SSP 372 The Shiftmatic Gearbox 0B81

Service Training
Commercial
Vehicles
Self-study Programme 372
The Shiftmatic Gearbox 0B81
Design and Function
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In addition to the two variants of the mechanical manual gearbox, the Crafter is also available with an automated
manual gearbox – the Shiftmatic gearbox.
This gearbox is basically the same as a manual gearbox on the inside. However, additional hydraulic components
combined with control technology allow gear changes to be automated.
You can use both an automatic shift program and a manual shift program.
The Shiftmatic gearbox is a both practical and low-cost alternative to an automatic gearbox.
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NEW Important
Note
The self-study programme shows the design and For current testing, adjustment and repair
function of new developments. instructions, refer to the relevant
The contents will not be updated. service literature.
2
Contents
In Brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gearbox Mechanics . . . .G.. V. o.lk.sw. a.g.en. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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spec
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Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
rrectness o
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Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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3
In Brief
Introduction
The Shiftmatic gearbox with the code 0B81 belongs to the group of fully-automatic gearboxes. This gearbox is
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based on the manual gearbox 0B7 - 330 Nm that is also usedswin
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Gear changes in the Shiftmatic gearbox are eitherthcompletely automatic or carried out as selected e oby the driver.
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Even though the Shiftmatic gearbox has a clutchs for power transmission, there is no clutch pedal like with c automatic
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gearboxes. The clutch is operated by a hydraulic system.
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The advantages of this gearbox are:
● Cheaper price and lower fuel consumption than an automatic gearbox

● Lower exhaust emissions than an automatic gearbox
● Lower weight compared with an automatic gearbox
● Less work for driver thanks to simple operation
● Short traction interruptions
● Low-wear, smooth and comfortable gearshifts
● Hill start assist as standard
4
Technical data
Developer/manufacturer DaimlerChrysler AG
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Gearbox type ss Automated 6-speed manual c
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Mounting Front/longitudinal mounting
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Gearbox control Electro-hydraulic system, consisting of sensors/actuators and
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gearbox control unit
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Number of shafts 3 shafts
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Drive shaft, layshaft, output shaft
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Torque transfer Max. 330Nm
Clutch
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Single-plate, self-adjusting dry clutch
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Clutch operation Electro-hydraulic

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Gearbox oil specification G 009 317 A2

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Gearbox oil capacity 1.5 l

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Change interval t. Co 320 000 km/10 years
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Hydraulic oil specification Prote
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PENTOSIN CHF 202
Hydraulic oil capacity 0.5 l lifetime filling
Length 572.8 mm
(distance from clutch bell housing – output flange)
Weight 52.5 kg
5
In Brief
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2.5l TDI engine
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Engine code BJK 80 kW
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engine code BJL 100 kW
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Ratio: i Gear pair Gear jumps
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Constant mesh 39
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39 x 45
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1st gear i1 = 5,014

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2nd gear by co i2 = 2,831Vo
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25 x 27 i2
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39 x 39 i2
3rd gear i3 = 1,789 = 1,582
25 x 34 i3
39 x 33 i3
4th gear i4 = 1,256 = 1,425
25 x 41 i4
i4
5th gear i5 = 1,0 = 1,256
i5
39 x 24 i5
6th gear i6 = 0,797 = 1,255
25 x 47 i6
39 x 23 x 41
Reverse iR = 4,569
25 x 23 x 14
Spread ϕ i1
= 6,291
i6
The gear jump is the transmission ratio of two neighbouring gears.

This ratio is given as a decimal valve or as a percentage.
i1 ⎛i ⎞
Example of decimal value: ---- = 1, 771 Example of percentage: ⎜ ----1 – 1⎟ . 100 % = 77, 1 %
i2 ⎝ i2 ⎠
6
Progressive gear-ratio steps were chosen for the Furthermore the Shiftmatic gearbox has a spread
Shiftmatic gearbox. The gear jumps become smaller of 6.291, which is particularly useful when the Crafter
as the gear number gets higher with this type of is used as a transport vehicle. This adjustment allows
gearing. As a result, the gear ratios between the a high starting ratio (i1) with good acceleration and a
higher gears are closer compared with the lower low minimum ratio (i6) for low engine speeds at high
gears. The Shiftmatic gearbox has therefore been speeds. This also reduces the fuel consumption.
specially configured for driving in higher gears.
Gearbox code
The gearbox code and the design data are located on
the left-hand side of the front gearbox casing.
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Code Day Month Prote
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7
In Brief
Function areas
Electronics
consisting of … ● Sensors
● Actuators
● Gearbox control unit
S372_061
Hydraulics
consisting of … ● Hydraulic pump

● Accumulator
● Slave cylinder with clutch release bearing
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Mechanics
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consisting of … ● Housing
● Shafts with gears and bearings
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● Shift unit
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The Shiftmatic gearbox d ran
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following functional u areas on the basis of its design or
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and operation:
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Selector lever
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● Electronics
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● Mechanics
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The electronics in the Shiftmatic gearbox are used for
evaluating and monitoring different system variables.
rrectness of i
The gearbox control unit with the sensors and
actuators that are connected to it are responsible for
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this in particular.
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Gearbox control unit
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The hydraulics transfer the variables calculated with
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the electronics to the gearbox mechanics. In this way,

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the gears are shifted and the clutch is operated with

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calculated in the electronics depending on the driving Prote
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Hydraulic unit
S372_008
Gearbox
9
Gearbox Mechanics
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Gearbox design aut
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The Shiftmatic gearbox is based on a manual
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gearbox.
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It uses components from the 0B7 - 330 Nm manual
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gearbox.
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The three main components are:
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● the front and
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● the rear gearbox case,
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● the gearbox shafts with shift unit.
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The two cases are made from a cast aluminium alloy. Front gearbox case
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(with clutch bell housing)
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Rear gearbox case

Gearbox shafts with
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S372_002
11
Gearbox Mechanics
Gearbox cross-section
The 0B81 Shiftmatic gearbox is a 2-step gearbox with All synchromeshed gears use needle bearings and
fully synchronizedgears. are distributed on the layshaft and the output shaft.
It has a drive shaft, a layshaft and an output shaft. The 5th gear is selected directly by the sliding sleeve
shifting to the drive shaft gear.
Synchromeshed gear Central Fixed gear

6th gear selector shaft 3rd gear
Sliding sleeve
5th/6th gear
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Drive shaft gear

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Clutch
Front gearbox case Gear Fixed gear Synchromeshed gear

(with clutch bell housing) (constant mesh) 6th gear 3rd gear
12
The gears are selected by the central selector shaft
either moving longitudinally or moving longitudinally
and rotating. The selector finger of the central selector
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Sliding sleeve Synchromeshed gear
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Fixed gear Synchromeshed gear
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4th gear 2nd gear 1st/2nd gear 1st gear
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Shift actuator
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Synchromeshed gear
Reverse gear
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Sliding sleeve
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Reverse gear
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Output shaft
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Output flange
Layshaft
Rear gearbox case
S372_001
Sliding sleeve Synchromeshed gear Fixed gear Fixed gear

