Transmission_Automatic_Gear_Management_en_2011_07.ppt
ZouhairWahbi
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85 slides
Sep 08, 2024
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About This Presentation
Transmission_Automatic_Gear_Management
Slide Content
4
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automatic transmission control
Work document 1 987 727 652
Name :............................................
Date: from ............... to ..............
Location :............................................
This training material serves as information for study purposes. It shall not be used for corrective maintenance of
of vehicles. Corrective maintenance should be carried out as per the respective and applicable workshop manuals.
All values specified here are application-dependent and therefore not generally applicable.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automatic transmission control
Work document 1 987 727 652
Name :............................................
Date: from ............... to ..............
Location :............................................
This training material serves as information for study purposes. It shall not be used for corrective maintenance of
of vehicles. Corrective maintenance should be carried out as per the respective and applicable workshop manuals.
All values specified here are application-dependent and therefore not generally applicable.
5
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Instruction leaflet for occupational safety
For your attention :
General regulation for Keep your hands away from moving
accident prevention components. Connect the engine tester
only when the engine is switched off
and during Ignition-off. Always
connect the black clip first.
Work on running engines only
with exhaust gas suction. Maintain
a safe distance from moving
components on BPS and LPS.
Noise zones Noise zones are indicated using signs.
Avoid unnecessary noise.
Always wear ear protection
against noise in the noise-zones.
Hazardous waste Discard cleaning cloth and other similar
material into containers provided for
them.
Use chemical binders to remove
gasoline and oil spills and similar
fluid leakages immediately.
Please do not alter or reset the settings on the training vehicles.
Please do not alter the settings on the PC / diagnostic tester or reset the settings.
No smoking Smoking is prohibited in all the
training rooms and on the entire shop
floor.
Fire extinguisher Locate the nearest fire extinguisher.
Read the printed operating instructions.
Call 123 in case of fire.
Emergency There are signboards to indicate the
escape routes emergency escape routes. Make note
of these signs/signboards.
Do not obstruct escape routes by
vehicles or other objects.
First Aid FIRST AID is mandatory for every one.
The sanitation room GF stocks
stretchers as well as material
for applying compression bandages.
Report any injury to your trainer.
Call 123 in case of injuries.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Instruction leaflet for occupational safety
For your attention :
General regulation for Keep your hands away from moving
accident prevention components. Connect the engine tester
only when the engine is switched off
and during Ignition-off. Always
connect the black clip first.
Work on running engines only
with exhaust gas suction. Maintain
a safe distance from moving
components on BPS and LPS.
Noise zones Noise zones are indicated using signs.
Avoid unnecessary noise.
Always wear ear protection
against noise in the noise-zones.
Hazardous waste Discard cleaning cloth and other similar
material into containers provided for
them.
Use chemical binders to remove
gasoline and oil spills and similar
fluid leakages immediately.
Please do not alter or reset the settings on the training vehicles.
Please do not alter the settings on the PC / diagnostic tester or reset the settings.
No smoking Smoking is prohibited in all the
training rooms and on the entire shop
floor.
Fire extinguisher Locate the nearest fire extinguisher.
Read the printed operating instructions.
Call 123 in case of fire.
Emergency There are signboards to indicate the
escape routes emergency escape routes. Make note
of these signs/signboards.
Do not obstruct escape routes by
vehicles or other objects.
First Aid FIRST AID is mandatory for every one.
The sanitation room GF stocks
stretchers as well as material
for applying compression bandages.
Report any injury to your trainer.
Call 123 in case of injuries.
6
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Guidelines for PL location visitors
•Please display the visitor's pass at all times when you are within the premises.
•Your visit is restricted only to those parts of the plant where your work station is
located or parts of the premises where you have to carry out duties.
•The identity card is not transferable and should be returned to the security officers of
the factory without being asked to do so at the end of the RB visit.
•We expect you to follow the instructions of our supervisory personnel.
•Video- and audio recordings are not permitted. Such devices are not allowed inside
the premises and should be deposited with the security officers.
•We request you to handle the information, documents, samples etc., which are
beyond the generally known information - confidentially.
We explicitly indicate that the above mentioned information etc. is solely the
unrestricted property of Robert Bosch GmbH.
You have agreed to comply with these
regulations by signing the training identity card.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Guidelines for PL location visitors
•Please display the visitor's pass at all times when you are within the premises.
•Your visit is restricted only to those parts of the plant where your work station is
located or parts of the premises where you have to carry out duties.
