0B5 7 Speed Dual Clutch PDF
0B5 7 Speed Dual Clutch PDF
0B5 7 Speed Dual Clutch PDF
20
0B5 S Tronic Transmission
Final drive/
differential (forward
of the dual clutch)
429_124
Connection for
Mechatronic
module
Transmission
plate with dual-
mass ywheel ATF, ller
and oil level
checking bolt
Connection
to ATF cooler
Dual clutch
(K1, K2)
Oil drip
pans
Seven-speed
gearbox
assembly
Center
differential
Final drive with
welded ring gear
and special tooth
geometry to
accommodate the
429_128 angled side shaft
Bi-planar Gear
angled lever
side shaft
21
0B5 S Tronic Transmission
Dual mass
ywheel Dual clutch
(K1, K2)
Stop
Transmission
plate
Hydraulic control
(Mechatronic
system) Connection
module for
ATF cooler
Direct Shift
Gearbox (DSG) Oil drain
Mechatronic J743 Electric port
connection
22
0B5 S Tronic Transmission
Gear
lever
Oil drip
pan
Serviceable
offset depth for
all shaft oil seals
when replaced
Selector
rail
Gear oil ll
and level 429_116
checking bolt
Self-locking center differential with 40/60
asymmetric/dynamic torque split. The
asymmetric-dynamic power distribution
provides sporty and agile driving
characteristics with slight emphasis to the
rear axle. When needed, the center differential
can deliver up to 85% power to the rear axle
or a maximum of 65% power to the front axle.
23
0B5 S Tronic Transmission
Clutch K1
Clutch K2
Input
shaft 2
24
0B5 S Tronic Transmission
Input
shaft 1
Spur pinion/
output to front
axle (beveloid
gearing) Output to rear
axle differential
7th gear
5th gear
Synchromesh
To facilitate extremely short shift times, all gear
synchronizers are carbon coated.
Gears one, two, and three are also triple cone
synchronizers due to the high stresses to which they are
subjected.
Gears 4, 5, 6, and 7 use single cone synchronizers.
25
0B5 S Tronic Transmission
429_126
Mechatronic
ATF system
pump
Note
ATF oil is subject to a xed replacement
interval (refer to maintenance).
Hypoid gear oil is designed for
lifetime use.
Front axle
differential
429_127
Gear
assembly
Transfer
case
26
0B5 S Tronic Transmission
429_121
Transverse
bore
Double oil
seal ring
Input shaft 2
27
0B5 S Tronic Transmission
Pressure
line K1
Dual
clutch
Pressure
line K2
Rotating
port
429_138
Suction
jet pump Oil pump
drive
Suction
lter 429_122
ATF pump
(external gear pump)
28
0B5 S Tronic Transmission
ATF Cooling
ATF cooling is provided by a heat exchanger integrated A differential pressure valve is integrated in the pressure
into the engine cooling system (ATF cooler). lter. It opens when the ow resistance rises above a
threshold value, for example when the lter is clogged
The supply line running to the ATF cooler accommodates
or the ATF is very cold. Therefore, circulation to the ATF
a pressure lter, which, in conjunction with the suction
cooler is always assured.
lter, provides effective ltering of the ATF. Both lters
are designed for lifetime use in the transmission, and are
not subject to a replacement interval. Notes on the ATF cooler:
If the ATF cooler is leaking, coolant will mix
with the ATF. Even the smallest amounts
of coolant in the ATF will impair clutch
control. The new glycol test 8E0 398 998
can be used to determine whether the ATF
contains glycol.
Notes on the ATF lter:
It is only necessary to replace the pressure
lter if the ATF has been contaminated due
to transmission damage. If swarf (metal
chips), abraded matter, or other foreign
ATF material is found mixed in with the ATF,
cooler
the ATF cooler must be ushed, and if
Engine cooling necessary, replaced.
system with
ATF cooler
Connection
module
ATF lter
(pressure lter)*
29
0B5 S Tronic Transmission
Oil drip
pans
Oil passage in
input shaft 1
429_125
Oil passage
to front
axle drive
Bi-planar
angled
side shaft
30
0B5 S Tronic Transmission
Parking Lock
The 0B5 transmission requires a parking lock since both Drive Position Sensor G676 is also actuated through the
clutches are open (disengaged) whenever the engine is selector shaft and the parking lock lever.
not running.
