Notes

51

Gearbox Assemblies
Overlapping gearshift operations/control All gearshift operations (from 1st to 6th gear and from 6th to 1st gear) are so-called overlapping gearshift operations. In other words: During gearshift, the clutch in the process of transmitting power retains its transmission capacity with reduced pressure until the corresponding clutch cutting in assumes the torque being applied. The gearshift operation is assisted by a brief reduction in engine torque on changing up or an increase in engine torque on changing down (with effect from new control unit generation, refer to Part 2 SSP 284, Page 15).

Engine torque intervention

Engine torque

Torque

Cutting-in clutch

Cutting-out clutch

Time Torque assumption overlap 283_032

52

By using overlapping gearshift operations, it is possible to effectively replace freewheeling by electrohydraulic clutch control, leading to great savings in terms of weight and space. The gearshift operations are monitored by evaluating the gearbox input speed profile (G182), enabling appropriate action to be taken as necessary (e.g. shift pressure increase, gear retention or implementation of emergency operation).

Evaluation of the speed profile during the gearshift operation permits continuous adaption of the overlap control. Charging and the pressure build-up process in the clutch are influenced by appropriately adapting the control current of the pressure regulating valves. For further information, refer to Part 2 SSP 284, Page 7 onwards.

Rapid charging Overlap Cutting-in clutch pressure

Pressure

Cutting-out clutch pressure Time 283_055

53

Gearbox Assemblies
Planetary gearbox
A new feature is the use of the so-called Lepelletier planetary gear train. This permits the implementation of six forward gears and one reverse gear employing only five selector elements (three clutches and two brakes).

Principle: A single planetary gear train is fitted upstream of the Ravigneaux double planetary gear train and provides 2-speed drive for the Ravigneaux gear train. Output is always via the ring gear of the Ravigneaux gear train. A further feature is multiple utilisation of brakes and clutches.

Primary planetary gear train, single planetary gear train

Secondary planetary gear train, Ravigneaux gear train

Planet gears Planet gear Planet carrier 283_036 Planet carrier 283_126

Advantages of Lepelletier planetary gear train: The extremely compact design allows for a reduction in overall length despite a greater spread, more gear ratio steps and high torque transmission. The use of far fewer components not only significantly reduces weight but also lowers manufacturing costs. Power flow and the different ratios of the individual gears are achieved by torque being channelled via various elements of the planetary gear trains with the other elements in each case being held stationary or two elements of a gear train being connected with one another.

54

Block diagram of Lepelletier planetary gear train in the 09E gearbox

To primary drive Flange shaft

283_125

Single planetary gear train: Sun gear (S1) Planet carrier (PT1) Ring gear (H1) = = = Stationary Clutch A/B Turbine shaft/ clutch E Input

Ravigneaux gear train: Large sun gear (S2) Small sun gear (S3) Planet carrier (PT2) Ring gear (H2) = = = = Clutch B Brake C Clutch A Clutch E Brake D Output

Explanation of block diagram 283_125 based on section with grey background

H1 S1 P1 PT1

H1 P1

PT1

H1 P1

S1

S1

P1

283_087

P1 P1 283_057 H1 PT1 283_059 55

Gearbox Assemblies
Gear description/torque profile
Power flow in 1st gear Selector elements: Clutch Brake A D The brake D blocks the planet carrier PT2. The torque is transmitted from the sun gear S3 to the short planet gears P3 and from there to the long planet gears P2. Supported by the planet carrier PT2, the torque is transmitted to the ring gear H2, which is connected to the output shaft.

The turbine shaft drives the ring gear H1 of the primary planetary gear train. The ring gear H1 drives the planet gears P1, which roll around the stationary sun gear S1, thus driving the planet carrier PT1. The clutch A connects PT1 to the sun gear S3 and thus channels the torque into the secondary planetary gear train.

In the interests of clarity, the torque profile is shown in the form of a block diagram. The following illustrations only show the upper half of the planetary gearbox in each case.

