identical to the engine R PM . G 182 is a H all sensor that is integrated w ith the M ulti-plate C lutch O il Tem perature Sensor G 509. Electrical w ires connect both sensors to the M echatronics. Signal utilization The transm ission input R PM signal is used to calculate the m ulti-disc clutches slip. For this calculation, the control m odule also uses the signals from sensors G 501 and G 502. W ith the calculated slip rate, the control m odule can regulate correctly the opening and closing of the clutches. G 182 S308_056 Effect of signal failure In case of signal failure, the control m odule uses the engine R PM from the C A N as a replacem ent signal. 41 Driveshaft 1 Speed Sensor G501 and Driveshaft 2 Speed Sensor G502 The tw o sensors located in the M echatronics unit are H all effect sensors. Sensor G 501 records the R PM of Input Shaft 1. Sensor G 502 records the R PM of Input Shaft 2. To identify the shaft R PM , each sensor detects an im pulsion w heel installed on the respective shaft. The im pulsion w heel is m ade of sheet m etal. A coat of rubber- m etal is deposited on the sheet m etal. This coat constitutes a ring of sm all m agnets w ith N orth and South poles. There is an air gap betw een each m agnet. G 501 G 502 Im pulsion W heel for G 501 Im pulsion W heel for G 502 Signal utilization W hen this signal is com pared to the transm ission input R PM signal, the control m odule calculates the output R PM of the m ulti-disc clutches K1 and K2, and can identify the clutch slippage. O nce the slippage is know n, the control m odule regulates the opening and closing of the clutches. This signal is also used to m onitor the currently selected gear in the transm ission. B y com paring this signal to the output R PM sensor signal, the control m odule can verify that the correct gear is engaged. Effect of signal failure In case of a signal failure, the affected transm ission circuit is closed. In case of sensor G 501 failure, it is only possible to drive in 2 nd gear. In case of sensor G 502 failure, it is only possible to drive in 1 st and 3 rd gear. A strong m agnet w ill destroy the im pulsion w heel. S308_026c S308_010a Sensors S308_106 42 Sensors Sender 1 for Transmission Output RPM G195 and Sender 2 for Transmission Output RPM G196 The sensors G 195 and G 196 are located in the M echatronics and are perm anently m ounted on the control m odule. Like all other R PM sensors in this transm ission, these sensors are H all effect sensors. Both sense the sam e im pulsion w heel on O utput Shaft 2. The tw o sensors are placed next to each other and are protected by a housing. As a result, tw o opposite signals are generated. If the signal of sensor G 195 is high, the signal of sensor G 196 is low . G 195 G 196 S308_026a G 196 G 195 Im pulsion W heel S308_050 Signal utilization W ith the detailed signals, the control m odule can identify the vehicle speed and the direction of travel. The direction of travel is identified by com paring the signals against each other. W hen a m odification of travel direction occurs, the signals com e in opposite order in the control m odule. Effect of signal failure In case of signal failure, the control m odule uses the vehicle speed signal and the travel direction signal from the A B S control m odule. 43 Sender 1 G193 and Sender 2 G194 for Hydraulic Pressure, Automatic Transmission The pressure sensors G 193 and G 194 are located in the electro-hydraulic control unit of the M echatronics. The sam e pressure that acts on the m ulti- disc clutch K1 acts on Sender 1 G 193. The m ulti-disc clutch K2 pressure acts on Sender 2 G 194. Parallel Plates C eram ic M em brane Substrate S308_107 G 193 G 194 S308_031 Effect of signal failure In case of failure of the pressure signal, or if the pressure does not build up, the corresponding transm ission circuit is closed. The transm ission can only be operated in 1 st and 3 rd gear, or in 2 nd gear. S308_108 Sensors Pressure sensor function The pressure sensor consists of a pair of electrically conductive parallel plates. The upper plate is m ounted on a ceram ic m em brane, w hich is deflected according to the pressure variation. The other plate is rigidly coupled to a ceram ic substrate. This substrate does not react to the pressure variation. The upper m em brane is bent according to the pressure variations, and the distance betw een the plates varies accordingly. As a result, a reliable signal is produced as a function of the transm ission fluid pressure. Signal utilization W ith these signals, the M echatronics electronic control m odule can identify the hydraulic pressure acting on the respective m ulti-disc clutch. Precise hydraulic pressure is required for the control m odule to regulate the m ulti-disc clutches. 