•The identity card is not transferable and should be returned to the security officers of
the factory without being asked to do so at the end of the RB visit.
•We expect you to follow the instructions of our supervisory personnel.
•Video- and audio recordings are not permitted. Such devices are not allowed inside
the premises and should be deposited with the security officers.
•We request you to handle the information, documents, samples etc., which are
beyond the generally known information - confidentially.
We explicitly indicate that the above mentioned information etc. is solely the
unrestricted property of Robert Bosch GmbH.
You have agreed to comply with these
regulations by signing the training identity card.
7
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• AUTOMATIC TRANSMISSION (AT)
• Torque converter
• Planetary gear
• Switching elements
• OVERVIEW OF THE AT-
TRANSMISSION
• Overview / Design
• Oil pump
• Parking lock
• Maintenance / Diagnosis
• Summary
• DUAL CLUTCH GEARBOX
• Overview / Design
• Mechatronics module
• Clutch systems
• Gearbox unit
• Oil circuit
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• AUTOMATIC TRANSMISSION (AT)
• Torque converter
• Planetary gear
• Switching elements
• OVERVIEW OF THE AT-
TRANSMISSION
• Overview / Design
• Oil pump
• Parking lock
• Maintenance / Diagnosis
• Summary
• DUAL CLUTCH GEARBOX
• Overview / Design
• Mechatronics module
• Clutch systems
• Gearbox unit
• Oil circuit
8
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• Maintenance / Diagnosis
• AUTOMATED SHIFT
TRANSMISSION (AST)
• Clutch actuator
• Selecting and engaging a gear
• Mechatronics module
• Summary
• Overview / Design
• Clutch adjustment
• Maintenance
• Summary
• CONTINOUSLY VARIABLE
TRANSMISSION (CVT)
• Overview / Design
• Transmission sensors
• Components
• Maintenance
• Summary
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• Maintenance / Diagnosis
• AUTOMATED SHIFT
TRANSMISSION (AST)
• Clutch actuator
• Selecting and engaging a gear
• Mechatronics module
• Summary
• Overview / Design
• Clutch adjustment
• Maintenance
• Summary
• CONTINOUSLY VARIABLE
TRANSMISSION (CVT)
• Overview / Design
• Transmission sensors
• Components
• Maintenance
• Summary
9
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• AUTOMATIC TRANSMISSION (AT)
• Torque converter
• Planetary gear
• Switching elements
• OVERVIEW OF THE AT-
TRANSMISSION
• Overview / Design
• Oil pump
• Parking lock
• Maintenance / Diagnosis
• Summary
• DUAL CLUTCH TRANSMISSION
• Overview / Design
• Mechatronics module
• Clutch systems
• Gearbox unit
• Oil circuit
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• AUTOMATIC TRANSMISSION (AT)
• Torque converter
• Planetary gear
• Switching elements
• OVERVIEW OF THE AT-
TRANSMISSION
• Overview / Design
• Oil pump
• Parking lock
• Maintenance / Diagnosis
• Summary
• DUAL CLUTCH TRANSMISSION
• Overview / Design
• Mechatronics module
• Clutch systems
• Gearbox unit
• Oil circuit
10
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Overview of the automatic transmission
Automatic manual transmission
(ASG or AMT)
Actuators ECU ActuatorsSensorsVariator with belt
Clutch actuator with
the K-ECU
Electro-hydraulics
module
Electronics
module
Hydraulics
module
Double clutch
transmission
(DKG or DCT)
Automatic
transmission (AT)
Continuously
variable transmission
(CVT)
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Overview of the automatic transmission
Automatic manual transmission
(ASG or AMT)
Actuators ECU ActuatorsSensorsVariator with belt
Clutch actuator with
the K-ECU
Electro-hydraulics
module
Electronics
module
Hydraulics
module
Double clutch
transmission
(DKG or DCT)
Automatic
transmission (AT)
Continuously
variable transmission
(CVT)
11
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• AUTOMATIC TRANSMISSION (AT)
• Torque converter
• Planetary gear
• Switching elements
• OVERVIEW OF THE AT-
TRANSMISSION
• Overview / Design
• Oil pump
• Parking lock
• Maintenance / diagnosis
• Summary
• DUAL CLUTCH TRANSMISSION
• Overview / Design
• Mechatronics module
• Clutch systems
• Gearbox unit
• Oil circuit
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• AUTOMATIC TRANSMISSION (AT)
• Torque converter
• Planetary gear
• Switching elements
• OVERVIEW OF THE AT-
TRANSMISSION
• Overview / Design
• Oil pump
• Parking lock
• Maintenance / diagnosis
• Summary
• DUAL CLUTCH TRANSMISSION
• Overview / Design
• Mechatronics module
