Service Training

Self-study programme 320

6-speed manual gearbox 0A5

Design and function

 S320_002

In addition to meeting increasing technical It is of a very short design, which takes into
demands, modern cars also have to represent consideration the restricted space available for
effective space concepts. However, to do this front transverse installation in the Transporter.
there should be no adverse effects on the design. It is therefore also suitable for use in future
passenger vehicle models.
More and more emphasis, therefore, is placed
on a space-saving component construction, This short design was made possible by
which is adapted to the respective installation distribution of the gear wheels on 4 shafts.
dimensions. The gear wheels could therefore be located
in a particularly space-saving way.
The 0A5 gearbox, developed for engines with
particularly high torque, such as the new R5 TDI
engine, is a good example of such a construc-
tion.

NEW Important
Note

This self-study programme shows the design For the latest testing, adjustment and repair
and function of new developments! instructions, please refer to the relevant
The contents will not be updated. service literature.

2
Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Gearbox mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gear layout diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Output shaft 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Output shaft 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Output shaft 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-cone synchronisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Transmission route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Clutch actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Slave cylinder with release bearing . . . . . . . . . . . . . . . . . . . . . . . 20

Gear selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Outer gear selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Joystick gear selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inner gear selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Gate selector movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gear selector movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Reverse light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Tachograph sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4motion version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Test yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3
 Introduction

General

The development of increasingly more powerful vehicles makes it necessary for a drive system to be
adapted to the performance return of the engine. On a 6-speed manual gearbox, a short layout of the
individual gears can be achieved to this end. An effective adaptation of the gear stages to the engine
characteristics lowers the speed level and the fuel consumption. Driving comfort and driving dynamics
can be improved at the same time.

S320_003

Initially, the newly developed 6-speed manual gearbox 0A5 will be installed in the Transporter 2004
together with the R5 TDI and V6 engines.

It is the first 6-speed manual gearbox installed transversely with a torque capability of up to 500 Nm.

4
Technical data

Gearbox designation 0A5

Input shafts 1

Output shafts 3

Forwards gears 6

Reverse gears 1

Maximum input torque 500 Nm

Provision for distance and speed In vehicles with tachograph, a special gearbox is
monitoring installed (with tachograph sender and sensor ring)

Gear oil specification SAE 75 W in accordance with TL 521 71

Gear oil volume 2.7 ltr. filled for life

Clutch actuation Hydraulic

Type of installation Front/transverse

Weight 72.6 kg (with oil)

Installation length 374,3 mm

Fitted with a bevel box and Haldex coupling, the gearbox will later also be installed
in a four-wheel drive version.

5
 Gearbox mechanics

Construction

On conventional gearboxes, fitted mostly with With its 4 shafts, the 0A5 gearbox belongs to a
two or three shafts, it is very difficult to shorten generation of short transmission units.
the design. Two opposing and meshed gear The very short overall length of 374 mm was
wheels form a gear wheel pair. The more gear achieved in this way; bringing with it
wheel pairs there are on the shafts, as is the case considerable advantages for installation.
for example on a 6-speed gearbox, the greater
the overall length of the gearbox.

Selector turret with

selector shaft

Gear housing
Input shaft

Reversing
light switch F4

Output shaft 3

Output shaft 1

Output shaft 2

6
Cable support
bracket

Clutch housing

S320_004

Differential
The gear 'box' comprises of both main housing
parts for the gears and clutch. These are made
from an aluminium alloy.
Bolted to the housing is also the cable support
bracket, which houses both cables for "gate"
and "gear" selection.

Gear wheel for final drive

7
 Gearbox mechanics

Gear layout diagram

The selector gears for 5th and 6th gear are located on the input shaft. 1st and 2nd gear are selected on
output shaft 1, 3rd and 4th gear are selected on output shaft 2. The selector gear for reverse can be
found on output shaft 3.

To minimise noise generation, the gear wheel pairs for 2nd to 4th gears and the gear wheel pair for the
final drive have been subjected to an additional honing measure to improve gear meshing.
The gear wheels for 2nd, 3rd and 4th gear have been ground, the selector gear for 4th gear has been
coroned.