For this purpose, a permanent magnet exerting a
The parking lock gear is connected to the output shaft. magnetic eld on the sensor is located on the parking
The pawl is actuated mechanically by the selector lever lock actuating lever.
via the selector lever cable.
Utilizing the signals generated by Drive Position Sensor
G676, the Mechatronic module recognizes the position of
the selector lever (P, R, N, D, or S).
Stop
Gear
lever
Dir
ect
ion
Drive Position of T
rav
Sensor G676 el
Permanent
magnet
429_117
Parking
lock gear
Locking
pawl
31
0B5 S Tronic Transmission
Transmission Control
Direct Shift Gearbox Mechatronic J743
The transmission is controlled by a newly developed The Mechatronic system acts as the central transmission
Mechatronic system. It enables precision control of gear control module. It combines the electro-hydraulic control
engagement speed and force when changing gears. This module (actuators), the electronic control module, and
means that regardless of the driving situation, rapid gear some of the sensors into a single unit.
shifts are also smooth.
Because of the longitudinal conguration, the rpm
sensors of both gearbox input shafts and the gear sensor
are located on a separate mounting bracket (PCB 3).
X
Gear
selector
module X
X
Gear Position Distance
Sensor 4 G490 (for
gear selector 4-6)
PCB 1
429_133
Electro-hydraulic
control module
32
0B5 S Tronic Transmission
Connector
Sensor
X Center module wiring
X differential harness
X Drive Position
Sensor G676
Transmission
Input Speed
X Sensor G612 429_130
X Transmission
Connector:
X Mechatronic
Input Speed
Sensor1 G632
wiring harness
Connector:
Gearbox
Control Connector: Wiring harness/
Module PCB 2 Gearbox cable duct
Control
Module PCB 1
Electronic
module
Connector: X Mounting points in the transmission case
wiring harness
(sensor module)
33
0B5 S Tronic Transmission
GS = Gear Selector
Shift
fork 4-6
GS 7-5
GS 1-3
Shift
fork 7-5
GS 2-R
Shift
fork 2-R
Shift
fork 1-3
Note
Before installing the Mechatronic system The selector rails/shift forks have no stops, with the
into the transmission, the gear selectors shift forks held in position by gear selectors. The only
and selector rails must be brought into stops are in the gear change sleeve and the synchronizer
alignment with each other. Refer to the assembly.
repair manual.
34
0B5 S Tronic Transmission
Dual
clutch
N438
(4-6)
Electro-hydraulic
control module
gear selector module
N434
(7-5)
N433
(1-3)
Gear
selector
Electro-hydraulic
control module
N471
N439
N435
N440
N472
N436
429_129
35
0B5 S Tronic Transmission
Electronics
Gear Position
Integrated Sensors Distance Sensor
4 G490 (for gear
selector 4-6)
The transmission control module, the four distance
sensors and the two hydraulic pressure sensors are
combined as a non-separable unit.
Gear Position
Two temperature sensors are integrated into the Distance Sensor
3 G489 (for gear
TCM. One sensor is positioned to supply precise ATF selector 7-5)
Gear Position
temperatures. Distance Sensor
2 G488 (for gear
The other sensor is integrated directly into the processor selector 1-3)
and measures critical component temperatures.
The two temperature senders monitor each other for
plausibility. Electronics temperature monitoring is very
important so that temperature reduction measures can
be made quickly, as needed.
Besides safety, ATF temperature is relevant to both
clutch control and hydraulic control. For this reason, ATF
temperature is also a key factor in control and adaptation
functions.
