Self-Study Programme 466 8 speed automatic gearbox 0C8.pdf

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Service Training
Self-study Programme 466
The 8-speed Automatic Gearbox 0C8
Design and Function
An 8-speed automatic gearbox will be introduced for the first time at Volkswagen in the Touareg 2011.
The 8-speed automatic gearbox 0C8 is a further development of the 6-speed automatic gearbox 09D from the
Japanese gearbox company AISIN AW CO LTD. Together with the extensive know-how provided by the
Volkswagen engineers, success has been achieved in adapting the gearbox to the Volkswagen technologies'
increased requirements.
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The self-study programme explains the
design and function of new
developments!
The contents will not be updated.
For current testing, adjustment and repair
instructions, refer to the relevant service literature.
Attention
Note
2
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gearbox design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
The torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
The torque converter lock-up clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
The oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The planetary gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The valve chest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Gearbox function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
The flow of power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Gearbox management system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
The automatic gearbox control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
The control unit for auxiliary hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . 37
The innovative thermal management system . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
The hill-holder function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
The selector lever module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Test yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3
Introduction
Thanks to the eight forward gears and the closer gear
ratio steps, consumption values and emission values
have been reduced even further in comparison with
the automatic gearbox 09D. Once again, the eight
forward gears are made possible using the
tried-and-tested Lepelletier gear set concept.
The automatic gearbox 0C8 can be supplied together
with the start/stop system, and is also designed for the
hybrid drive. All engine variants in the Touareg are
available exclusively with this gearbox.
The self-study programme describes the design and
function of the 8-speed automatic gearbox 0C8 as it
is installed in the Touareg.
The function and design of those components which
are required in the gearbox for the start/stop system
and the hybrid drive are described.
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4
Technical data
Developer/manufacturer
Designation
Gearbox features
AISIN AW CO. LTD Japan
Automatic gearbox 0C8
Electrohydraulically controlled 8-speed planetary gearbox with a single
primary planetary gear set and a downstream Ravigneaux planetary gear set as a
secondary planetary gear set (planetary gearbox concept according to Lepelletier)
Hydrodynamic torque converter with slip-controlled torque converter lock-up clutch
Design for longitudinal mounting in combination with a transfer box
Control system
Hydraulic control unit (valve chest) in the sump with an external electronic
control unit
Dynamic shift program DSP with separate sports programme in "position S" and the
"Tiptronic" shift programme for changing gear manually
Special feature: Starting off in 2nd gear is possible in Tiptronic mode
Torque
Achievement of top speed
Spread
ATF service
Weight
Emergency operation characteristics
Depending on version, up to 1000Nm
Depending on the engine, in either 6th or 7th gear
7.17 to 7.25
ATF: Refer to ELSA for service intervals
Depending on gearbox adaptation to the engine,
between 91kg and 108kg
In the case of faults which arise during vehicle operation:
in gears 1-4 = 3rd gear
in gears 5-8 = 7th gear
as of restarting the vehicle, 3rd gear and reverse gear only
5

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