3rd/4th gear 4th gear 2nd gear 1st gear/reverse gear
13
Gearbox Mechanics
Power transmission
The engine torque is transmitted to the gearbox via
the drive shaft. The gear pair for the constant mesh,
which is always in use, transfers the power flow to the
layshaft. G. Volkswagen
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In all gears except for 5th gear, therispower flow is ran
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the respective gear pair for the selected gear.
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5th gear is selected directly. In this case, the power
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drive shaft to the output shaft.
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When the driver selects reverse gear, the power flow
runs between the layshaft and output shaft via an
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individual gear mounted on an additional shaft that
reverses the rotation of the output shaft. 1st gear
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2nd gear
Reverse gear
14
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3rd gear
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6th gear
4th gear
15
Gearbox Mechanics
Drive shaft
The drive shaft is mounted in the front gearbox case
with a fixed deep-groove ball bearing.
The cylindrical roller bearing works as a moveable

bearing between the drive shaft and output shaft.
It is in the drive shaft bore hole.
The drive shaft gear for the constant mesh is part of

the drive shaft.
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Synchronizer hub
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5th/6th gear
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Sliding sleeve
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Cylindrical roller 5th/6th gear
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bearing
Bore
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Drive shaft Deep-groove ball
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16
Output shaft
The output shaft uses a deep-groove ball bearing that
is fitted in the rear gearbox casing as a fixed bearing.
The cylindrical roller bearing works as a moveable
bearing between the drive shaft and output shaft.
The fixed gears for 3rd and 4th gear are part of the
output shaft. The synchromeshed gears for 1st, 2nd,
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6th and reverse gear have needle bearings and agen
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called idler gears and they rotate constantly
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corresponding fixed gears. s
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The synchromeshed gears only connect to the output S372_069
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shaft via the respective sliding sleeve and the The synchronizer hubs for 1st/2nd gear,
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accompanying synchronizer hub to transfer the 5th/6th gear and reverse gear are permanently
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torque once a gear has been selected. connected to the output shaft via splines.
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Sliding sleeve Synchromeshed gear Synchronizer hub
5th/6th gear 2nd gear 1st/2nd gear
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Synchronizer hub Sliding sleeve Sliding sleeve
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5th/6th gear 1st/2nd gear reverse gear f inform

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Synchronizer hub
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S372_032
Output shaft
Cylindrical roller
bearing
Fixed gear Synchromeshed gear Deep-groove ball
3rd gear reverse gear bearing
Synchromeshed gear Fixed gear Synchromeshed gear

6th gear 4th gear 1st gear
17
Gearbox Mechanics
Layshaft
One fixed and one moveable bearing are also used
as bearings for the layshaft.
The deep-groove ball bearing is fitted in the front
gearbox case as a fixed bearing and the cylindrical
roller bearing as a moveable bearing in the rear
gearbox case.
The fixed gears for 1st and 2nd gear are part of the
layshaft.
The synchromeshed gears for 3rd and 4th gear are
idler gears on needle bearings. The fixed gear for
6th gear as well as the constant mesh are press-fitted S372_070
onto the layshaft.
The synchronizer hub for 3rd/4th gear also meshes

with the layshaft via a gear.
Deep-groove ball Sliding sleeve Synchronizer hub

bearing 3rd/4th gearen AG. Volksw3rd/4th
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Fixed gear Synchromeshed gear Fixed gear

6th gear 4th gear 1st gear/reverse gear
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Constant mesh Synchromeshed gear Fixed gear

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3rd gear 2nd gear

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18
Synchromesh
Different synchromeshes are used for the individual gears in one gearbox to allow adjustment to different speeds.
1st/2nd gear — triple synchromesh

The engine speed differences are greatest in 1st and 2nd gear. Therefore triple synchromesh is used here. In the
synchromesh, a frictional surface is formed between the frictional cone on the synchromeshed gear and the inner
ring, a second one between the inner Aring
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Frictional cone Inner ring Intermediate ring Synchronizer ring
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Synchromesh splines
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3rd/4th gear — double synchromesh

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The double synchromesh in 3rd and 4th gear has a special feature on the Shiftmatic gearbox 0B81.
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It consists of a synchro-hub with synchromesh splines that can be replaced separately and fits onto the
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synchromeshed gear. t. Co py
rig
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rig by
The friction surfaces for the double synchromesh are between the inner ring and intermediate ring as well
by copy Vo
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as between the synchronizer ring and intermediate ring. Prote AG.
Inner ring Intermediate ring Synchronizer ring
Synchromeshed gear Synchro-hub with S372_065

synchromesh splines
19
Gearbox Mechanics
5th/6th gear – single synchromesh

In 5th/6th gear, single synchromesh is used due to the small engine speed differences. The separate synchro-hub
with synchromesh splines is the special feature in this case.
The single synchromesh has just one frictional surface between the frictional cone on the synchro-hub and the
synchronizer ring.
Synchro-hub with Frictional cone Synchronizer ring

synchromesh splines
AG. Volkswagen AG d
agen oes
olksw not
Synchromeshed gear y V gu
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spec
es, in part or in w
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S372_066
rrectness of i
Reverse gear – single synchromesh

l purpos
The reverse gear in the Shiftmatic gearbox is single synchromesh. The only frictional surface here is between the
nform
ercia
frictional cone on the synchromeshed gear and the synchronizer ring.

m
a
com
tion in
r
te o
Frictional cone Synchronizer ring

thi
s
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do
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rp
cum
fo
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ng
t.
Synchromeshed gear
op
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C py
t. rig
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pyri by
Vo
co lksw
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Prote AG.
Synchromesh splines
S372_067
You will find more information on synchromesh in

self-study programme 320 “6-Speed Manual Gearbox 0A5”.
20
Shifter unit
The shift unit is used to engage the selected gear with As the selector fork for the 5th/6th gear and the
AG. Volkswagen AG d
agen oes
lksw
its shifter rails and selector forks. TheVocentral selector selector
not fork of the 3rd/4th gear carry out a rotary
by gu
ise
d
shaft is the central part of this rshifter unit. It has the movement ainstead
ran
tee of a longitudinal movement,
tho
task of transferring the movement
u to the selector forks. rotating sliders or mounted on the selector forks to
are
a ac
ss
The movement is transferred to the sliding sleeves by transfer the movement onto the sliding sleeve.
ce
e
nl
pt
du
an
the selector forks for the respective gear pair.
itte
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erm
ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
Selector fork
or c
Central selector shaft thi reverse gear

te
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Selector fork op
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5th/6th gear t. C rig
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Prote AG.
Selector fork
1st/2nd gear
Selector fork joints
S372_009
Slider Selector fork

3rd/4th gear
21
Gearbox Mechanics
Shifter unit with shift actuator

The central selector shaft has three selector fingers.
These selector fingers are pushed to the respective
position to operate a selector fork by the rotary
movement of the central selector shaft. Rotary
movement of the central selector shaft to the left
causes a downwards gate change and rotary
movement to the right causes an upwards gate
change. The central selector shaft causes a
longitudinal movement for a gear change
within the gate.
Selector finger
3rd/4th gear/
Selector finger reverse gear
5th/6th gear
Central selector shaft
AG. Volkswagen AG d
agen oes
olksw not
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ab
ility
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wit
is n
h re
ole,
6th gear
spec
Selector finger
1st/2nd gear
t to the co
5th gear
2nd gear
rrectness
4th gear
o
cial p
f inform
3rd gear
mer
atio
om
n
c
i
or
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te
sd
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t. Co py
rig
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rig by
copy Vo
by lksw
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22 Prote AG.
The gearshifts are calculated in the electronic manual
gearbox control unit J514 on the basis the driver’s shift
selection or the driving situation and applied by the
hydraulic system.
The central selector shaft is bolted to the shift actuator

on the hydraulic system for this reason.
lksw
AG. Vo agen AG
Due to pressure agen build-up or reduction
does in the various
olksw not
y
chambers V gu selector
of the shift actuator, the central
d b ara
rise nte
thoshaft is set in a rotary movement with longitudinal
eo
au ra
ss displacement or only in a longitudinal movement.c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tio
Reverse gear
n in
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thi
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t.
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Cop py
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pyri by
Vo
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by
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Prote AG.
Shift actuator
1st gear
S372_010
23
Gearbox Mechanics
Shift actuator
The shift actuator forms the interface between the The second hydraulic cylinder is the hydraulic brake.
mechanics and hydraulics. It consists of two hydraulic This cylinder is a single-acting hydraulic cylinder that
cylinders. The double-acting hydraulic cylinder is the has a coil spring to return it into position. The pressure
shift cylinder. It is connected to the central selector piston is mounted on the underside and the brake
shaft on the left via the piston rod. The selector sleeve piston on the upperside. The upper part of the brake
with gate guide is fitted on the piston rod of the shift piston has a cylindrical shape like the outer contour
cylinder on the right-hand side. The guide pin that is of the selector sleeve. To improve the friction effect
press-fitted onto the piston rod is located inside the between the selector sleeve and the brake piston, the
gate guide. selector sleeve has a knurled surface.
AG. Volkswagen AG d
agen oes
olksw Chamber 1 not Chamber 2
y V gu
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ri
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s a Piston rod Shift cylinder c
s
(double-acting)
ce
e
Selector sleeve with knurling