Automatic Transmission Hydraulic Pressures Sensors
1 and 2 are utilized for clutch pressure monitoring and
for adaptation of the primary pressure and sub-gearbox
Gear Position
pressures. Distance Sensor
1 G487 (for gear
selector 2-R)
Automatic
Permanent Transmission
magnet Hydraulic
Automatic 429_137
Hall Pressure
Sensor 1 G193 Transmission
sensor
Hydraulic
Pressure
Sensor 2 G194
Selector
Control rail
module
temperature Four distance sensors determine the position of each
sensor
selector rail/shift fork. The TCM requires this information
to immediately diagnose non-allowed positions and to
activate a limp home program, if necessary.
An exact travel measurement is also essential for
precision gear shifting. The various phases of the
synchronization and gearshifting processes can then be
activated sequentially.
Temperature
429_136
sensor in
processor
Transmission
control
module
36
0B5 S Tronic Transmission
Note
To measure the precise distance traveled
by the gear selector, the shift mechanism
must be adapted to the transmission
control module using the VAS Scan Tool. 429_171
Transmission Input Speed Sensors 1 and 2, as well as Determination of the clutch output speed for
the gear sensor are mounted together on a common computing clutch slip
mounting bracket (PCB 3).
Determination of the synchronization speed for shift
Both engine speed senders are intelligent sensors. control
With three Hall sensors and the corresponding evaluation
electronics, it is possible to distinguish between driving
forward, driving in reverse, and a weak magnetic eld.
The control module receives the information from the
senders pre-evaluated in the form of a pulse width
modulated signal.
The various states are indicated to the control module
by different pulse widths. For example, when driving
forward, the engine speed signal has a different pulse
width than when reversing.
Drive Position
Encoder disc, Sensor G676
input shaft 2
Encoder disc,
input shaft 1 Connector Sensor
module/wiring
harness
429_173
Transmission
Input Speed
Sensor 2 G612
Transmission PCB 3
Input Speed (sensor module)
Sensor 1 G632
37
0B5 S Tronic Transmission
G676 is located in the gearbox and is an integral part of A permanent magnet exerting a magnetic force on the
the sensor module. This is a contactless travel sensor gear sensor is located on the parking lock lever. The
which is used to determine the selector lever positions parking lock lever is connected to the gear lever by a
(P, R, N, D, and S). shaft. It is actuated by the selector lever by means of a
selector lever cable.
Drive Position
Sensor G676
Connector
Sensor module/
wiring harness to
gearbox control
module
429_167
Permanent
magnet
The transmission control module requires data on The position sensor is a PLCD travel sensor. The
selector lever position to perform the following functions abbreviation PLCD stands for Permanent Magnetic
and generate the following signals and information: Linear Contactless Displacement sensor and describes a
contactless sensor which measures linear travel using a
Information on driver input/vehicle operating state permanent magnet.
(forward, reverse, neutral) for activation of the clutches
and gear selectors The signal generated by this sensor is very important
for gearbox control and is safety-critical. For this reason,
Information for selection of shift program D or S G676 consists of two redundant sensors arranged in
Signal for controlling the starter inhibitor parallel.
Signal for controlling the P/N lock (shift-lock) The TCM always evaluates both sensors.
Information for reverse gear (for example, back-up
lights, Park Assist System, etc.)
Control of the selector lever position indicator in the
instrument cluster and gearshift mechanism
Note
The gear sensors must be adapted to the
transmission control module using the
VAS Scan Tool.
38
0B5 S Tronic Transmission
Outer plate
carrier of
clutch K1
X
Cooling oil
outlets
PCB 2
X = plugged
connection to gear
selector valve
Clutch Oil
Temperature
Transmission Sensor G509
Input Speed
Connector to Sensor -3- G641
transmission
control module
Sensors G641 and G509 are integral parts of PCB2. G641 G509 measures and monitors the temperature of the
is a Hall sensor. It measures the input speed of the dual cooling oil emerging from the dual clutch. Clutch
clutch (engine speed after the dual-mass ywheel). The temperature can be derived from this information.
outer plate carrier of clutch K1 serves as an encoder disc.
When a dened oil temperature is reached, safety
The clutch input speed signal: precautions are taken to prevent a further rise in
temperature.