Output shaft 3

Output shaft 1

Input shaft

Output shaft 2
Gear wheel for
final drive

Coroning is a type of advanced

gear wheel honing. It is a special
fine hardening procedure using
tempered steel profile rings with
diamond coating.

S320_001

8
Shaft layout diagram

For reasons of clarity, the shafts in the gear layout diagram are shown on one level. The actual shaft
layout can be seen in the cross-section below.

Forward gears 1 to 4 feature 3-cone synchronisation (Smith synchronisation).

Gears 5 and 6 have simple synchronisation. Reverse gear has simple outer ring synchronisation.

The torque is transmitted via three output shafts that are continually meshed with the final drive gear
wheel. The torque is transmitted from the input shaft via either one of the output shafts to the final drive.

Cross-sectional
flow
Output shaft 1

Output shaft 3

Input shaft

Cross-sectional
flow

Output shaft 2
Gear wheel for
final drive
S320_006

When reverse gear is selected, the torque flows via the selector gear for 1st gear, located
on output shaft 1. Welded to this selector gear is the reverse gear wheel, from which
torque is transmitted to output shaft 3 and then to the final drive.

9
 Gearbox mechanics

Input shaft

The input shaft is mounted in the gear 'box' with

a grooved ball bearing and in the clutch housing
with a roller bearing.
In this way, a fixed/floating type mounting is
achieved. This fixed/floating type mounting
improves selection when the gears are cold and
avoids excessive play when the gears are hot.

S320_008

Selector gear Selector gear

6th gear 5th gear
Meshing Meshing
Synchro-hub 2nd/3rd gear 1st gear
Gear wheel
Grooved ball 4th gear
bearing
Roller bearing

S320_007

Locking collar

The selector gears for 5th and 6th gear are of The gear wheel for 4th gear is pressed in place
the floating type, mounted on a needle roller on the shaft.
bearing.
For the selector gears of 5th and 6th gear there is
The 1st gear is designed to provide meshing for a simple synchronisation system.
the input shaft.
The synchro-hub for 5th and 6th gear is fixed
A further common meshing on the input shaft is firmly in place on the input shaft via an inner
used by both 2nd and 3rd gears. spline connection.

10
Output shaft 1

Output shaft 1 is mounted in the gear 'box' and

in the clutch housing with a taper roller bearing
at each end.

Oil is supplied by means of a hollow in the

output shaft. This hollow was also introduced as
a weight reduction measure.

S320_010

Selector gear
Synchro-hub 1st gear
Selector gear
Reverse gear
2nd gear
Meshing for
final drive
Taper roller bearing
Taper roller
bearing

Channel for oil supply

S320_009
Locking collar

On output shaft 1, the selector gears for 1st and For the selector gears of 1st and 2nd gear there
2nd gear are mounted on a needle roller is a 3-cone synchronisation system.
bearing (floating type).
Reverse is welded to the selector gear for 1st The synchro-hub for 1st and 2nd gear is fixed
gear. firmly in place on output shaft 1 via an inner
spline connection.
The meshing for the final drive is fixed on output
shaft 1.

11
 Gearbox mechanics

Output shaft 2

Output shaft 2 is mounted in the gear 'box' and

in the clutch housing with a taper roller bearing
at each end.

Oil is supplied by means of a hollow in the

output shaft. This hollow was also introduced
as a weight reduction measure.

S320_012
Selector gear
3rd gear
Gear wheel
5th gear Synchro-hub
Gear wheel
Selector gear Meshing for
6th gear
4th gear final drive
Taper roller
bearing
Taper roller bearing

S320_011
Channel for oil supply

Locking collar

On output shaft 2, the selector gears for 3rd and For the selector gears of 3rd and 4th gear there
4th gear are mounted on a needle roller bearing is a 3-cone synchronisation system.
(floating type).
The synchro-hub for 3rd and 4th gear is fixed
The gear wheels for 5th and 6th gear are shrink- firmly in place on output shaft 2 via an inner
fitted on the output shaft. spline connection.

The meshing for the final drive is fixed on output

shaft 1.