nl
pt
du
Permanent magnet
an
itte
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(longitudinal direction)
erm
ab
ility
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Gate guide
hole
spec
es, in part or in w
t to the co
Guide pin
rrectness of i
l purpos
Brake piston
Magnet holder Permanent magnet
nf
ercia
(direction of rotation) Piston rod

or
Hydraulic
m
m
atio
Return spring
m
brake
o
n in
(coil spring)
or c
thi
te
sd
a
Pressure piston
iv
o
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cu
S372_011
o
m
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ng
t.
yi Co
Cop py
t. rig
yri
gh Hydraulic channelsby Chamber 3 ht
cop Vo
by lksw
cted agen
Prote AG.
24
There is a solenoid valve for each hydraulic channel If the gear is changed within a gate, pressure is only
(chamber) in the shift actuator. The solenoid values applied to chamber 1 or chamber 2. This causes the
are used to build up or reduce pressure. piston rod of the shifter cylinder to be moved
lengthways.
The piston rod of the shift cylinder is moved to the
right by pressure being built up in chamber 1 or to the If the gear is changed together with a shifting gate,
left by pressure being built up in chamber 2. pressure is applied to chamber 3 as well as chamber 1
or chamber 2. This in turn causes the piston rod of the
However, if pressure is also applied in chamber 3 of shifter cylinder to be moved lengthways and rotated.
the hydraulic brake, then the selector sleeve cannot lkswage es n
o ot g
b yV ua
be rotated by the brake piston. The piston d rod of the Two permanent magnets ran are mounted on the piston
ir se tee
ho
shift cylinder is rotated in addition ato
u being moved
t rod using a magnet holder or a to recognise the
ss is caused by the c
longitudinally. The rotary movement longitudinal movement and the rotary movement.
ce
e
nl
pt
du
positive drive of the guide pin in the “stepped” gate
an
itte
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erm
guide.
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Neutral position of the gearbox/shift actuator
l purpos
The neutral position on the Shiftmatic gearbox is not just available in the 3rd and 4th gear shifting gate as on a
nform
ercia
manual gearbox, but also in each shift gate. The gearbox always switches to neutral in the respective shifting gate
m
depending on the speed. The neutral position in the shifting gate of the 1st and 2nd gear starting from 1st gear is
at
om
ion
shown as an example. In this position, the guide pin is on the left in the upper step of the gate guide.
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
S372_072 S372_073
25
Gearbox Mechanics
AG. Volkswagen AG d
agen oes
olksw not
V gu
Changing gear without changing shifting gate ise
d by ara
nte
or eo
th
au ra
ss c
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un
pt
an
d
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Shifting up gears 1 > 2; 3 > 4; 5 > 6
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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thi
s
iva
do
Chamber 2
r
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fo
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ng
t.
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Cop py
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Vo S372_085
co lksw
by
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Prote AG.
Shifting down gears 2 > 1; 4 > 3; 6 > 5
Chamber 1
S372_086
26
Starting position Final position
When shifting up to an even gear, pressure is built up in chamber 2 of the shift cylinder. This causes the piston rod
to move longitudinally to the left. The selector sleeve then rotates to the right because of the positive drive.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
ss c
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nl
pt
du
an
itte
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
S372_012 S372_013
rrectness of i
l purpos
nform
mercia
at
om
When shifting down to an odd gear, pressure is built up in chamber 1 of the shift cylinder. This causes the piston rod
on
c
in t
or
to move longitudinally to the right. The selector sleeve then rotates to the left because of the positive drive.
his
ate
do
priv
cum
for
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
S372_014
S372_015
27
Gearbox Mechanics
Gear change with shifting gate change
Shift up gears 2 > 3; 4 > 5 and shift R > 1
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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Chamber 1 Chamber 3
ce
le
un
pt
an
d
itte
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rm
ab
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ility
ot
wit
, is n
h re
hole
spec S372_087
es, in part or in w
t to the co
Shift down gears 3 > 2; 5 > 4 and shift 1 > R

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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fo
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t. Co py
rig
h ht
rig by
copy Vo
by lksw
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Prote AG.
Chamber 2 Chamber 3
S372_088
28
Starting position Final position
When the gearbox shifts up to an odd gear, pressure is first built up in chamber 3 of the hydraulic brake and then
in chamber 1 of the shift cylinder. The pressure built-up in chamber 3 causes the selector sleeve to be locked and the
pressure built-up in chamber 1 also causes rotation to the right due to the positive drive in the blocked selector
sleeve in addition to the longitudinal movement of the piston rod to the right.
S372_016 S372_017
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
When the gearbox shifts down to an even gear, ispressure
ed is first built up in chamber 3 of atheran hydraulic brake and
or tee
h
aut
then in chamber 2 of the shift cylinder. The pressure built-up in chamber 3 locks the selector sleeve or and the pressure
ac
ss
built-up in chamber 2 of the selector cylinder also causes rotation to the left, in addition to the longitudinal
ce
le
un
pt
an
d
movement of the piston rod, due to the positive drive in the locked selector sleeve.
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
S372_018 S372_019
m
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
29
Hydraulics y Volksw
agen
AG. Volkswagen AG d
oes
not
gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
Hydraulic system
d
itte
y li
erm
ab
ility
ot p
All components in the hydraulic system are fitted directly on the gearbox or inside it. This saves on hoses and thus
wit
is n
h re
space.
ole,
spec
t to the co
The hydraulic system consists of the following main
rrectne
components:
ss
● Hydraulic oil tank
o
cial p
f in
● Breather
form
mer
● Slave cylinder with clutch release bearing
atio
om
n
● Accumulator
c
i
or
n thi
e
● Hydraulic control unit with shift actuator

t
sd
iva
o
r
● Hydraulic pump for gearbox V387

p
cum
r
fo
en
ng
t.
yi Co
Cop Slave cylinder with py
t.
clutch release bearing
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
S372_020
Hydraulic control unit with
shift actuator
Hydraulic pump for gearbox V387
30
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
Breather
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
S372_021
Hydraulic oil tank
Accumulator
31
Hydraulics
Hydraulic oil system

The mechanics of the automated manual gearbox are controlled by an electro-hydraulic system.
There is a separate hydraulic oil system in addition to the gearbox oil system.
0.5l of G 004 000 M2 (PENTOSIN CHF 202) is wused AG. Volkswagen AG doil. It is filled for life.
agen as the hydraulic oe s no
ks
Vol t gu
d by ara
e nte
ris
utho eo
ra
a
Hydraulic oil tank ss c
ce
le
un
pt
an
d
itte
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The hydraulic oil tank is bolted to the underside of the
erm
ab
Breather
ility
rear gearbox case. It is used as a reservoir for the
ot p
wit
is n
hydraulic oil. In addition to supplying the hydraulic
h re
ole,
oil, it also has the task of settling and defoaming the
spec
oil.
t to the co
The oil filler screw and the oil drainage screw are
rrectne
located on one side and the suction and return neck
on the other.
ss o
cial p
f inform
The riser pipes for checking the oil level and filling oil
mer
S372_038
atio
are located on the top. The hydraulic oil tank is
om
n
c
covered by a sealed lid. Hydraulic oil tank
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Lid with seal
Suction connection
Return neck
Oil drainage screw
S372_052
Oil tank
Riser pipe
Oil level check Riser pipe Oil filler screw
for filling oil
32
The cross-section of the rear gearbox case shows the
separate oil systems in the gearbox, the gearbox oil
system and the hydraulic oil system.
Breathing and thus pressure compensation of the

hydraulic system is ensured by a breather cap.
This is fitted on the left of the gearbox housing and
connected to the hydraulic system by hoses.
Breather
Rear
gearbox case
Gearbox oil
AG. Volkswagen AG d
Hydraulic oil agen oes
olksw not
y V gu
d b ara
rise nte
Suction connection tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
S372_046
rrectness of i
Deflector Riser pipe Riser pipe

for oil level check for filling oil with
l purpos
with sealing screw sealing screw

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
See the repair guide for how to fill

iv
o
r
rp
cu
o
hydraulic oil.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
33
Hydraulics

G do
age V387 is mounted n AG. Volkswagen A
The hydraulic pump for ogearbox
lksw asesanounit on the front left-hand side of the gearbox case together
y V t gu
with a 12 V electric b
dmotor. ara
ise n r tee
ho
aut or
ac
ss
ce
e
nl
pt
du
The hydraulic pump maintains the working pressure
an
itte
y li
erm
that is required for precise clutch operation and
ab
ility
ot p
gearshifts. A pressure sensor constantly sends the
wit
, is n
h re
hydraulic pressure to the electronic manual gearbox
hole
spec
control unit J514. If the pressure falls below 39 bar
es, in part or in w
t to the co
after several shift processes, the electric motor is
activated and switched off again at a pressure of
55 bar.
rrectness of i
l purpos
A gear wheel pump is used as the hydraulic pump.