Allows more precise clutch control
Is used for adapting the clutches
Is used for regulating micro-slip
39
0B5 S Tronic Transmission
High temperatures have a negative impact on the useful If the clutch cooling oil temperature exceeds a value
life and performance of electronic components. Due of approx. 320F (160 C), as determined by G509, the
to the integration of the transmission control module clutch is within a critical temperature range that can
into the transmission housing (lubricated by ATF), it is damage it. These temperatures occur, for example, when
very important to monitor the temperature of both the accelerating on extreme gradients, when towing a trailer,
electronics and ATF. or when the vehicle is held stationary on an uphill slope
using the accelerator and the clutch without engaging
When the temperature reaches approx. 275F (135C)
the brake.
(measured by one of the two temperature sensors in the
transmission control module), the electronics must be As a safety precaution, engine torque is reduced when
protected against a further rise in temperature. When cooling oil temperature exceeds 320F (160 C.) If the
this threshold value is exceeded, the transmission control cooling oil temperature continues to rise, engine torque
module initiates a reduction in engine torque to reduce is gradually reduced, sometimes to idle. When the engine
heat input. is at idle, the clutches are open and there is no power
transmission from the engine to the drive wheels.
Up to a temperature of approx. 293F (145 C), engine
torque can be reduced gradually until the engine is at When the protective function is initiated, an entry is
idle. When the engine is at idle, the clutches are open made in the fault memory and the following text message
and there is no power transmission from the engine to is displayed in the instrument cluster: You can continue
the drive wheels. driving to a limited extent.
When the protective function is activated, an entry is As an additional safety precaution, the clutch
made in the fault memory and the following text message temperature is determined using a computer model. If
is displayed in the instrument cluster: You can continue the computed temperature exceeds a pre-dened value,
driving to a limited extent. the above mentioned precautions are taken.
40
0B5 S Tronic Transmission
In the B8 series, a new data and diagnostic log is used If a vehicle with S tronic needs towing, the conventional
for the engine control modules, the TCM, and the restrictions of automatic transmissions apply:
airbag control module. The previous data blocks and
numberings are no longer used. Individual measured Selector lever in position N
data is now available and listed as full text in alphabetical A maximum towing speed of 30 mph (50 km/h) must
order. This required measured data can then be not be exceeded
specically selected. A maximum towing distance of 30 mi (50 km) must not
be exceeded
clearing the fault memory
Explanation:
The fault memories of the engine and transmission
control module are always cleared jointly. If the fault When the engine is at standstill, the oil pump is not
memory of the transmission control module is cleared, driven and certain parts of the transmission are no
then the fault memory in the engine control module will longer lubricated. Exceeding a speed of 30 mph (50 km/h)
be cleared as well. The converse applies if the memory of results in unacceptably high rotational speeds within
the engine control module is cleared. the gearbox and dual clutch, because one gear is always
engaged in both sub-gearboxes.
If these towing cautions are not observed, serious
transmission damage can occur.
41
0B5 S Tronic Transmission
42
0B5 S Tronic Transmission
Displays/Warnings
The 0B5 transmission features new information and Display 1
warning technology in the instrument cluster, which will
alert the driver to a system malfunction or the initiation
of a protective function.
The following warnings are displayed:
Gearbox fault:
You can continue
Display 1 appears when faults the driver may not notice
driving
are recognized by the transmission control module,
which then activates a suitable substitute signal.
These faults result in no, or only negligible, loss of
performance. The purpose of the warning is to prompt
the driver to take the vehicle to an Audi dealer at the next
opportunity.
Display 2
Display 2 appears when gearbox protection functions and
faults result in a loss of performance.
This can have the following effects:
Display 3
Display 3 appears when the limp home program,
Driving with sub-gearbox 1, is active because reverse
gear cannot be selected at the same time.
Text messages disappear after ve seconds, and are Gearbox fault:
displayed again for ve seconds at ignition ON. Yellow You can continue
warning symbols are permanently displayed. driving to
a limited
extent only No
reverse gear
43