P2 = 0.886 rpm

H2 = 0.239 rpm PT1 = 0.657 rpm

H1 = 1 rpm P1 = 1.520 rpm

S1 = 0 rpm

n/engine

Turbine shaft = 1 rpm

S2 = 0.536 rpm

S3 = 0.657 rpm

PT2 = 0 rpm

283_070 56

Power flow in 2nd gear Selector elements: Clutch Brake A C The clutch A connects PT1 to the sun gear S3 and thus channels the torque into the secondary planetary gear train. The brake C blocks the large sun gear S2. The torque is transmitted from the sun gear S3 to the short planet gears P3 and from there to the long planet gears P2. The long planet gears P2 roll around the stationary sun gear S2 and drive the ring gear H2.

The turbine shaft drives the ring gear H1 of the primary planetary gear train. The ring gear H1 drives the planet gears P1, which roll around the stationary sun gear S1, thus driving the planet carrier PT1.

P2 = 0.488 rpm

H2 = 0.427 rpm PT1 = 0.657 rpm

H1 = 1 rpm P1 = 1.520 rpm

S1 = 0 rpm

n/engine

Turbine shaft = 1 rpm

S2 = 0 rpm

S3 = 0.657 rpm

PT2 = 0.295 rpm

283_071

57

Gearbox Assemblies
Power flow in 3rd gear Selector elements: Clutch Clutch A B The clutch A connects PT1 to the sun gear S3 and thus channels the torque into the secondary planetary gear train. The clutch B also channels the torque to sun gear S2 in the secondary planetary gear train. Closing of the two clutches A and B blocks the secondary planetary gear train. The torque is then transmitted directly from the primary planetary gear train to the output shaft.

The turbine shaft drives the ring gear H1 of the primary planetary gear train. The ring gear H1 drives the planet gears P1, which roll around the stationary sun gear S1, thus driving the planet carrier PT1.

P2 = 0 rpm

H2 = 0.657 rpm PT1 = 0.657 rpm

H1 = 1 rpm P1 = 1.520 rpm

S1 = 0 rpm

n/engine

Turbine shaft = 1 rpm

S2 = 0.657 rpm

S3 = 0.657 rpm

PT2 = 0.657 rpm

Secondary planetary gear train is blocked

283_072

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Power flow in 4th gear Selector elements: Clutch Clutch A E The clutch A connects PT1 to the sun gear S3 and thus channels the torque into the secondary planetary gear train. The clutch E connects the turbine shaft to the planet carrier of the secondary planetary gear train PT2 and thus also channels the torque into the secondary planetary gear train. The long planet gears P2, meshed with the short planet gears P3, drive the ring gear H2 together with the planet carrier PT2.

The turbine shaft drives the ring gear H1 of the primary planetary gear train and the outer plate carrier of clutch E. The ring gear H1 drives the planet gears P1, which roll around the stationary sun gear S1, thus driving the planet carrier PT1.

P2 = 0.462 rpm

H2 = 0.875 rpm PT1 = 0.657 rpm

H1 = 1 rpm P1 = 1.520 rpm

S1 = 0 rpm

n/engine

Turbine shaft = 1 rpm

S2 = 1.279 rpm

S3 = 0.657 rpm

PT2 = 1 rpm

283_073

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Gearbox Assemblies
Power flow in 5th gear Selector elements: Clutch Clutch B E The clutch B connects PT1 to the sun gear S2 and thus channels the torque into the secondary planetary gear train. The clutch E connects the turbine shaft to the planet carrier of the secondary planetary gear train PT2 and thus also channels the torque into the secondary planetary gear train. The long planet gears P2 drive the ring gear H2 together with the planet carrier P2 and the sun gear S2.

The turbine shaft drives the ring gear H1 of the primary planetary gear train and the outer plate carrier of clutch E. The ring gear H1 drives the planet gears P1, which roll around the stationary sun gear S1, thus driving the planet carrier PT1.