• Clutch systems
• Gearbox unit
• Oil circuit
12
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automatic transmission (AT)
AisinWarner 8-speed (Lexus) since 2007
ZF 6-speed 6HP26 (BMW) since 2003
Aisin 6-speed 09G; 09K; 09M (VW) since 2004
Mercedes 7-speed Tronic
since 2003
Mercedes 7-speed Tronic Plus
since 2010
GM AF40 Gen 2 (Opel Insignia) since 2010
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automatic transmission (AT)
AisinWarner 8-speed (Lexus) since 2007
ZF 6-speed 6HP26 (BMW) since 2003
Aisin 6-speed 09G; 09K; 09M (VW) since 2004
Mercedes 7-speed Tronic
since 2003
Mercedes 7-speed Tronic Plus
since 2010
GM AF40 Gen 2 (Opel Insignia) since 2010
13
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automatic transmission (AT) - Characteristics
Automatic transmission (AT)
Hydrodynamic converter as drive-off element
Immense further development works took place in the last
10 years in power density
(number of gears, spreading, efficiency)
Optimization potential in:
Agility
Driving pleasure
Consumption
Advantage
Excellent switching quality
Today possible up to 8 driving stages (in Lexus)
Spreading up to 6.7 (Porsche 4.3 and 5 driving stages of DC)
Less interruption in traction force while switching
High torque transmission up to (1000 Nm)
Disadvantage
Complicated and costly technology
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automatic transmission (AT) - Characteristics
Automatic transmission (AT)
Hydrodynamic converter as drive-off element
Immense further development works took place in the last
10 years in power density
(number of gears, spreading, efficiency)
Optimization potential in:
Agility
Driving pleasure
Consumption
Advantage
Excellent switching quality
Today possible up to 8 driving stages (in Lexus)
Spreading up to 6.7 (Porsche 4.3 and 5 driving stages of DC)
Less interruption in traction force while switching
High torque transmission up to (1000 Nm)
Disadvantage
Complicated and costly technology
14
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Structure of a modern automatic transmission (AT)
1.Name the parts of the torque converter!
Pump, turbine, guide wheel on freewheeling mechanism and oil.
2.Which type of planetary gears are used in the range of automatic
transmission (AT)?
Wheel set concepts: Simpson, Ravigneaux, Simpson and Lepelletier.
1.Gear output to drive shaft
2.Planetary wheel-set
3.Multi-disk clutches
4.Converter
5.Turbine
6.Converter clutch
7.Gear input
8.Module for transmission
control
1 52 3 4 76
8
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Structure of a modern automatic transmission (AT)
1.Name the parts of the torque converter!
Pump, turbine, guide wheel on freewheeling mechanism and oil.
2.Which type of planetary gears are used in the range of automatic
transmission (AT)?
Wheel set concepts: Simpson, Ravigneaux, Simpson and Lepelletier.
1.Gear output to drive shaft
2.Planetary wheel-set
3.Multi-disk clutches
4.Converter
5.Turbine
6.Converter clutch
7.Gear input
8.Module for transmission
control
1 52 3 4 76
8
15
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Torque converter - Functional principle
1.Pump wheel
2.Guide wheel
3.Turbine wheel
4.Housing cover
Basic function
The ventilator is switched on and rotating
(left). If another ventilator is placed on the
opposite side, then the air flow will rotate the
blade of the second ventilator.
Structure
1
2 3
4
ATF flow direction in the
converter housing
3
21
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Torque converter - Functional principle
1.Pump wheel
2.Guide wheel
3.Turbine wheel
4.Housing cover
Basic function
The ventilator is switched on and rotating
(left). If another ventilator is placed on the
opposite side, then the air flow will rotate the
blade of the second ventilator.
Structure
1
2 3
4
ATF flow direction in the
converter housing
3
21
16
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Torque converter - Structure and function
1.Name the main parts of the torque converter!
Pump (is welded to the converter housing), turbine (it is connected with the
transmission shaft), guide wheel, converter clutch.
1.Turbine
2.Pump
3.Guide wheel
4.Converter clutch
5.Torsional damper
6.Friction lining
7.Drive
8.Free wheel
9.Support for guide
wheel
10.Output
1
2
3
4
5
6
7
8
10
9
1 2
3
1
3
1
2
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Torque converter - Structure and function
1.Name the main parts of the torque converter!