S372_037
The hydraulic oil is drawn in from the hydraulic oil
nf
ercia
or
tank via the suction neck and transferred to the
m
m
atio
m
accumulator and valve block via a steel pipe.

o
n in
c

or
thi
e
with electric motor

t
sd
iva
The oil is returned to the hydraulic oil tank through the

o
r
rp
cu
o
return line on the valve block.

f
en
ng
t.
yi Co
Cop pyGear wheel pump
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Delivery connection
Intake connection
Hydraulic pump for

gearbox V387 with Delivery pipe to
electric motor valve block
Suction pipe from

hydraulic oil tank S372_048
34
Accumulator
The accumulator is mounted on the right-hand side of the rear gearbox case. The accumulator is connected to the
valve block by a steel pipe. The gearbox hydraulic pressure sender G270 is mounted between the delivery pipe
connection and accumulator.
n AG. Volkswagen AG
Whenever necessary, the accumulator passes ageon does to the hydraulic system.
the stored pressure
lksw no ot g
yV ua
db ran
ir se tee
ho
aut or
ac
On the inside, the ss
accumulator
a piston consists of
ce
le
un
pt
and a pressurised gas filling. When hydraulic
an
d
itte
y li
pressure starts to build up, the piston is pressed
rm
ab
pe
ility
against the gas and compresses it. If the hydraulic
ot
wit
, is n
pressure suddenly falls, the gas expands again and
h re
hole
spec
the working pressure is maintained. The filled pressure
es, in part or in w
t to the co
accumulator can bridge up to three shift procedures
without the hydraulic pump being run. Nitrogen is
used as the pressurised gas.
rrectness of i
l purpos
nform
ercia
S372_050
m
a
com
t
Accumulator
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw Valve block delivery
cted agen
Prote AG. pipe connection
Gearbox hydraulic
pressure sender G270
Accumulator
Hydraulic oil
Pressurised gas Piston with seals S372_047

(nitrogen)
35
Hydraulics
Hydraulic control unit

The hydraulic control unit is mounted on the rear left-hand side of the gearbox.
It consists of the valve block, the shift actuator, a fine

filter and four solenoid valves. Selector lever valve 1
N284, selector lever valve 2 N285 and the clutch
actuator valve N255 are control valves. The solenoid
for hydraulic brake, ShiftmaticAN431 is a switching
n G. Volkswagen AG do
swage
valve with pressure limitation.
lk es n
Vo ot g
by ua
ed ran
oris tee
th or
The au
advantage of the
valve block is its compact and ac
ss
ce
space-saving design. The need for pipes has been
le
un
pt
an
d
reduced and fewer seals are required.

itte
y li
erm
ab
It is important that you reduce the hydraulic pressure
ility
ot p
before carrying out repair work as the valve block is S372_036
wit
is n
h re
under constant pressure.
ole,
spec
Hydraulic control unit
t to the co
rrectness o
Shift actuator
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
Valve block
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Clutch actuator valve N255
yri
gh by
ht
cop Vo
by lksw
cted agen
Prote AG.
Selector lever valve 1 N284

Return line to hydraulic oil tank
Fine filter
S372_024
Solenoid for hydraulic
brake, Shiftmatic N431
36
AG. Volkswagen AG d
agen oes
olksw not
V gu
Clutch actuator valve N255 d by ara
rise nte
tho eo
au ra
s
The clutch actuator valve
s N255 is used to activate the c
ce
e
nl
pt
slave cylinder with clutch release bearing and thus
du
an
itte
y li
operate the clutch via the hydraulic oil system.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
S372_028
rrectness of i
l purpos
nform
ercia
Selector lever valve 1 N284 is used for longitudinal

m
at
om
movement of the central selector shaft to the right and
ion
c
in t
r
thus to shift to 1st, 3rd and 5th gear.

o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw S372_028
cted agen
Prote AG.
Selector lever valve 2 N285 is used for longitudinal

movement of the central selector shaft to the left and
thus to shift to 2nd, 4th and 6th gear.
S372_028
Solenoid for hydraulic brake,

Shiftmatic N431
The solenoid for hydraulic brake, Shiftmatic N431 is

used to control the hydraulic brake in the shift
actuator. The selector sleeve in the shift actuator is
blocked and the central selector shaft rotates due to
the positive drive of the guide pin in the selector
sleeve.
S372_029
37
Hydraulics
Slave cylinder
ksw
agewith
n AG. Volkclutch
swagen AG release bearing
does
n
ol ot g
yV ua
edb ran
The slave cylinder
ori s with clutch release bearing is a tee Front gearbox case
th or
module auon the drive shaft. Activation of the clutch ac (clutch bell housing)
ss
ce
le
actuator valve N255 builds up pressure in the slave

un
pt
an
d
itte
cylinder and presses the clutch diaphragm spring
y li
erm
ab
tongues over the clutch release bearing. The clutch
ility
ot p
wit
is then disengaged.
is n
h re
ole,
spec
Despite there being a breather valve on the slave
t to the co
cylinder with clutch release bearing, ventilation is not
necessary as the whole gearbox hydraulic system
rrectne
including the clutch is vented.
ss
A clutch travel sender G162 fitted to the slave
o
cial p
f in
cylinder with clutch release bearing measures the
form
mer
disengagement travel and sends the information to

atio
om
electronic manual gearbox control unit J514. n

c
S372_035
i
or
n thi
te
sd
iva
o
pr
Slave cylinder with

c
Drive shaft
um
r
fo

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
cted
by lksw
agen Hydraulic connection
Prote AG.
Slave cylinder with

S372_023
Breather
Clutch travel sender G162
Important
Hydraulic system is vented and may not
be ventilated separately.
38
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
tho eo
au ra
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nl
pt
du
an
itte
y li
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ab
Arrangement and operation
ility
ot p
wit
, is n
h re
hole
The clutch actuator valve N255 is activated to engage the clutch allowing the hydraulic pressure to build up against
spec
es, in part or in w
the slave cylinder. In the slave cylinder, the hydraulic pressure is transferred to the pressure piston via the piston
t to the co
seal and an intermediate ring. This moves the pressure piston towards the diaphragm spring tongues. The piston
thus presses against the outer ring, inner ring and the clutch release bearing consisting of ball bearings in a cage.
rrectness of i
The longitudinal movement of the clutch release bearing pushes the diaphragm spring tongues and thus
disengages the clutch. l purpos
nf
ercia
The preload spring presses against the clutch release bearing when the clutch is not engaged. For this reason, the
orm
m
outer ring runs constantly at the clutch speed. This reduces bearing noise. The speed compensation between the
atio
om
n in
inner and outer ring is achieved with the ball bearings that run in a cage. The clutch release bearing has a lifetime
or c
thi
e
grease filling as lubrication. To protect the slave cylinder with clutch release bearing from dirt, bellows have been
t
sd
iva
o
r
fitted between the two parts.

rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
Piston seal rig by
ht
Preloaded spring copy Vo
lksw
by
cted Intermediate ring agen
Prote AG.
Slave cylinder housing
Pressure piston
Hydraulic oil inlet Cage
Guide sleeve
Diaphragm spring
tongues
Inner ring
Clutch travel sender G162 Ball bearing Clutch release

bearing
Outer ring
Bellows Iron core S372_080
Upon longitudinal movement, the iron core fitted to the slave cylinder causes changes to the magnetic field in the
coils of the clutch travel sender G162 that are used to determine the disengagement travel.
39
Hydraulics
Hydraulic diagram
The hydraulic diagram provides an overview of the
components interacting in the hydraulic system.
Delivery pipe to valves

and accumulator
Delivery and return line for

chamber 1 of the shift actuator Slave cylinder with
clutch release
bearing
chamber 2 of the shift actuator

chamber 3 of the shift actuator
Gearbox hydraulic
Delivery and return pipe of pressure sender G270
slave cylinder with clutch release
bearing
Intake pipe
AG. Volkswagen AG d
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olksw not
Return pipe byV gu
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Accumulator ce
e
Control line for

nl
pt
du
an
overpressure limitation
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
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f
en
ng
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t. Co py
rig
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rig by
copy Vo
by lksw
cted agen
Prote AG.
40
Chamber 1
Shift actuator
AG. Volkswagen AG d
agen oes
olksw 2
Chamber not
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un
pt
Chamber 3
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Clutch actuator
valve N255
ss o
cial p
f inform
mer
atio
m
Selector lever
o
n
c
i
valve 1 N284
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Selector lever copy by
Vo
by lksw
valve 2 N285 cted agen
Prote AG.

Hydraulic oil tank

S372_031
41
Hydraulics
Hydraulic circuit diagram

Components
This circuit diagram shows the hydraulic oil circuit for the Shiftmatic gearbox AG. Volkswagen AG d
agen using hydraulic circuit
oes symbols for the
lksw n
yV
o
individual hydraulic components. The following hydraulic circuitd bdiagrams should illustrate variousotswitching
gu
ara
ise nte
or
positions of the solenoid valves for the individual shift processes with and without gate changes. eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Shift actuator
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Slave cylinder
with clutch release bearing
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
i t.
py Co
t. Co py
rig
Clutch
h ht
rig by
opy Vo
by c actuator valve N255
lksw
cted agen
Gearbox hydraulic Prote AG.
Selector lever
Accumulator valve 1 N284
Check valve Selector lever

valve 2 N285
Hydraulic pump Filter

for gearbox V387
Filter
S372_078
Hydraulic oil tank
42
lkswage es n
o ot g
byV ua
Neutral position o
ir se
d ran
tee
th or
au ac
ss
At the start of each shift procedure, the power flow between the engine and gearbox has to be interrupted by
ce
le
un
pt
an
d
disengaging the clutch. To allow this, the clutch actuator valve N255 is activated electrically during the whole shift
itte
y li
erm
ab
procedure and the hydraulic pressure can be applied to the slave cylinder with release bearing. As the Shiftmatic
ility
ot p
gearbox switches to neutral in the respective shift gate depending on the speed, it is shown here in the example
wit
is n
h re
starting with 1st gear (shift gate 1st/2nd gear).
ole,
spec
Once the clutch has been disengaged, selector lever valve 2 N285 is activated electrically to accelerate the piston.
t to the co
The piston is then slowed down again by the electrical activation of selector lever valve 1 N284 so that it reaches its
centre position in the shift cylinder. The guide pin is then on the left in the upper step of the gate guide.
rrectness o
Shift actuator
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
Slave cylinder
Co
Cop py
with clutch release bearing t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Clutch
actuator valve N255
Gearbox hydraulic
Selector lever

valve 2 N285

for gearbox V387
S372_089
Pressure free
Filter Hydraulic pressure

Pressure reduction
Hydraulic oil tank Electrically activated
43
Hydraulics
Changing gear without changing shifting gate

A gear change without gate change is shown as a gear being shifted up within a gate. Firstly, pressure is built up in
the slave cylinder with clutch release bearing due to the clutch actuator valve N255 being activated. This
disengages the clutch. The selector lever valve 2 N285 is then activated moving the piston in the shift cylinder to the
left until the guide pin is positioned on the left of the gate guide. As the solenoid for hydraulic brake, Shiftmatic
N431 blocks the pressure, there is also no pressure on the hydraulic brake pressure piston so that the selector sleeve
in the shift actuator can rotate freely.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b Shift actuator aran
rise tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Slave cylinder
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Clutch
nf
ercia
actuator valve N255

rm
m
Gearbox hydraulic
atio
om

n in
or c
thi
te
sd
iva
o
r
Selector lever
rp
cu
Accumulator
o
valve 1 N284
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Check valve Prote AG.
Selector lever
valve 2 N285

for gearbox V387
Filter
S372_090
Hydraulic oil tank
44
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
e
nl
pt
du
an
itte
The pressure reduction during the shift procedure is the reverse of the pressure build-up. First, selector lever valve 2
y li
erm
ab
N285 is returned to its rest position by the spring force. The pressure is then built-up in the shift actuator. The
ility
ot p
wit
pressure reduction in the slave cylinder with clutch release bearing is then carried out in such a way using the
, is n
h re
hole
clutch actuator valve N255 that the clutch can be engaged easily again. This is controlled by the current for the
spec
es, in part or in w
clutch actuator valve N255. Once the pressure has been reduced in the chambers of the shift actuator and in the
t to the co
slave cylinder with clutch release bearing, the shift process is complete.
rrectness of i
l purpos
nform
ercia
Shift actuator
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Slave cylinder pyri by
Vo
co lksw
with clutch release bearing cted
by agen
Prote AG.
Clutch
actuator valve N255
Gearbox hydraulic
Selector lever

valve 2 N285

for gearbox V387
S372_091
Pressure free

Pressure reduction
45
Hydraulics
Gear change with shifting gate change

A gear change with gate change is shown as a gear being shifted up with gate change. Firstly, the clutch is
disengaged by activating the clutch actuator valve N255 and thus pressure is built up in the slave cylinder with
clutch release bearing. The solenoid for hydraulic brake, Shiftmatic N431 is then switched to flow through so that
the hydraulic brake is activated and the selector is prevented from rotating. The selector lever valve 1 N284 is then
opened and pressure starts to build up against the shift cylinder piston in the shift actuator. Since the selector sleeve
is now locked, the piston rod rotates to the right in addition to moving lengthways. This occurs due to the positive
drive of the guide pin in the gate guide.
Shift actuator
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Slave cylinder ed
ris nte
o
h release
with clutch bearing eo
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Clutch
spec
es, in part or in w
actuator valve N255

t to the co
Gearbox hydraulic
rrectness of i
Selector lever
l purpos

nform
mercia
at
om
io
Check valve
n
Selector lever
c
in t
or
valve 2 N285
his
ate
do
priv
cum
for
Filter
en
g
Hydraulic pump
n
i t.
py Co
for gearbox V387 t. Co py
rig
rig
h
by
ht Solenoid for hydraulic
py
by co Vo
lksw brake, Shiftmatic N431
cted agen
Prote AG.
Filter
S372_092
Hydraulic oil tank
46
Once the gear has been selected, the pressure is reduced again. For this, both valves N284 and N431 are moved
back to the rest position by a spring. This allows the pressure in the shift actuator chambers to be reduced again.
Next, the pressure in the slave cylinder with clutch release bearing is reduced in a controlled manner by activating
the clutch actuator valve N255. This allows the clutch to engage smoothly and easily. Once the pressure in the shift
actuator chambers and in the slave cylinder with clutch release bearing has been reduced, the shift process is
complete. Volkswa n AG. gen AG
wage does
Volks not
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th
au ra
c
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ce
e
nl
pt
du
an
itte
y li
Shift actuator
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Slave cylinder t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
Clutch
t
sd
iva
actuator valve N255

r
rp
cu
o
Gearbox hydraulic
m
f
en
ng
t.
op
yi Co
C py
t. rig
gh ht
pyri by
Vo
o
c by lksw Selector lever
Accumulator cted agen
Prote AG. valve 1 N284

valve 2 N285

for gearbox V387
S372_093
Pressure free

Pressure reduction
47
Hydraulics
Pressure relief system

A pressure relief system has been AG.integrated in the hydraulic oil system of the Shiftmatic gearbox to protect
Volkswagen A
agen G do
es n
components from overloading.
olksw The pressure relief is performed
ot g by the solenoid for hydraulic brake, Shiftmatic
y V ua
d b r
N431. During all e a
risshift procedures, the hydraulic pressure is napplied
tee constantly via a control line on valve N431.
tho or
au the valve can also be controlled with the hydraulic
This meanssthat ac pressure in addition to electrical activation.
s
ce
le
The valve stays in its rest position at a system pressure of 55 bar.