44 Sensors Multi-plate Clutch Oil Temperature Sensor G509 The M ulti-Plate C lutch O il Tem perature Sensor G 509 is integrated w ith the Sensor for Transm ission R PM G 182. It m easures the tem perature of the transm ission fluid leaving the m ulti-disc clutches. The m ulti- disc clutches generate m ore heat than any other com ponent in the transm ission, and the transm ission fluid leaving them m ust be m onitored accurately. This sensor is built so that it can m easure the tem perature very quickly and very precisely. It can record tem peratures from 55C to + 180C (-67F to 356F). G 509 S308_056 Signal utilization W ith the signals from tem perature sensor G 509, the control m odule regulates the am ount of clutch cooling fluid and initiates other m easurem ents to protect the transm ission. Effect of signal failure In case of signal failure, the control m odule uses the signals from sensors G 93 and G 510 as replacem ent signals. 45 Transmission Fluid Temperature Sensor G93 and Control Module Temperature Sensor G510 Sensors G 93 and G 510 are integrated into the M echatronics unit, w hich is surrounded by transm ission fluid. Excessive heat in the transm ission fluid can dam age the M echatronics. These tw o sensors m easure the tem perature of the M echatronics and the fluid surrounding it. A s a result, transm ission fluid tem perature increases can be detected early enough to prevent a rapid increase in the M echatronics tem perature. . G 93 G 510 S308_026d Signal utilization B oth sensor signals are used to m easure the M echatronics tem perature. In addition, based on the sensor signals, a w arm -up control program is started. B oth sensors are used to check each other. Effect of signal failure W hen tem perature reaches 138C (280F), the M echatronics initiates a reduction in engine torque. A t tem peratures above 145C (293F), the m ulti-disc clutches are no longer provided w ith fluid pressure and the clutches open. Sensors 46 Sensors Gear Position Distance Sensors 1 to 4 G487, G488, G489, G490 These H all effect position sensors are located in the M echatronics. A long w ith the m agnets and the gearshift forks, they produce a signal allow ing the control m odule to know the position of the gear actuator. Each position sensor m onitors the position of a gear actuator/gearshift fork, w hich allow s a decision betw een tw o gears : G 487 for gears 1/3 G 488 for gears 2/4 G 489 for gears 6/R G 490 for gears 5/N G 487 G 488 G 489 G 490 S308_025 Signal utilization O nce it has received the exact position, the control m odule lets the gear actuator use the transm ission fluid pressure to shift gears. Position Sensor M agnet S308_048 Effect of signal failure If a position sensor fails to provide a signal, the affected transm ission circuit is closed. The gears in the affected transm ission circuit can no longer be used. 47 Selector Lever Sensor System Control Module J 587 The Selector Lever Sensor System C ontrol M odule J587 is integrated in the selector lever. It functions sim ultaneously as a control m odule and as tw o separate sensors. A s a control m odule, it w orks to control the solenoid for the selector lever interlock. The selector lever lighting is integrated. A t the sam e tim e, it contains a H all effect sensor to recognize the position of the selector lever and a H all effect sensor to recognize the Tiptronic controls. The signals for selector lever position and for Tiptronic are sent to the M echatronics and to the control m odule for application of the shift table. H all Sensor for Tiptronic position Selector Lever Sensor System C ontrol M odule J587 H all sensors S308_041 Sensors 48 Actuators Pressure Control Valve 3 N217 (Main Pressure Valve) The Pressure C ontrol Valve 3 N 217 is located in the electro-hydraulic control unit of the M echatronics. It is a m odulation valve. The m ain pressure in the M echatronics hydraulic system is regulated by this valve. The m ost im portant factor in com puting m ain pressure is clutch pressure, w hich depends on engine torque. Engine tem perature and engine speed are used to correct the m ain pressure. The control m odule continually adjusts the m ain pressure based on current conditions. N 217 S308_054_1 Effect of signal failure If the pressure control valve is defective, the m axim um m ain pressure w ill be used. A s a result, fuel consum ption m ay increase and gearshifts m ay becom e harsh. 