P2 = 0.566 rpm

H2 = 1.153 rpm PT1 = 0.657 rpm

H1 = 1 rpm P1 = 1.520 rpm

S1 = 0 rpm

n/engine

Turbine shaft = 1 rpm

S2 = 0.657 rpm

S3 = 1.420 rpm

PT2 = 1 rpm

283_074

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Power flow in 6th gear Selector elements: Brake Clutch C E The long planet gears P2 roll around the stationary sun gear S2 and drive the ring gear H2. Clutches A and B are open. The primary planetary gear train is not involved in power transmission.

The brake C blocks the sun gear S2. The clutch E connects the turbine shaft to the planet carrier of the secondary planetary gear train PT2 and thus channels the torque into the secondary planetary gear train.

P2 = 1.652 rpm

H2 = 1.447 rpm PT1 = 0.657 rpm

H1 = 1 rpm P1 = 1.520 rpm

S1 = 0 rpm

n/engine

Turbine shaft = 1 rpm

S2 = 0 rpm

S3 = 2.226 rpm

PT2 = 1 rpm

Primary planetary gear train just free-wheels

283_075

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Gearbox Assemblies
Power flow in reverse gear Selector elements: Clutch Brake B D The clutch B connects PT1 to the sun gear S2 and thus channels the torque into the secondary planetary gear train. The brake D blocks the planet carrier PT2. The torque is transmitted from the sun gear S2 to the long planet gears P2. Supported by PT2, the torque is transmitted to the ring gear H2, which is connected to the output shaft. The ring gear H2 is driven in the direction opposite to that of engine rotation.

The turbine shaft drives the ring gear H1 of the primary planetary gear train. The ring gear H1 drives the planet gears P1, which roll around the stationary sun gear S1, thus driving the planet carrier PT1.

P2 = 1.086 rpm

H2 = 0.294 rpm PT1 = 0.657 rpm

H1 = 1 rpm P1 = 1.520 rpm

S1 = 0 rpm

n/engine

Turbine shaft = 1 rpm

S2 = 0.657 rpm

S3 = -806 rpm

PT2 = 0 rpm

283_076

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Gearshift matrix

Gear N88 P/N Reverse gear 1st gear 2nd gear 3rdgear 4thgear 5thgear 6thgear

Solenoid valve logic N215 N216 N217 N218 N233 N371 A

Clutch logic B C D E

Actuation governed by operating status Actuated

Brake/clutch D/E

Torque converter clutch

System pressure

Selector valve 1

Clutch A

Clutch B

Brake C

63

HV-A HV-B HV-D2

HV-D1 HV-E

WS Dr.Red.V KV-C KV-D1 KV-D2

Sys.Dr.V

SPV KV-B

KV-E

KV-A

SV1 RSV

Sch.V ATF cooler SV2

WKV

WDV

283_088

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Hydraulic system diagram

Dr.Red.V EDS1 (N215) EDS2 (N216) EDS3 (N217) EDS4 (N218) EDS5 (N233) EDS6 (N371) HV - A HV - B HV - D1 HV - D2 HV - E KV - A KV - B KV - C KV - D1 KV - D2 KV - E MV1 (N88) RSV Sch.V SPV SV1 SV2 Sys. Dr.V WDV WKV WS

Pressure reduction valve Solenoid pressure control valve 1 Solenoid pressure control valve 2 Solenoid pressure control valve 3 Solenoid pressure control valve 4 Solenoid pressure control valve 5 Solenoid pressure control valve 6 Holding valve - Clutch A Holding valve - Clutch B Holding valve - Brake D Holding valve - Brake D2 Holding valve - Clutch E Clutch valve - Clutch A Clutch valve - Clutch B Clutch valve - Brake C Clutch valve - Brake D1 Clutch valve - Brake D2 Clutch valve - Clutch E Solenoid valve 1 Non-return valve Lubrication valve Compensation valve Selector valve 1 Selector valve 2 System pressure valve Torque converter pressure valve Torque converter clutch valve Selector slide

Depressurised Torque converter pressure System pressure Control pressure Pilot pressure