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Shift actuator
rrectness o
cial p
f inform
mer
atio
m
Slave cylinder
o
n
c
i
or

thi
te
sd
iva
o
pr
cum
r
fo
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Clutch
actuator valve N255
Gearbox hydraulic
Selector lever

valve 2 N285

for gearbox V387
Filter
S372_094
Hydraulic oil tank
48
If the hydraulic pressure rises above 75 bar, however, the spring force of the clutch actuator valve N431 is
counteracted and the valve is pushed to its centre position. This short-circuits the hydraulic oil system so that the
pressure cannot rise any further.
Shift actuator
Slave cylinder
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
Clutch
pe
actuator valve N255 ility

ot
wit
, is n
Gearbox hydraulic h re
hole
spec
es, in part or in w
t to the co
Selector lever
rrectness of i
l purpos

nform
ercia
valve 2 N285
m
a
com
tion in
Filter
r
Hydraulic pump
te o
thi
s
iva
for gearbox V387

do
r

rp
cum
fo

en
ng
i t.
py Co
t. Co py
rig
rig
h
by
ht S372_095
copy Vo
by lksw
cted Pressure free
agen
Prote AG.

Pressure reduction
49
Electronics
System overview
Control unit with display

in dash panel insert J285
Selector lever E313
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Gearbox hydraulic pressure senderrisG270 nte
ho eo
aut ra
ss c
ce
e
nl
Electronic
pt
du
an
ignition lock D9
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Gearbox speed sender G38
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Gear detection sensor G604

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv

um
for
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Driver door contact switch F2
50
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
Diagnosis connector
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
D9
s
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
yi Selector lever valve 1 N284

t.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Electronic manual gearbox Selector lever valve 2 N285

control unit J514
Solenoid for hydraulic brake,

Shiftmatic N431
J510 Hydraulic pump for gearbox V387
Gearbox hydraulic pump

relay J510
S372_060
51
Electronics
Sensors
Gearbox speed sender G38 AG. Volkswagen AG d
agen oes
olksw not
b yV gu
ara
The gearbox speed sender G38 edis mounted on the
nte
ris
tho eo
right-hand side of the rearaugearbox case. ra
ss c
ce
e
nl
pt
du
The sensor measures the speed on the synchromeshed
an
itte
y li
erm
gear for the reverse gear on the output shaft.
ab
ility
ot p
wit
, is n
Signal use
h re
hole
spec
es, in part or in w
t to the co
The signal from the gearbox speed sender G38 is
used to determine the clutch speed and thus also the
gearbox input speed from the transmission ratio.
rrectness of i
l purpos
The electronic manual gearbox control unit J514 needs

these speeds to calculate the biting point of the clutch
nform
ercia
as well as to control the clutch procedures.

m
at
om
ion
c
in t
r
Function
o
his
e
Gearbox speed sender G38 S372_044

at
do
priv
cum
or
The gearbox speed sender G38 is a differential Hall

f
en
ng
t.
yi Co
sensor that measures the tooth backlash on a . Cop py
ht rig
ferromagnetic sender wheel. Two Hall elements are py
rig by
Vo
ht
co
used that measure the left and right sides of a tooth. by lksw
cted agen
Prote AG.
The output signal that is also converted into a
rectangular signal is formed from the difference of
both signals. Gearbox speed sender G38
This sensor type measures very accurately and is not

sensitive to disturbance, like, for example, Synchromeshed gear – reverse gear
temperature fluctuations in the gearbox.
Effects of signal failure
If the signal fails, the gearbox emergency mode will

be activated. Gear changes are then only possible in
manual mode up to 3rd gear.
Automatic mode is deactivated.
S372_051
52
Gearbox hydraulic pressure sender
G270
The gearbox hydraulic pressure sender G270 is
mounted directly on the accumulator on the right-
hand side of the rear gearbox case.
Signal use
The gearbox hydraulic pressure sender G270

determines the current pressure in the hydraulic
system and transfers it to the electronic manual
gearbox control unit J514. If the working pressure falls
below 39 bar, the gearbox hydraulic pump relay J510
is triggered by the electronic manual gearbox control
unit and the hydraulic pump for gearbox V387 is thus
activated. At a pressure of 55 bar, the hydraulic pump
for gearbox is switched off again.
Function S372_059
Accumulator
A diaphragm with strain resistors is fitted inside the

olkswagen AG
pressure sensor. As soon as pressure is applied toagthe en AG. V does
olksw not
diaphragm, the resistances change due tobythe V Gearbox
gu hydraulic
d ara
ise pressure sender
nte G270
stretching. The resulting drop in voltageor is converted eo
th
au
into a pressure value by the electronic manual
ra
c
ss
ce
le
un
gearbox control unit J514.

pt
an
d
itte
y li
erm
ab

ility
ot p
wit
is n
h re
ole,
If the signal fails, the gearbox emergency mode will

spec
be activated. Gear changes are then only possible in

t to the co
manual mode up to 3rd gear.

Automatic mode is deactivated.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
53
Electronics
Selector lever E313

The selector lever for the Shiftmatic gearbox E313 uses Signal use
a so-called “shift by wire” system. This means that
there is no mechanical connection between the The electronic manual gearbox control unit J514 uses
selector lever and gearbox. the selector lever position to calculate the driver’s
gear shift requirement.
The selector lever E313 has three stable positions:
Function
– Forwards gear “O”
– Neutral “N” A permanent magnet is mounted on the underside
– Reverse gear “R” of the G
selector lever, which causes changes in the
A . Volkswagen AG d
agen o
olkswmagnetic field within theessensor
not range of the housing
byV gu
ara
and 3 unstable positions: ed lid.
ris nte
tho eo
s au ra
c
s
– Shift up “+” The 6 selector lever positions are encoded in a shift
ce
e
nl
pt
du
an
– Shift down “–” logic of 4 signals. This logic is used by the electronic
itte
y li
erm
ab
– Automatic mode (auto shift) “A” manual gearbox control unit J514 to evaluate the
ility
ot p
selector lever position and thus the driver’s gear shift
wit
, is n
h re
The positions for forwards “O”, neutral “N” and requirement.
hole
spec
reverse “R” are held horizontally by the holding roller
es, in part or in w
t to the co
locking in the housing lid. There are 2 further locking Effects of signal failure
positions in the guide housing for vertical locking.
rrectness of i
One of the locking positions is for vertical locking of If the signal fails, only automatic mode will be
the “forwards” and “neutral” driving positions and the available.
l purpos
other for locking the reverse gear.
nf
ercia
If two or more signals fail, gear selection and thus the
orm
The unstable positions are preset by the gate guide in gearbox will be disabled and an “F” will appear in
m
atio
om
the lid and in the guide housing. the combi instrument gear indicator. It will also not be
n in
or c
thi
possible to start the engine.
te
sd
iva
After tapping an unstable position, a spring returns