Pump (is welded to the converter housing), turbine (it is connected with the
transmission shaft), guide wheel, converter clutch.
1.Turbine
2.Pump
3.Guide wheel
4.Converter clutch
5.Torsional damper
6.Friction lining
7.Drive
8.Free wheel
9.Support for guide
wheel
10.Output
1
2
3
4
5
6
7
8
10
9
1 2
3
1
3
1
2
17
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Torque converter - converter clutch
1.What is the function of the converter clutch?
The converter clutch is used for eliminating the
slip during the torque transmission. The slip
between the pump and the turbine is locked up
by activating the converter clutch and thus, the
efficiency is improved.
1.Torque converter
2.Converter clutch
3.Turbine
4.Pump
5.Guide wheel
6.Lubricating valve
7.Non-return valve
8.ATF cooler
9.Converter clutch valve
10.Converter pressure valve
11.Pressure control valve
Oil supply / converter clutch closed
2
1
3
4
5 6 7
8
9
10
11
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Torque converter - converter clutch
1.What is the function of the converter clutch?
The converter clutch is used for eliminating the
slip during the torque transmission. The slip
between the pump and the turbine is locked up
by activating the converter clutch and thus, the
efficiency is improved.
1.Torque converter
2.Converter clutch
3.Turbine
4.Pump
5.Guide wheel
6.Lubricating valve
7.Non-return valve
8.ATF cooler
9.Converter clutch valve
10.Converter pressure valve
11.Pressure control valve
Oil supply / converter clutch closed
2
1
3
4
5 6 7
8
9
10
11
18
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Oil pump
1.Which type of the oil pump is used in the range of AT transmission?
Internal gear pump (crescent pump for Mercedes 7-speed Tronic; ZF 6HP;
Aisin etc.) and double vane pump ZF 8HP.
2.What should be taken care of while repairing the torque converter?
The driver of the oil pump shall engage itself in the grooves of the
converter hub.
1.Pressure side
2.Crescent moon
3.Inner toothed wheel
4.Suction side
5.External toothed wheel,
driven by the engine
6.Driving tabs
1
2 3 4
5 6
Oil pump transmission-side
Oil pump engine side
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Oil pump
1.Which type of the oil pump is used in the range of AT transmission?
Internal gear pump (crescent pump for Mercedes 7-speed Tronic; ZF 6HP;
Aisin etc.) and double vane pump ZF 8HP.
2.What should be taken care of while repairing the torque converter?
The driver of the oil pump shall engage itself in the grooves of the
converter hub.
1.Pressure side
2.Crescent moon
3.Inner toothed wheel
4.Suction side
5.External toothed wheel,
driven by the engine
6.Driving tabs
1
2 3 4
5 6
Oil pump transmission-side
Oil pump engine side
19
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Planetary gear - Basic principle
Ravigneaux-planetary wheel set
Simpson-Planetary wheel set
Lepelletier-planetary wheel set
The system is based on a simple planetary wheel set and a downstream
double planetary wheel set as per Ravigneaux. The basic principle is to
operate the sun wheels and the planet carriers of the double planetary
wheel set with different speeds.
The long planetary wheels are engaged in the Ravigneaux-set with the
big sun wheel and the planetary wheels of the small sun wheel
simultaneously. Special feature of this set is the common planet carrier
due to which a compact design is possible.
In case of Simpson-set, the planet wheel carrier of one of the set is
connected to the hollow wheel of the other.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Planetary gear - Basic principle
Ravigneaux-planetary wheel set
Simpson-Planetary wheel set
Lepelletier-planetary wheel set
The system is based on a simple planetary wheel set and a downstream
double planetary wheel set as per Ravigneaux. The basic principle is to
operate the sun wheels and the planet carriers of the double planetary
wheel set with different speeds.
The long planetary wheels are engaged in the Ravigneaux-set with the
big sun wheel and the planetary wheels of the small sun wheel
simultaneously. Special feature of this set is the common planet carrier
due to which a compact design is possible.
In case of Simpson-set, the planet wheel carrier of one of the set is
connected to the hollow wheel of the other.