65

Gearbox Assemblies
Parking lock
The parking lock is designed to stop the vehicle rolling away. It is of conventional design, i.e. it is actuated (purely mechanically) by the selector lever with a Bowden cable. The parking lock gear is connected to the ring gear 2 and the output shaft. The ratchet which engages in the toothing of the parking lock gear thus blocks output to the transfer case. Front and rear axle are locked. If one axle is raised, compensation can be achieved via the Torsen differential if the raised wheels are free to turn. This does however result in destruction of the Torsen differential when towing the vehicle, for example. To facilitate release of the parking lock, the handbrake should be applied before engaging the parking lock.

Selector lever shaft

Linkage

Tapered slide 283_034

Position P

Parking lock gear

Positions R, N, D, S

Ratchet Tapered slide 283_085 66

Torque profile / Four-wheel drive

Front-axle bevel gear unit Side shaft Rear-axle bevel gear unit

Front-axle differential

Flange shaft

Torque converter clutch

Front-axle spur gear unit Torsen differential

Rear-axle differential

Primary drive

To rear left wheel Torque flow Bevel spur gear

Direction of rotation/forward travel

Rotation in opposite direction to engine rotation

Planetary gearbox Rotation in direction of engine rotation Parking lock gear Planetary gearbox 283_038

To front left wheel

Torque converter

Parking lock gear

Primary drive

A special feature of the 09E gearbox is the angled position of the input shaft (side shaft) with respect to the front axle. The torque is transmitted by a bevel spur gear (beveloid teeth) at an angle of 8 to the side shaft spur gear.

Torsen differential

Side shaft Front-axle spur gear unit 283_058 67

Gearbox Assemblies
Transfer case cooling
To accommodate future versions, the 09E is already designed with connections for transfer case oil cooling. For such purposes, the transfer case oil pump is not only responsible for lubricating the transfer case but also for the flow through an optional heat exchanger.

Return Supply

Transfer case oil heat exchanger

283_050

The transfer case oil cooling diagram shown does not correspond to the final series status, as the design had still to be finalised at the time of compilation of this SSP.

68

From heat exchanger

To heat exchanger

With transfer case oil cooling

Pressure relief valve To sump Primary drive bearing housing

Without transfer case oil cooling

Primary drive Torsen differential

Hollow shaft with front-axle spur gear unit

Oil funnel

Sump

Needle bearing Planetary gearbox housing Transfer case housing 283_140

69

Gearbox Assemblies
Transfer case oil pump
Primary drive bearing housing Collector Pressure relief valve

Hexagon

Oil pump Transfer case housing

Sump

The oil pump (rotor-type pump) provides efficient lubrication of all transfer case components. The pump is located in the front housing section of the transfer case and is driven by the side shaft by means of a hexagon connection. From the sump, the pump conveys the oil into a collector. The oil is routed via a duct in the primary drive bearing housing to the lower primary drive mount and some of the oil is returned to the sump. The pressure relief valve in the oil pump protects the components against excessive pressure.

From the collector, the oil is conveyed in a further duct to the oil funnel, which routes the oil into the hollow shaft of the front-axle spur gear unit. From there, it is transferred to the front shaft bearing and via the needle bearing of the rear-axle flange shaft into the Torsen differential. Such a design permits reliable lubrication with a low oil level, which in turn minimises hydraulic losses and foaming.

70

Collector

Side shaft spur gear with hexagon socket for driving oil pump

Hexagon socket Planetary gearbox housing Oil funnel

283_060

Primary drive bearing housing

To sump Oil funnel Primary drive

Pressure relief valve

Torsen differential

Hollow shaft with front-axle spur gear unit Planetary gearbox housing Transfer case housing Sump

Needle bearing

283_062 71

All rights reserved. Subject to technical modification. Copyright* 2002 AUDI AG, Ingolstadt Department I/VK-35 D-85045 Ingolstadt Fax 0841/89-36367 000.2811.03.20 Technical status as at 10/02 Printed in Germany

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