r
rp
cu
o
m
f
the selector lever E313 to the starting position for

en
ng
t.
yi Co
op
forwards “O”. . C py
rig
ht ht
rig by
copy Vo
by lksw
The selector lever E313 has contact-free sensors. Prote
cted AG.
agen
This avoids wear and ensures safe operation.
54
Gear knob
AG. Volkswagen AG d
agen oes
olksw not S372_041
y V gu
d b ara
se n
ri tee
ho
aut or
ac
ss Selector lever E313
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Housing lid with
h re
ole,
sensors
spec
t to the co
Catch for locking roller
rrectne
Gate guide in
ss
housing lid
o
cial p
f inform
mer
atio
om
n
c
Connector
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
gh Locking roller
t. rig
ht
pyri by
Vo
co lksw
by
cted agen
Prote
Guide housing AG.
Permanent magnet
Selector lever housing,

underside
55
Electronics
Clutch travel sender G162 Slave cylinder with clutch

release bearing
The clutch travel sender G162 is a contact-free
position sensor that measures the disengagement
. Volkswagen AG
travel directly on the slave cylinderlkwith gen AG does
o swa clutch release not
y V gu
b
bearing. The sensor is boltededdirectly to the slave ara
ris nte
cylinder with clutch release o eo
ut bearing.
h
a r ac
ss
ce
le
un
pt
Signal use
an
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ility
The signal from the clutch travel sender G162 is used
ot
wit
, is n
together with the gearbox speed sender G38 to
h re
hole
spec
control the clutch position and to determine the
es, in part or in w
t to the co
following three operating modes in the electronic Iron core
manual gearbox control unit J514:
- clutch biting point,
rrectness of i
- clutch engaging point and S372_057
l purpos
- clutch wear.
This allows the clutch to be controlled smoothly and
nform
ercia
safely.
m
a
com
tion in
r
The clutch used in the Crafter is a self-adjusting For this reason, it is necessary to teach in the clutch
te o
thi
s
iva
single-plate dry clutch, which means the biting point again when a new clutch is fitted or if
do
r
rp
cum
fo
disengagement travel always stays constant. there is a malfunction.

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The “clutch biting point” indicates at which
opy
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disengagement travel the clutch biting point occurs cted
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between the engine and gearbox. At this moment, the A ring with iron core mounted on the slave cylinder
clutch starts to slip and the synchromeshed gears in with clutch release bearing causes the magnetic field
the gearbox start to turn. in the 2 coils of the clutch travel sender G162 to
change. Evaluation electronics convert this change
At the “clutch engaging point”, full power transmission into the position signal.
occurs between the engine and gearbox when a gear
is selected. The clutch is fully closed and does not slip. Effects of signal failure
The “clutch wear” is a value stored in the control unit If the signal fails, the gearbox emergency mode will
that takes the wear of the friction lining into be activated. Gear changes in manual mode are then
consideration. A new friction lining with a high only possible up to 3rd gear and an “F” appears in
frictional value requires a slower pressure build-up in combi instrument gear indicator.
the clutch actuator valve N255 compared with a worn
lining. The scale of the necessary pressure reduction is
determined using the clutch wear. The activation time
of the valve is varied so that smooth clutch operation
is always possible.
You will find more information in the
Guided fault finding – Learn new clutch
biting point.
56
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Driver door contact switch F2 ut
hor eo
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nl
The driver door contact switch F2 is fitted in the driver
pt
du
an
Connector for driver door contact
itte
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door lock unit and is not directly visible from the
erm
ab
switch F2 and central locking
outside.
ility
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Door lock unit
h re
hole
It is a mechanical switch that is reset by a spring.
spec
Cable for
es, in part or in w
door inside handle
t to the co
rrectness of i
Signal use
l purpos
The signal from the driver door contact switch F2 is
nf
ercia
used together with the signal from the gearbox
orm
m
atio
hydraulic pressure sender G270 and the ambient
om
n in
c
temperature sensor G17 to determine whether and

or
thi
e
when the hydraulic pump for gearbox V387 needs to

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be activated.
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If the gearbox hydraulic pressure sender G270 ht. rig
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measures a pressure below 39 bar, the hydraulic by co Vo
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pump will need to be run before the engine is started Prote AG.
to provide the necessary hydraulic system pressure.
S372_054
If the ambient temperature sensor records a
temperature below –20 °C, the hydraulic pump will
run as soon as the driver’s door is opened due to the
viscosity of the hydraulic oil. If the temperature is Another function that is controlled with the signal from
above that, this will not happen until the driver’s door the door contact switch F2 is the gearbox neutral
is closed. switching. Before the gearbox is switched to neutral, a
warning signal sounds under the following conditions:
The signal from the door contact switch F2 is also - engine running
used for the roll away warning in the Crafter. A - gear selected
warning signal will sound as soon as the driver’s door - no pedal pressed
is opened and the handbrake is not engaged. - driver’s door open
The gearbox is only switched to neutral after another
three seconds.
The gearbox continues normal operation and there is

no emergency mode.
57
Electronics
Gear detection sensor G604

The gear detection sensor G604 is located on the top
of the rear gearbox housing. It is used for contact-free
detection of the longitudinal movement and rotary Gear detection sensor G604
movement of the central selector shaft that is
connected to the piston rod.
lkswage es n
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Signal use o
ir se tee
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au ac
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The electronic manual gearbox control unit J514 uses
ce
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pt
an
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the position signals from the gear detection sensor

itte
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erm
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G604 to determine the selected gear and thus also
ility
ot p
the gear gate.
wit
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spec
Function
t to the co
One permanent magnet for detecting the longitudinal
rrectne
movement and one for the rotation direction is fitted
on the piston rod of the shift actuator. When the
ss
piston rod is moved or rotated, the permanent
o
cial p
f in
magnets change the magnetic field in the coils of the
form
mer
gear detection sensor G604. The electronic manual
atio
om
gearbox control unit J514 calculates the position of the
n
c
i
or
n thi
central selector shaft from these signals.
te
sd
iva
o
pr
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Effects of signal failure en

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If the signal fails, gear selection and thus the gearbox pyri by
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will be disabled and an “F” will appear in the combi cted
Piston rod agen
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instrument gear indicator. It will also not be possible Magnet holder
to start the engine.
Permanent magnet Permanent magnet

(longitudinal direction) (direction of
rotation)
58
Actuators
The clutch actuator valve N255 is a control valve. This
solenoid valve can control the volume flow and thus
the hydraulic pressure by regulating the flow.
Intermediate positions are possible in addition to
“open” and “closed”. This property is necessary to
make the clutch procedure safe and precise. The valve
is opened with an electrical current and is returned to
the closed position by the spring force.
S372_028
If the signal fails, gear selection and thus the gearbox

will be disabled and an “F” will appear in gen AG. Volkswagen AG d
athe combi oes
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instrument gear indicator. It will also byV
not be possible to gu
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start the engine. tho eo
au ra
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ss
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un
pt
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ab
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ility
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, is n
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spec

es, in part or in w
t to the co
The selector lever valve 1 N284 is a control valve.

It is used to shift gears 1, 3 and 5.
rrectness of i
The valve is opened with an electric current.

l purpos
It is returned to the closed position by a spring.

nform
ercia

m
a
com
tion in
r
te o

thi
S372_028
s
iva
do
will be disabled and an “F” will appear in the combi

r
rp
cum
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instrument gear indicator. It will also not be possible

en
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to start the engine. . Cop py
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59
Electronics

The selector lever valve 2 N285 is a control valve. It is
used to shift gears 2, 4 and 6 as well as reverse G. Volkswagen AG d
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The valve is opened with an electricbcurrent.
yV It is gu
ara
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returned to the closed positionhby
risea spring. nte
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au ac
ss
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nl
pt
du
an
itte
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erm
ab
ility
S372_028
ot p
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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or c
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te
sd
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Solenoid for hydraulic brake, o

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rp
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o
Shiftmatic N431
f
en
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t.
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Cop py
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The solenoid for hydraulic brake, Shiftmatic N431 is copyri by
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used to control the hydraulic brake in the shift Prote
cted AG.
agen
actuator. This solenoid valve is black/white or binary

operated valve, but with 3 positions. The valve is open
when fully powered. It is returned to the closed
position by a spring. The middle position has a
pressure limitation function in which the hydraulic oil
S372_029
system is short-circuited and the pressure cannot rise
any further.