20
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Planetary gear – Ravigneaux-planetary wheel set (7-speed
Tronic)
1.Converter-lock-up
clutch
2.Turbine wheel
3.Pump wheel
4.Guide wheel
5.Multi-disk brake B1
6.Multi-disk brake B3
7.Large hollow wheel
8.Short planetary
wheels
9.Small hollow wheel
10.Double planet wheel
carriers
11.Multi-disk clutch 1
12.Long planetary
wheels
13.Sun wheel
14.Multi-disk clutch 2
15.Hollow wheel
16.Planet wheel carrier
17.Planetary wheels
18.Sun wheel
19.Hollow wheel
20.Planet wheel carrier
21.Planetary wheels
22.Sun wheel
23.Multi-disk brake BR
24.Multi-disk brake B2
25.Multi-disk clutch 3
1
2 3
4
5 6
7
8 9
10
12
13
11
14
15
16
17
18
22
21
19
23 24
25
20
Ravigneaux-wheel set Front wheel set Rear wheel set
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Planetary gear – Ravigneaux-planetary wheel set (7-speed
Tronic)
1.Converter-lock-up
clutch
2.Turbine wheel
3.Pump wheel
4.Guide wheel
5.Multi-disk brake B1
6.Multi-disk brake B3
7.Large hollow wheel
8.Short planetary
wheels
9.Small hollow wheel
10.Double planet wheel
carriers
11.Multi-disk clutch 1
12.Long planetary
wheels
13.Sun wheel
14.Multi-disk clutch 2
15.Hollow wheel
16.Planet wheel carrier
17.Planetary wheels
18.Sun wheel
19.Hollow wheel
20.Planet wheel carrier
21.Planetary wheels
22.Sun wheel
23.Multi-disk brake BR
24.Multi-disk brake B2
25.Multi-disk clutch 3
1
2 3
4
5 6
7
8 9
10
12
13
11
14
15
16
17
18
22
21
19
23 24
25
20
Ravigneaux-wheel set Front wheel set Rear wheel set
21
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Planetary wheel set – Mercedes 7-speed Tronic
1.Short planetary
wheel
2.Long planetary
wheel
3.Planet wheel carrier
4.Sun wheel
5.Planetary wheel
6.Planet wheel carrier
7.Hollow wheel
1
2
3
4
Ravigneaux-wheel set
5
6
7
Simple wheel set
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Planetary wheel set – Mercedes 7-speed Tronic
1.Short planetary
wheel
2.Long planetary
wheel
3.Planet wheel carrier
4.Sun wheel
5.Planetary wheel
6.Planet wheel carrier
7.Hollow wheel
1
2
3
4
Ravigneaux-wheel set
5
6
7
Simple wheel set
22
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Switching elements – multi-disk clutch
1.What is the function of the multi-disk clutches?
The multi-disk clutches connect different
elements of single wheel sets to each other and
thus, enable a torque transmission as also speed
conversion.
2.How are they controlled?
The clutches are closed hydraulically. For this, a
piston is impacted with oil pressure such that it
presses the laminated disk packs together.
1.Oil feed input
2.Internal disk
3.Disk carrier
4.Back-pressure spring
5.Outer disk
6.Multi-disk clutch 1
7.Multi-disk clutch 2
8.Multi-disk clutch 3
7
6
5
2
8
5
4
2
3
1
Mercedes 7-speed Tronic
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Switching elements – multi-disk clutch
1.What is the function of the multi-disk clutches?
The multi-disk clutches connect different
elements of single wheel sets to each other and
thus, enable a torque transmission as also speed
conversion.
2.How are they controlled?
The clutches are closed hydraulically. For this, a
piston is impacted with oil pressure such that it
presses the laminated disk packs together.
1.Oil feed input
2.Internal disk
3.Disk carrier
4.Back-pressure spring
5.Outer disk
6.Multi-disk clutch 1
7.Multi-disk clutch 2
8.Multi-disk clutch 3
7
6
5
2
8
5
4
2
3
1
Mercedes 7-speed Tronic
23
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Switching elements – Brakes
1.Which types of brakes are used?
Multi-disk - band brakes hold the
components firmly in the
planetary gear and is used for
selecting the gear.
1.Outer disk
2.Internal disk
3.Multi-disk brake 1
4.Multi-disk brake 2
5.Multi-disk brake 3
6.Multi-disk brake 4
7.Drum-rotation direction
8.Brake band
9.AT-housing
10. Piston linkage
11. Piston
7
8
9
10 11 12
1
23
4
5 6
Multi-disk brake (Mercedes 7-speed
Tronic)
Drum-brake (Toyota)
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Switching elements – Brakes
1.Which types of brakes are used?
Multi-disk - band brakes hold the
components firmly in the
planetary gear and is used for
selecting the gear.