12
Output shaft 3

Output shaft 3 is also mounted in the gear 'box'

and in the clutch housing with a taper roller
bearing at each end.

Oil is supplied by means of a hollow in the

output shaft. This hollow was also introduced as
a weight reduction measure.

S320_014

Selector gear
reverse
Meshing for
Synchro-hub final drive

Taper roller bearing Taper roller

bearing

Channel for
oil supply

S320_013
Locking collar

Located on output shaft 3 is a selector gear and For the selector gear there is a simple outer ring
locking collar for the reverse gear. synchronisation.
The selector gear for reverse gear is mounted on
a needle roller bearing (floating type). The synchro-hub for reverse gear is fixed firmly
in place on output shaft 3 via an inner spline
The meshing for the final drive is fixed on output connection.
shaft 1.

13
 Gearbox mechanics

Outer ring Locking element

3-cone synchronisation in 3 locations with
(intermediate ring)
(1st to 4th gear) 120° spacing
Synchro-ring
Before a gear wheel on the input shaft can be (outer) Synchro-ring
engaged with a gear wheel on the output shaft (inner)
by way of the synchro-hub and locking collar, the
gear wheels have to be brought to the same
rotation speed. This procedure is referred to as
synchronisation.
It occurs during the gear selection process via a
friction cone on the selector gear and friction
cones on the synchro-rings.

Selector Selector
gear gear
Outer ring
S320_017
(intermediate ring)
Synchro-ring Synchro-ring Synchro-hub
(outer) (inner) Locking collar

Selector gear

Coupling teeth

Friction cone
of selector gear

S320_018

With an increase in the number of friction cone Each 3-cone synchronisation comprises of:
pairs, a greater overall friction area is given for
synchronisation. In this way, the efficiency of the – a selector gear friction cone
cones is increased considerably and the force – a synchro-ring (inner)
required for gear engagement is reduced. – an outer ring (intermediate ring)
– a synchro-ring (outer).
This results in an improvement in gear
synchronisation.

14
Locking and synchronisation positions

When a gear is selected, the locking collar is Neutral position

moved by a selector fork from the neutral central
position in direction of the selector gear in
Selector gear
question. When doing this, it takes 3 locking Locking element
elements with it. These move the synchro-ring
(outer) axially. With the outer ring (intermediate
ring) and the synchro-ring (inner ring), the
locking elements press the friction cone on the
selector gear.

If the locking collar and the selector gear are not

rotating at the same speed, a friction torque is
built up between the friction cones. This turns the S320_060
Synchro-
outer ring until the side protrusions come into
hub Locking Synchro-ring
contact with the recesses in the synchro-hub. The
tooth peaks of the inner teeth then come into collar (outer)
contact with the sloped parts of the synchro-ring
locking teeth, thus preventing the locking collar
from moving axially in direction of the synchro- Locking and synchronisation positions
ring.
Tooth peak Locking tooth
Friction torque between the
– synchro-ring (outer) / outer ring (intermediate
ring)
– outer ring (intermediate ring) / synchro-ring
(inner ring) and
– synchro-ring (inner ring) and friction cone of
selector gear
causes rotation speed to be increased or decrea-
S320_061
sed until motion is synchronised between locking
collar and selector gear. Synchro-ring protrusion Synchro-hub
recesses

Engagement position Coupling

Engagement position
teeth
As soon as motion has been synchronised, force
is no longer exerted around the outside of the
synchro-ring (outer). This is now rotated by the
tooth peaks from the inner teeth of the locking
collar. Rotation continues until the locking collar
is no longer "engaged" and can be pushed into
the coupling teeth of the selector gear. Once this
has occurred, power is transmitted between the
gearbox shaft and selector gear.
S320_062

15
 Gearbox mechanics

Transmission route

The engine torque is transmitted via the input shaft into the gearbox and, depending on which gear is
engaged, through one of the three output shafts to the final drive gear wheel.

For reverse gear, the same occurs via output shaft 3 (reverse gear shaft). Direction is reversed via the
selector gear for 1st gear, which in this instance has no positive connection with output shaft 1.