60
The hydraulic pump for gearbox V387 is a module
consisting of a 12 V electric motor and a hydraulic
pump. A gear wheel pump is used as a hydraulic
pump.
The hydraulic pump is switched on and off by the

gearbox hydraulic pump relay J510.
If the signal fails (gearbox hydraulic pump relay J510

or hydraulic pump for gearbox V387), gear selection S372_022
and thus the gearbox will be disabled and an “F” will
appear in the combi instrument gear indicator. Itgewill
AG. Volkswagen AG d
a n oes
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also not be possible to start the engine.by V gu
ara
ed nte
oris e
th or
au ac
ss
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
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for
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61
Electronics
Functional Diagram
E313 Selector lever
F2 Driver door contact switch
G38 Gearbox speed sender

G162 Clutch travel sender
G270 Gearbox hydraulic pressure sender
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G604 Gear detection
Volk not
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oris tee
th or
J386 au
Driver door
control unit ac
ss
J404
ce
Terminal 15 relief relay
le
un
pt
an
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J510 Gearbox hydraulic pump relay

itte
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erm
ab
J514 Electronic manual gearbox control unit
ility
ot p
J519 Onboard supply control unit
wit
is n
h re
J681 Terminal 15 voltage supply relay 2
ole,
spec
N255 Clutch actuator valve t to the co

N284 Selector lever valve 1
rrectne
N285 Selector lever valve 2

N431 Solenoid for hydraulic brake, Shiftmatic
ss o
cial p
f in
V387 Hydraulic pump for gearbox

form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
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Cop py
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Input signal
ht
pyri by
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Output signal Prote AG.
Positive
Earth
CAN data bus
62
63
S372_079
rrectness of i
t to the co nf
spec orm
h re atio
wit n in
ility thi
sd
ab
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an m
pt en
ce
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Co
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s
ng e
fo nl
rp
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com ot p
mercia , is n
l purpos hole
es, in part or in w
Service
Location of electronic manual

gearbox control unit J514
The electronic manual gearbox control unit J514 is

mounted inside the console under the seat on the left-
hand side of the vehicle.
Electronic manual gearbox

control unit J514
AG. Volkswagen AG d
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un
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ab
ility
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S372_082
wit
is n
h re
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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64
65
Notes
rrectness of i
t to the co nf
spec orm
h re atio
wit n in
ility thi
sd
ab
y li ocu
an m
pt en
ce
t.
c
ra
Co
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py
nte
rig
ara
ht
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Test Yourself
Which answers are correct?
One or several of the answers could be correct.
1. Which statement about the Shiftmatic gearbox is correct?
a) It is a semi-automatic gearbox.
a) It is a fully automatic gearbox.
c) It is an automated manual gearbox.
2. Which statement about the triple synchromesh is correct?
a) It can shift gears faster than double synchromesh.

lkswage es n
b) Vo
In triple synchromesh, a frictionalbysurface occurs less than in double ot gsynchromesh.
d ua
ran
ir se tee
th o
u or
c) Greater speed differences a are compensated in the triple synchromesh than ac double
with synchronization.
ss
ce
le
un
pt
an
d
itte
3. Which component is the central element of the shift unit?

y li
erm
ab
ility
ot p
wit
is n
a) 1st/2nd gear selector fork

h re
ole,
spec
a) 3rd/4th gear selector fork

t to the co
a) 5th/6th gear selector fork

rrectne
d) Reverse gear selector fork

ss o
cial p
f inform
e) Shift actuator
mer
atio
om
n
c
f) Central selector shaft

i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
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pyri by
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cted agen
Prote AG.
66
4. Which statement about the shift actuator is correct?
a) It is activated electrically.
b) It is activated hydraulically via solenoid valves.
c) It is used for the horizontal movement and rotation of the central selector shaft.
5. What kind of hydraulic pump is used for the Shiftmatic gearbox?
a) Axial piston pump
b) Radial piston pump
c) Gear wheel pump
6. What characterises the selector lever E313 on the Shiftmatic gearbox?

AG. Volkswagen AG d
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ara
a) It uses a “shift by swire”
ed system. nte
ri
ho eo
aut ra
ss c
b) It is connected mechanically to the Shiftmatic gearbox.
ce
le
un
pt
an
d
itte
y li
rm
c) It has contact-free sensors.

ab
pe
ility
ot
wit
, is n
h re
7. How many signals does the electronic manual gearbox control unit J514 use to evaluate the 6 selector
hole
spec
lever positions?
es, in part or in w
t to the co
a) 4
rrectness of i
b) 5
l purpos
c) 6
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
i t.
py Co
t. Co py
rig
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rig by
copy Vo 1. b, c; 2. c; 3. f; 4. b, c; 5. c; 6. a, c; 7. a
by lksw
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Prote AG.
Answers
67
372
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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n in
or c
thi
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© VOLKSWAGEN AG, Wolfsburg

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t.
All rights and rights to make technical alterations reserved. yi Co
op
000.2811.79.20 Technical status 03/2006 t. C py
rig
gh ht
pyri by
Vo
Volkswagen AG co lksw
by
Service Training VSQ-1 cted agen
Prote AG.
Brieffach 1995
38436 Wolfsburg
❀ This paper was manufactured from pulp that was bleached without the use of chlorine.

SSP 372 The Shiftmatic Gearbox 0B81

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SSP 372 The Shiftmatic Gearbox 0B81

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Service Training

Self-study Programme 372

The Shiftmatic Gearbox 0B81

Design and Function

Gearbox Mechanics . . . .G.. V. o.lk.sw. a.g.en. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

The advantages of this gearbox are:

● Cheaper price and lower fuel consumption than an automatic gearbox

Mounting Front/longitudinal mounting

Gearbox control Electro-hydraulic system, consisting of sensors/actuators and

gearbox control unit

Number of shafts 3 shafts

Clutch operation Electro-hydraulic

Gearbox oil specification G 009 317 A2

Gearbox oil capacity 1.5 l

Hydraulic oil capacity 0.5 l lifetime filling

2.5l TDI engine

1st gear i1 = 5,014

The gear jump is the transmission ratio of two neighbouring gears.

Explanation: HRF 24 3 0006

consisting of … ● Hydraulic pump

. Volkswagen A●G Shift actuator

Gearbox control unit

the electronics to the gearbox mechanics. In this way,

the gears are shifted and the clutch is operated with

The three main components are:

● the gearbox shafts with shift unit.

(with clutch bell housing)

Rear gearbox case

Synchromeshed gear Central Fixed gear

Drive shaft gear

Front gearbox case Gear Fixed gear Synchromeshed gear

Sliding sleeve Synchromeshed gear

Rear gearbox case

Sliding sleeve Synchromeshed gear Fixed gear Fixed gear

The cylindrical roller bearing works as a moveable

The drive shaft gear for the constant mesh is part of

Cylindrical roller 5th/6th gear

5th/6th gear 1st/2nd gear reverse gear f inform

Synchromeshed gear Fixed gear Synchromeshed gear

The synchronizer hub for 3rd/4th gear also meshes

Deep-groove ball Sliding sleeve Synchronizer hub

Fixed gear Synchromeshed gear Fixed gear

Constant mesh Synchromeshed gear Fixed gear

3rd gear 2nd gear

1st/2nd gear — triple synchromesh

3rd/4th gear — double synchromesh

Inner ring Intermediate ring Synchronizer ring

Synchromeshed gear Synchro-hub with S372_065

5th/6th gear – single synchromesh

Synchro-hub with Frictional cone Synchronizer ring

Reverse gear – single synchromesh

frictional cone on the synchromeshed gear and the synchronizer ring.

Frictional cone Synchronizer ring

You will find more information on synchromesh in

Central selector shaft thi reverse gear

Selector fork joints

Slider Selector fork

Shifter unit with shift actuator

Central selector shaft

The central selector shaft is bolted to the shift actuator

Selector sleeve with knurling

(direction of rotation) Piston rod

positive drive of the guide pin in the “stepped” gate

Shifting down gears 2 > 1; 4 > 3; 6 > 5