1.Outer disk
2.Internal disk
3.Multi-disk brake 1
4.Multi-disk brake 2
5.Multi-disk brake 3
6.Multi-disk brake 4
7.Drum-rotation direction
8.Brake band
9.AT-housing
10. Piston linkage
11. Piston
7
8
9
10 11 12
1
23
4
5 6
Multi-disk brake (Mercedes 7-speed
Tronic)
Drum-brake (Toyota)
24
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics module
1.What are the functions of the floats?
The floats 1 and 2 close the openings between the
oil chamber and the wheel set space if the oil level
increases.
1.Variable magnet valve brake 2
2.Variable magnet valve clutch 2
3.Variable magnet valve working
pressure
4.Variable magnet valve converter-
lock-up clutch
1.Variable magnet valve clutch 3
2.Variable magnet valve brake 3
3.Variable magnet valve brake 1
4.Variable magnet valve clutch 1
5.Float 1
6.Plug-in coupling
7.Electronic Control Unit
8.Valve housing
9.Intermediate metal sheet
10.Valve housing
11.Turbine speed sensor
12.Internal speed sensor
13.Output speed sensor
14.Float 2
15.Electrical control unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics module
1.What are the functions of the floats?
The floats 1 and 2 close the openings between the
oil chamber and the wheel set space if the oil level
increases.
1.Variable magnet valve brake 2
2.Variable magnet valve clutch 2
3.Variable magnet valve working
pressure
4.Variable magnet valve converter-
lock-up clutch
1.Variable magnet valve clutch 3
2.Variable magnet valve brake 3
3.Variable magnet valve brake 1
4.Variable magnet valve clutch 1
5.Float 1
6.Plug-in coupling
7.Electronic Control Unit
8.Valve housing
9.Intermediate metal sheet
10.Valve housing
11.Turbine speed sensor
12.Internal speed sensor
13.Output speed sensor
14.Float 2
15.Electrical control unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
25
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Electronic unit
1.Where is the transmission control unit built?
The transmission control unit is built in the transmission housing (below)
along with the electronic module.
10.Output speed sensor
11.Control solenoid valve working
pressure
12.Control solenoid valve clutch 1
13.Control solenoid valve clutch 2
14.Control solenoid valve clutch 3
15.Control solenoid valve brake 1
16.Control solenoid valve brake 2
17.Control solenoid valve brake 3
18.Control solenoid valve
converter-lockup clutch
10. Diagnosis
11. Plug-in coupling
12. Connection sensor
13. Internal speed sensor
14. Turbine speed sensor
12
13
14
1
2 3 4 5
6
7
8
9
10
11
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Electronic unit
1.Where is the transmission control unit built?
The transmission control unit is built in the transmission housing (below)
along with the electronic module.
10.Output speed sensor
11.Control solenoid valve working
pressure
12.Control solenoid valve clutch 1
13.Control solenoid valve clutch 2
14.Control solenoid valve clutch 3
15.Control solenoid valve brake 1
16.Control solenoid valve brake 2
17.Control solenoid valve brake 3
18.Control solenoid valve
converter-lockup clutch
10. Diagnosis
11. Plug-in coupling
12. Connection sensor
13. Internal speed sensor
14. Turbine speed sensor
12
13
14
1
2 3 4 5
6
7
8
9
10
11
26
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Selector lever module
1.What is the function of the blocking magnet?
The blocking magnet R/P is controlled via an
electronic selector level module. The R/P-
blocking magnet releases the selector lever
and thus, enables a switching from the
selector lever position P.
1.Leaf springs of the switch lock
2.Locking lever
3.R/P blocking magnet
4.Selector lever control unit
5.One-touch module +/-
6.Connection for control cable ignition
lock
7.Return spring R/P blocking magnet
8.Return spring
9.Selector lever control unit with
Tiptronic switch
10.Functional unit
1
2
3 4
5
4
8
7
6
6
10
3
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Selector lever module
1.What is the function of the blocking magnet?
The blocking magnet R/P is controlled via an
electronic selector level module. The R/P-
blocking magnet releases the selector lever
and thus, enables a switching from the
selector lever position P.
1.Leaf springs of the switch lock
2.Locking lever
3.R/P blocking magnet
4.Selector lever control unit
5.One-touch module +/-
6.Connection for control cable ignition
lock
7.Return spring R/P blocking magnet
8.Return spring
9.Selector lever control unit with
Tiptronic switch
10.Functional unit
1
2
3 4
5
4
8
7
6
6
10
3
27
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Parking lock
1.What is the function of the parking lock?
The parking lock secures the vehicle
against rolling away.
2.How is it actuated?