49 Pressure Control Valve 1 N215 and Pressure Control Valve 2 N216 (Clutch Valves) The Pressure C ontrol Valves N 215 and N 216 are located in the electro-hydraulic control unit of the M echatronics. They are m odulation valves and produce the control pressure for the m ulti-disc clutches Pressure C ontrol Valve N 215 for m ulti-disc clutch K1 and Pressure C ontrol Valve N 216 for m ulti-disc clutch K2. Engine torque is the basis for the com putation of clutch pressure. The control m odule adjusts clutch pressure based on the actual friction coefficient of the m ulti- disc clutches. N 215 N 216 S308_054_4 Effect of signal failure In case of failure of a pressure control valve, the corresponding transm ission circuit is closed. This failure w ill be displayed in the instrum ent panel insert. Actuators 50 Actuators Pressure Control Valve 4 N218 (Coolant Valve) The Pressure C ontrol Valve N 218 is located in the electro-hydraulic control unit. It is a m odulation valve and controls a hydraulic slide valve to regulate the volum e of clutch cooling fluid. To control the valve, the control m odule uses the signal from the M ulti-Plate C lutch O il Tem perature Sensor G 509. N 218 S308_054_2 Effect of signal failure If the pressure control valve cannot be actuated, the m axim um cooling fluid volum e flow s through the m ulti-disc clutches. In case of low outside tem perature, this could result in problem s shifting gears as w ell as a higher fuel consum ption. 51 Solenoid Valves 1 N88, 2 N89, 3 N90 and 4 N91 (Gear Actuator Valves) The four solenoid valves are located in the electro-hydraulic control unit of the M echatronics. These are O N /O FF valves. They regulate all fluid pressure of the m ultiplexer slide valves for the gear actuators. W hen de-energized, the solenoid valves are closed and no fluid pressure is provided to the gear actuators. Solenoid Valve 1 N 88 controls the fluid pressure to shift the 1 st and 5 th gears Solenoid Valve 2 N 89 controls the fluid pressure to shift 3 rd gear and N eutral Solenoid Valve 3 N 90 controls the fluid pressure to shift 2 nd and 6 th gears Solenoid Valve 4 N 91 controls the fluid pressure to shift 4 th gear and Reverse N 90 N 89 N 88 N 91 S308_054_13 Effect of signal failure In case of failure of a solenoid valve, the corresponding transm ission circuit, containing the corresponding gear actuator, w ill be closed. The vehicle can only be driven in 1 st and 3 rd gears, or only in 2 nd gear. Actuators 52 Actuators Solenoid Valve 5 N92 (Multiplexer Valve) The Solenoid Valve 5 N 92 is located in the M echatronics electro-hydraulic control unit. It controls the m ultiplexer in the hydraulic control unit. W hen the solenoid valve is activated, gears 2, 4 and 6 can be shifted. W hen the solenoid valve is deactivated, gears 1, 3, 5, and Reverse can be shifted. N 92 S308_054_11 Effect of signal failure The m ultiplexer slide valve rem ains in its resting position. It can no longer be activated by fluid pressure. Incorrect gear shifting m ay occur. It is also possible that the vehicle w ill not engage any gear. 53 Pressure Regulating Valve 5 N233 and Pressure Regulating Valve 6 N371 (Safety Valves) Pressure Regulating Valves N 233 and N 371 are housed in the M echatronics hydraulic m odule. They are m odulation valves. They regulate the safety valves inside the M echatronics valve body. In case of a safety related failure in a transm ission circuit, the safety valve cuts the hydraulic pressure of the corresponding transm ission circuit. Pressure Regulating Valve 5 N 233 controls the safety slide valve in transm ission circuit 1. Pressure Regulating Valve 6 N 371 controls the safety slide valve in transm ission circuit 2. N 371 N 233 S308_054_6a Effect of signal failure In case of failure of a pressure control valve, it is no longer possible to shift any gear in the corresponding transm ission circuit. If transm ission circuit 1 shuts dow n, it is only possible to drive in 2 nd gear. If transm ission circuit 2 shuts dow n, it is only possible to drive in 1 st or 3 rd gear. Actuators 54 9 31 N89 N88 A J 329 v Functional Diagram A Battery E313 Selector Lever F4 B ack-up Light Sw itch F319 Selector Lever Park Position Lock Sw itch G 93 Transm ission Fluid Tem perature Sensor G 182 Sensor for Transm ission R PM G 193 Sender 1 for H ydraulic Pressure G 194 Sender 2 for H ydraulic Pressure G 195 Sender for Transm ission O utput R PM G 196 Sender 2 for Transm ission O utput R PM