S320_020
S320_021

S320_027
S320_022

16
S320_023 S320_025

S320_024 S320_026

17
 Gearbox mechanics

Differential

The differential is mounted in the gear 'box' via

taper roller bearings. The final drive gear wheel
is fixed to the differential housing by rivets and is
permanently meshed with all three output shafts.

The flanged shafts are sealed to the outside by

two radial shaft O-rings of identical design.

S320_016

Gear wheel for

Gear wheel of
final drive
output shaft 2

Gear housing
Clutch housing

Differential housing

Right flanged
Left flanged shaft
shaft

Radial shaft
O-ring
Radial shaft
O-ring Taper roller
bearing
Taper roller
bearing S320_015

18
Clutch actuation

The clutch is actuated hydraulically by a The clutch hydraulic system works with brake
component, which is comprised of slave cylinder fluid and is joined to the brake fluid reservoir.
and clutch release bearing. This component is
bolted in the clutch housing.

Clutch housing

Brake fluid

S320_045

Slave cylinder with

clutch release
bearing

The clutch actuator mechanism can only be exchanged as a unit.

19
 Gearbox mechanics

Slave cylinder with release bearing

The guide sleeve is joined permanently to the A grooved seal, which is flush fitted to the piston,
slave cylinder housing. seals the slave cylinder from the housing and
guide sleeve.
Located between the slave cylinder and guide
sleeve is a piston, which moves axially when The clutch release bearing is filled-for-life with
placed under pressure. grease.

Piston

Guide sleeve

Slave cylinder
housing

Input shaft

S320_046

Clutch housing

Brake fluid
Grooved seal

20
 Diaphragm
spring
Released position Outer ring

Spring pressure from the preload spring causes Preload spring

the outer ring to be permanently pressed against
the diaphragm spring of the clutch. The outer
ring, therefore, always rotates at the same speed
as the clutch. The balance of speed between
inner and outer ring is achieved by means of ball
bearings. These rotate in a cage around the
shaft.

S320_066

Inner ring Ball bearings

Clutch actuated Piston

Slave cylinder
When the clutch pedal is pressed, pressure is
generated by a master cylinder. This pressure is Brake fluid
then transmitted to the slave cylinder by way of
brake fluid. The piston is subjected to pressure
and pushed along the guide sleeve in direction
of the diaphragm spring. The clutch is thereby
actuated.

S320_067

Guide sleeve Diaphragm spring

21
 Gear selection

Outer gear selector mechanism

On the gearbox of the Transporter 2004, an outer gear selector mechanism with joystick and pull ring is
featured for the first time in the Volkswagen Group. The example described here, therefore, is based on
the selector mechanism from this gearbox.

As a measure to isolate vibrations and load The mechanics (relay lever and gearbox selector
change jolts from the power unit, the gearbox is lever with balance weight) converts the back and
equipped with a cable operated gear selector forth motion of the 2 cables in up and down and
mechanism. rotating motion of the selector shaft.

The cables transfer the gate and gear selection

motion respectively to the gear selector shaft.

To adjust the cable selector

mechanism, comprehensive
information can be found in the
Electronic Service Archive (ELSA).
Relay lever

Gearbox selector lever

Selector shaft

S320_028

22
 Joystick gear selection

The joystick comprises of two main assembly

groups, the gearstick and the selector housing.
The gearstick is mounted on a pivot ball for
freedom of movement. In this way, all of the main
'gate' and 'gear' selector positions can be
reached.
S320_030 Gear selector
movement

Gate selector
movement
Gearstick

Pull ring

Long arm spring Pivot ball

Selector housing

Mounting with
ball head
S320_058
S320_029

Cable lock mechanism Cable lock mechanism

Gate selector cable gear selector cable

A four gate layout was chosen for the gearbox, Installed on the selector lever are cable lock
in which the reverse gear is located on the upper mechanisms for the 'gate' and 'gear' selector
left. The position of the other gears is based on cables. To ensure good freedom of movement,
the common H principle. the attachments are of the ball head type.
To hold the selector lever in the centre position,
As a safety measure to prevent unintentional there is a long-arm spring.
selection of the reverse gear, a pull ring system
has been installed on the gear lever in
conjunction with joystick gear selection.