It is actuated by the selector lever via
Bowden wire (mechanically) or with the
help of the blocking magnet (electrically).
1.Resting plate
2.Spring
3.Cone
4.Parking lock wheel
5.Parking ratchet
6.Guide bushing
1
2
3
4
5
6
4
5
Mercedes
VW-Group
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Parking lock
1.What is the function of the parking lock?
The parking lock secures the vehicle
against rolling away.
2.How is it actuated?
It is actuated by the selector lever via
Bowden wire (mechanically) or with the
help of the blocking magnet (electrically).
1.Resting plate
2.Spring
3.Cone
4.Parking lock wheel
5.Parking ratchet
6.Guide bushing
1
2
3
4
5
6
4
5
Mercedes
VW-Group
28
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Maintenance / diagnosis - General information
Towing:
The selector lever should be set in position "N". The towing speed should not exceed 50km/h and a distance of
50 km. Vehicles with all-wheel drive may not be towed with raised front- or rear axle.
The oil pump is not operated while towing due to which the lubrication of the rotating components fails.
Transmission oil (ATF):
No ATF-change is provided within the maintenance intervals (Lifetime filling). Always read the technical
documents while re-filling.
Final test:
Delete error memory and carry out the test drive. Prerequisites:
- The transmission oil level of the automatic transmission is OK.
- The transmission oil level of the torque converter is OK.
The final test has to be carried out mandatorily after repairing the transmission control. It consists of following
tests:
- Test drive:
- Leakage test: After completing all the necessary operations on the transmission control and its components,
leakage tests
must be carried out.
- Diagnosis tester (self-diagnosis): After a test drive, read the error memory again.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Maintenance / diagnosis - General information
Towing:
The selector lever should be set in position "N". The towing speed should not exceed 50km/h and a distance of
50 km. Vehicles with all-wheel drive may not be towed with raised front- or rear axle.
The oil pump is not operated while towing due to which the lubrication of the rotating components fails.
Transmission oil (ATF):
No ATF-change is provided within the maintenance intervals (Lifetime filling). Always read the technical
documents while re-filling.
Final test:
Delete error memory and carry out the test drive. Prerequisites:
- The transmission oil level of the automatic transmission is OK.
- The transmission oil level of the torque converter is OK.
The final test has to be carried out mandatorily after repairing the transmission control. It consists of following
tests:
- Test drive:
- Leakage test: After completing all the necessary operations on the transmission control and its components,
leakage tests
must be carried out.
- Diagnosis tester (self-diagnosis): After a test drive, read the error memory again.
29
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Automotive Aftermarket
Automatic transmission control
42
Maintenance / diagnosis – Transmission oil level check
1.Where can you find information on
the maintenance of automatic
transmission?
ESI[tronic] C and M.
1.Overflow pipe
2.ATF oil
3.Oil pan
4.Locking screw
1 2
3
4
Test pre-requisites (always refer the service manual):
1.The transmission oil temperature using the diagnosis tester
2.Transmission oil temperature: 35...45 °C
3.Engine is running in idle condition
4.Selector lever position P.
5.Unscrew the locking screw [4].
6.If the automatic transmission is correctly filled, approx. 1 drop
drips every second from the overflow pipe.
7.Screw the locking screw with a new sealing.
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
42
Maintenance / diagnosis – Transmission oil level check
1.Where can you find information on
the maintenance of automatic
transmission?
ESI[tronic] C and M.
1.Overflow pipe
2.ATF oil
3.Oil pan
4.Locking screw
1 2
3
4
Test pre-requisites (always refer the service manual):
1.The transmission oil temperature using the diagnosis tester
2.Transmission oil temperature: 35...45 °C
3.Engine is running in idle condition
4.Selector lever position P.
5.Unscrew the locking screw [4].
6.If the automatic transmission is correctly filled, approx. 1 drop
drips every second from the overflow pipe.
7.Screw the locking screw with a new sealing.
30
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
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Automotive Aftermarket
Automatic transmission control
Maintenance / diagnosis – Adjustment
The Adjustments function can be understood as learning of different components and functions about the
automatic transmission control unit. Following adjustments can be carried out:
Reset adaptation values.
Note(s):
- The function 'Reset adaptation values' enables the deletion of internal adaptation parameters of the automatic
transmission control unit.
-After exchanging or renewing one or many components, it is recommended to execute the function 'Reset
adaptation values'.
When should the adjustment be made?
