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Code letters, group numbers, ratios, equipment > < Gearbox identification

Leon Mk1

General notes
General notes
Gearbox:
The semi-automatic gearbox 02E is also known as the dual clutch gearbox. Engine torque is transmitted to the gearbox through the dual-mass flywheel. The gearbox has the same structure as a manual 6-speed gearbox. The two multi-plate "wet" clutches are regulated hydraulically and actuated alternately so that the gearbox is operated like an automatic gearbox, i.e. the gears are engaged automatically (or manually via the tiptronic function). There is no clutch pedal.
Gear selection mechanism
The selector lever position is no longer transmitted mechanically via the selector lever cable and multi-function switch (driving range sensor) as on the automatic gearbox. The selector lever positions and gear changes are transmitted to the gearbox control unit by a separate selector mechanism control unit via CAN bus. That is, the gears are changed without using a lever cable. Only when the selector lever is in „P“ does the parking block engage mechanically using the selector lever cable.
Gear oil
The gear oil level in gearbox → Chapter and final drive (front) → Chapter is checked and topped up together.
t  Only the oil available as a replacement part may be used in the dual clutch gearbox 02E. Other types of oil will cause malfunctions and/or failure of the gearbox; for Part No. refer to → Chapter.
The oil level in the pair of bevelled gears is controlled and corrected separately → Chapter.
t  For the bevelled gears, only the shaft oil supplied as spare must be used. The use of other oil sorts may lead to functional interferences or damage in the bevelled gear.
   
Function of the oil
t  The oil is not used to lubricate the gearbox
t  The oil transports the finest of wear particulates of the differential to the filters, keeps the lubricating film on the tooth flanks of the differential intact and is also used as a pressure media for the correct operation of the gearing mechanism.
t  Additionally, it also seals the slider and helps the synchronising hub when changing gear. Next to the noise insulation, it is used to store and transport heat. Thus, the oil takes over several versatile functions. The oil of the automated manual gearbox 02E fulfils the highest demands.
t  To maintain this oil performance capacity, the gearbox filter should also be replaced whenever the oil is changed during a maintenance service.
Oil filter change
The oil filter does not have to be changed as a matter of course.
Do not change the filter if:
t  The gearbox oil cooler or its O-rings have been renewed and no coolant has got into the oil.
t  The oil seal for the selector shaft has been renewed.
t  The oil seal for the flange or stub shaft has been renewed.
t  a non leakproof cover of the mechatronic control unit, of the multiple clutch or the oil pump has been replaced.
t  the gearbox input speed sender -G182- has been replaced with the clutch temperature sender -G509-.
The filter must be changed if:
t  the vehicle has been driven for 60,000 kilometres (perform maintenance service).
t  Coolant has got into the oil.
t  Metal particles have been found in the oil.
t  The clutch is burnt out or has a mechanical defect.
  N01-0453
Oil drain and inspection screw -A-
To gearbox manufacture date „20 September 2004“, gearboxes were constructed with 2 plugs.
The second plug was then discontinued, and oil could be drained and the level checked with only one plug -A-.
A plastic overflow tube (with 8 mm hexagon socket head bolt, tightening torque: 3 Nm) is located behind the plug. Its length determines the oil level in the gearbox.
  N34-10673
Oil level check and troubleshooting
t  → Anchor The versatile functions of the oil are described here. Oil cannot disappear »without leaving traces«. Oil will only be missing if there is a leak in the gearbox.
t  If the gearbox is covered with oil, first the oil leak has to be found. The leak must be eliminated before changing the oil and restoring the correct filling level → Chapter.
t  The leak can neither be identified nor eliminated by simply refilling with oil. A wrong feeling of safety is conveyed.
Regulations for oil waste management
Used oils should be taken to an appropriate centre for their correct disposal.
t  Used oils pollute the environment when not correctly disposed of.
t  It must not be mixed with solvents, brake fluid, coolant or similar.
t  Always follow the instructions shown on the oil container.
Modifications in the shift points, up and down
When shifting up or down, the gearshifts are automatically selected using the possible range of gear shifts according to the position of the accelerator pedal and the speed of travel.
l  The possible range of a gear change will be adapted for maximum engine power during extreme ascents.
l  The possible range of a gear change will be adapted for maximum engine braking power during extreme descents
l  The engine braking effect may be used by directly selecting a specific gear using the Tiptronic, for example, when driving with a trailer on downhill slopes
  N00-10244

Code letters, group numbers, ratios, equipment > < Gearbox identification