23
 Gear selection

Inner gear selector mechanism

The gear selector movements are transferred to Selector shaft

the gearbox via the selector shaft. Selector cover

The selector shaft bearing points are at the top in

the selector cover and in the bottom in a cover
cap, which is bolted to the gear 'box'. Coulisse pin

Stop sleeve with Selector finger for

selector finger 1st and 2nd gear,
5th and 6th gear
Reverse gear
Selector shaft
Selector finger
Bolts for attachment 3rd and 4th gear
on gear 'box'
Cover cap

Axle
S320_031
Selector bracket for
reverse gear
Bearing
sleeve
Depending on the gear selected, the selector
lever engages with its selector fingers in one of
the selector forks for 1st to 6th gear, or in the
Pedestal selector bracket for reverse gear, and actuates
the selector fork, or bracket. The selector forks
are mounted on both sides by bearing sleeves in
the gearbox and clutch housing. They can
thereby be moved axially to select a gear.

Selector fork Reverse gear is selected via a selector bracket.

1st and 2nd gear The bracket is bolted to the gear 'box' via a
pedestal and has rotational movement on an
axle.
Selector fork
5th and 6th gear S320_032

Selector fork
3rd and 4th gear

24
 Gate selector movement
Gearstick

The gate selector movement (left and right Gate selector

movement of gearstick) is converted to back and movement
forth movement at the selector cable.

The gearstick is mounted with rotational

movement on a pivot ball, which is attached to
the selector housing.
S320_035

S320_034

Pivot ball

Relay lever
Gate selector cable
Glide element

Gearbox
selector
lever

Back and forth motion of the gate selector cable

is converted, by way of a relay lever mounted on
the gearbox, to up and down motion of the
selector shaft. To do this, the gate selector cable
is attached to the relay lever.

This is joined with freedom of movement to the

gearbox selector lever via a glide element.

The up and down motion brings the selector

Selector shaft
lever into the correct position for gear
engagement. The respective selector finger is
thereby at the correct height for engagement in
the chosen selector fork/bracket.
S320_033

Selector finger for Selector fork

3rd and 4th gear 3rd and 4th gear
Cover cap

25
 Gear selection

Gear selector movement

Gearstick
The gear selector movement (back and forth
motion of gearstick) is transmitted to the gear
selector cable.

When a gear is selected with the gearstick, the

tilting motion is converted into back and forth
movement at the selector cable.

S320_038
Gear selector
movement

Pivot ball

Gear selector cable S320_037

Locking collar
Axle reverse gear
Gearbox selector lever

Selector bracket for

reverse gear
S320_071

The back and forth motion of the gear selector

cable turns the selector lever about its axis. This
rotational movement causes the selector finger to
move the respective selector fork connected to it.
For reverse gear, the rotational movement is
converted into a swing motion at the selector
bracket (axle rotation).

The relay lever, for transmission of the gate

selector movement on the gearbox, is connected
Selector shaft to the gearbox selector lever and remains in its
selected position due to glide element
Selector finger for movement.
3rd and 4th gear The affected selector fork/selector bracket
engages in the locking collar and converts the
movement to axial motion of the locking collar.
S320_036 The gear is selected.

Selector fork
3rd and 4th gear

26
 Reverse gear

In conjunction with the joystick selector

mechanism, a reverse gear lock with pull ring is
installed for the first time in a Volkswagen.
S320_040
The reverse gear lock is integrated in the
trigger.
Gearstick knob

To engage reverse gear, the pull ring of the

trigger should be pulled in direction of the Trigger with
Locking lug pull ring
gearstick knob.

Lock

Long arm spring

Selector housing

Long arm spring

S320_039

The gearstick is held centrally in the start position

(3rd/4th gear gate) by a long arm spring.

S320_041

Locking lug
When 1st gear is selected, the locking lug
1st/2nd gear stop prevents unintentional selection of the reverse
gear. The lug hits the 1st/2nd gear stop (part of
selector housing).

S320_042

By lifting the pull ring, the locking lug is raised

over the 1st/2nd gear stop and selection of
reverse gear becomes possible.