G 487 G ear Position D istance Sensor 1 G 488 G ear Position D istance Sensor 2 G 489 G ear Position D istance Sensor 3 G 490 G ear Position D istance Sensor 4 G 501 D riveshaft 1 Speed Sensor G 502 D riveshaft 2 Speed Sensor G 509 M ulti-plate C lutch O il Tem perature Sensor G 510 Tem perature Sensor (in C ontrol M odule) J Engine control m odule J329 Voltage Supply Term inal 15 (B + ) Relay J519 Vehicle Electrical System C ontrol M odule J527 Steering C olum n Electronic System s C ontrol M odule J587 Selector Lever Sensor System C ontrol M odule J743 D irect Shift G earbox (D SG ) M echatronics N 88 Solenoid Valve 1 N 89 Solenoid Valve 2 N 90 Solenoid Valve 3 N 91 Solenoid Valve 4 N 92 Solenoid Valve 5 N 110 Shift Lock Solenoid N 215 Pressure C ontrol Valve 1 for Autom atic Transm ission N 216 Pressure C ontrol Valve 2 for Autom atic Transm ission N 217 Pressure C ontrol Valve 3 for Autom atic Transm ission N 218 Pressure C ontrol Valve 4 for Autom atic Transm ission N 233 Pressure C ontrol Valve 5 for Autom atic Transm ission N 371 Pressure C ontrol Valve 6 for Autom atic Transm ission 55 S308_100 a Term inal 30 over safety sw itch SC 21 K-W ire C A N D rivetrain high C A N D rivetrain low Functional Diagram A B C 31 J 519 J 743 N91 N90 N92 N215 N216 J ... G93 G195 G501 G510 G196 G502 G487 G489 G488 G490 N217 N218 N233 N371 F4 G193 G194 x G182 J 587 E313 J 527 v a L101 N110 F319 J ... J ... G509 A x y y B C 56 CAN-Databus-Links CAN-Databus-Links The schem atic below show s the M echatronics links for the D irect Shift G earbox in the C A N D atabus structure of the vehicle. J104 A B S C ontrol m odule w ith ED L J248 D iesel D irect Fuel Injection (D FI) Engine C ontrol M odule J285 C ontrol M odule w ith Indicator U nit in the Instrum ent Panel Insert J519 Vehicle Electrical System C ontrol M odule J527 Steering C olum n Electronic System s C ontrol M odule J533 D ata B us O n-Board D iagnostic Interface J587 Selector Lever Sensor System C ontrol M odule J623 Engine C ontrol M odule (EC M ) J743 D irect Shift G earbox (D SG ) M echatronics D iagnostic connector C A N -D ata bus D rivetrain C A N -D ata bus C om fort S308_080 57 Diagnostic Diagnostic The vehicle diagnostic, test, and inform ation system VAS 5051 provides the follow ing operating m odes: G uided Fault Finding G uided Functions Guided Fault Finding operating mode In the G uided Fault Findingm ode, the D irect Shift G earbox defines a test plan using sensors, actuators, and the M echatronics. Sensors: G 93 Transm ission Fluid Tem perature Sensor G 182 Sensor for Transm ission R PM G 193 Sensor 1 for H ydraulic Pressure G 194 Sensor 2 for H ydraulic Pressure G 195 Sender for Transm ission O utput R PM G 196 Sender 2 for Transm ission O utput R PM G 487 G ear Position D istance Sensor 1 G 488 G ear Position D istance Sensor 2 G 489 G ear Position D istance Sensor 3 G 490 G ear Position D istance Sensor 4 G 501 D riveshaft 1 Speed Sensor G 502 D riveshaft 2 Speed Sensor G 509 M ulti-Plate C lutch O il Tem perature Sensor G 510 Tem perature Sensor (in Control M odule) Actuators: N 88 Solenoid Valve 1 N 89 Solenoid Valve 2 N 90 Solenoid Valve 3 N 91 Solenoid Valve 4 N 92 Solenoid Valve 5 N 110 Shift Lock Solenoid N 215 Pressure C ontrol Valve 1 N 216 Pressure C ontrol Valve 2 N 217 Pressure C ontrol Valve 3 N 218 Pressure C ontrol Valve 4 N 233 Pressure C ontrol Valve 5 N 371 Pressure C ontrol Valve 6 Mechatronics: J743 M echatronics gear m onitoring J743 M echatronics shifting m onitoring J743 M echatronics pow er supply voltage Guided Functions operating mode In the G uided Functionsoperating m ode, the D irect Shift G earbox executes a test plan to test the oil levels. Pay attention to the instructions in VAS 5051 w hen testing sensors and actuators. 58 Service Special Tools A new special tool, the VAS 6252, has been created to check and adjust the fluid level of the D irect Shift G earbox. This tool has a quick release coupling to easily control the fluid level. A three-w ay valve on the fluid bottle connection allow s for easy replacem ent of the bottle. Adapter Three-w ay valve Q uick coupling S308_110 Be careful not to m ix different types of transm ission fluids. Poor operation or internal dam age can result. 59 Notes 60 Notes
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For assistance, please call: Volkswagen Academy Concierge 1 877 791 4838 (8:00 a.m. to 8:00 p.m. EST) Or, E-Mail: concierge@volkswagenacademy.com Volkswagen of America, Inc. 3800 Hamlin Road Auburn Hills, MI 48326 Printed in U.S.A. May, 2004