S320_043

27
 Sensors

Reversing light switch

The reversing light switch is screwed in on the

side of the gear housing.

S320_069
Reversing
Lug light switch F4

Selector shaft

Stop sleeve
Button

Reversing
S320_054
light switch F4

During selection of gears 1 to 6, the button of the

reversing light switch F4 engages in a recess in
the stop sleeve.

When reverse gear is selected, the stop sleeve is

moved upwards axially together with the selector
lever. When doing this, the button reaches a
horizontal position at the same height as a lug in S320_055
the window of the stop sleeve.

During gear selection, the button of the reversing Stop sleeve Selector finger
light switch comes into contact with the lug. The
button is activated and the electrical circuit is
Lug
closed.

28
Tachograph sender

If the gearbox is installed in a vehicle with tachograph, the differential is supplemented with a
tachograph sender G75.

Tachograph sender G75

Sensor ring

Gear wheel for final drive S320_057

The signals for the tachograph sender G75

are generated at a sensor ring located in the
differential housing by means of an impulse
sender wheel. These are sent to the tachograph
G24 for evaluation.

The sender is installed externally in an opening

in the clutch housing. S320_070

The sensor ring and tachograph sender are not installed during series
production. No provision has been for retrofitting.

29
 4motion version

Bevel box

The gearbox will later also be installed in a four-

wheel drive version in conjunction with a bevel box
and Haldex coupling.

In this instance, the manual gearbox forms a unit

with the bevel box. The bevel box is connected to the
differential of the manual gearbox, via which drive
torque is transmitted to the rear axle.
S320_063

Manual gearbox Bevel box

Taper roller bearing

Gear teeth - hollow shaft Drive shaft - right

Taper roller bearing

Flange

S320_064

Shaft bevel gear

Bevel gear

Hollow shaft with gear teeth

Drive shaft - left

Differential housing

Gear wheel for final drive

30
Design and function

Drive for the bevel box is transmitted to a hollow From the gear teeth of the hollow shaft, torque is
shaft, which features gear teeth to drive the transmitted further to a shaft, which has gear
bevel box. This hollow shaft is joined to the teeth to form a bevel gear. The bevel gear is
differential housing. Within the shaft runs the meshed at 90 degrees to the shaft bevel gear
drive shaft for the front right final drive. and redirects the transmission route to the rear
final drive.

Hollow shaft with gear teeth Gear teeth of hollow shaft

Differential housing

Drive shaft - right

Bevel gear Shaft bevel gear

S320_068

31
 Test yourself

Which answers are correct?

One or more or all answers could be correct.

1. What are the advantages of the 4-shaft gearbox principle?

a) Smoother running
b) Requires less space
c) Greater environmental compatibility

2. Which gears are engaged with the selector gears on output shaft 1?

a) 5th/6th gear
b) 1st/2nd gear
c) 3rd/4th gear

3. Mark the transmission route for 5th gear in this diagram.

S320_059

4. Which gears have 3-cone synchronisation?

a) 5th/6th gear
b) Reverse gear
c) 1st to 4th gear

32
5. What does the "3" mean with regards to the type of synchronisation?

a) The gearbox has synchronisation systems for three gears.

b) One synchronisation system with three cones.
c) Synchronisation is carried out in three stages.

6. What fine hardening procedure is used on the gear wheels of the gearbox?

a) Lapping
b) Coroning
c) Grinding

7. The reverse gear lock on joystick gear selection …

a) is of the push down type, common within the Group.

b) is a modified push down type.
c) is actuated via a pull ring.

8. The hollow design of the gearbox shaft serves as a means of

a) increasing torsional rigidity.

b) assuring smooth running.
c) supplying oil.

9. The clutch is actuated

a) hydraulically via a clutch release lever and separate clutch release bearing
with bearing bush.
b) via a hydraulic unit, comprising of slave cylinder and clutch release bearing.
c) mechanically via a clutch release lever, which moves a clutch release bearing
mounted on the input shaft in axial direction.

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Answers
1. b.; 2. b.;
3. Transmission route diagram;
S320_025
4. c.; 5. b.; 6. b., c.; 7. c.; 8. c.; 9. b.
Test yourself
Notes

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