– after changing the transmission
– after replacing the transmission control unit
– after changing the ATF
– after repairing the transmission (e.g. changing the
slide-valve gear-box, repairing the clutches)
– after replacing the position of the acceleration
pedal-sensor
– in case of complaints regarding the switching
comfort
– possible engine exchange or replacing the ECU
It is recommended to carry out an adaptation drive after the adjustment!
(See technical information)
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Maintenance / diagnosis – Adjustment
The Adjustments function can be understood as learning of different components and functions about the
automatic transmission control unit. Following adjustments can be carried out:
Reset adaptation values.
Note(s):
- The function 'Reset adaptation values' enables the deletion of internal adaptation parameters of the automatic
transmission control unit.
-After exchanging or renewing one or many components, it is recommended to execute the function 'Reset
adaptation values'.
When should the adjustment be made?
– after changing the transmission
– after replacing the transmission control unit
– after changing the ATF
– after repairing the transmission (e.g. changing the
slide-valve gear-box, repairing the clutches)
– after replacing the position of the acceleration
pedal-sensor
– in case of complaints regarding the switching
comfort
– possible engine exchange or replacing the ECU
It is recommended to carry out an adaptation drive after the adjustment!
(See technical information)
31
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Automatic transmission control
Summary
1.Name the parts of the torque converter!
Pump, turbine, guide wheel on free run and oil.
2.Which type of oil pumps are used in the area of the AT transmission?
Internal gear pump (crescent pump for Mercedes 7-speed Tronic; ZF 6HP; Aisin
etc.) and double vane pump ZF 8HP.
3.What is the function of the blocking magnet?
The blocking magnet R/P is controlled via electronic selector lever module.
The R/P-blocking magnet releases the selector lever and thus, enables a
switching from the selector lever position P.
4.Where can you find information on the maintenance of automatic transmission?
ESI[tronic] C and M.
5.What is the function of the parking lock?
The parking lock protects the vehicle from rolling away.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Summary
1.Name the parts of the torque converter!
Pump, turbine, guide wheel on free run and oil.
2.Which type of oil pumps are used in the area of the AT transmission?
Internal gear pump (crescent pump for Mercedes 7-speed Tronic; ZF 6HP; Aisin
etc.) and double vane pump ZF 8HP.
3.What is the function of the blocking magnet?
The blocking magnet R/P is controlled via electronic selector lever module.
The R/P-blocking magnet releases the selector lever and thus, enables a
switching from the selector lever position P.
4.Where can you find information on the maintenance of automatic transmission?
ESI[tronic] C and M.
5.What is the function of the parking lock?
The parking lock protects the vehicle from rolling away.
32
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
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Automotive Aftermarket
Automatic transmission control
Table of contents
• AUTOMATIC TRANSMISSION (AT)
• Torque converter
• Planetary gear
• Switching elements
• OVERVIEW OF THE AT-
TRANSMISSION
• Overview / Design
• Oil pump
• Parking lock
• Maintenance / diagnosis
• Summary
• DUAL CLUTCH TRANSMISSION
• Overview / Design
• Mechatronics module
• Clutch systems
• Gearbox unit
• Oil circuit
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• AUTOMATIC TRANSMISSION (AT)
• Torque converter
• Planetary gear
• Switching elements
• OVERVIEW OF THE AT-
TRANSMISSION
• Overview / Design
• Oil pump
• Parking lock
• Maintenance / diagnosis
• Summary
• DUAL CLUTCH TRANSMISSION
• Overview / Design
• Mechatronics module
• Clutch systems
• Gearbox unit
• Oil circuit
33
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• Maintenance / diagnosis
• AUTOMATED SHIFT
TRANSMISSION (AST)
• Clutch actuator
• Selecting and engaging a gear
• Mechatronics module
• Summary
• Overview / Design
• Clutch adjustment
• Maintenance
• Summary
• CONTINOUSLY VARIABLE
TRANSMISSION (CVT)
• Overview / Design
• Transmission sensors
• Components
• Maintenance
• Summary
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• Maintenance / diagnosis
• AUTOMATED SHIFT
TRANSMISSION (AST)
• Clutch actuator
• Selecting and engaging a gear
• Mechatronics module
• Summary
• Overview / Design
• Clutch adjustment
• Maintenance
• Summary
• CONTINOUSLY VARIABLE
TRANSMISSION (CVT)
• Overview / Design
• Transmission sensors
• Components
• Maintenance
• Summary
34
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
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Automotive Aftermarket
Automatic transmission control
Dual clutch transmission (DCT or DKG)
VW DSG 6-speed since 2003 VW DSG 7-speed since 2007
BMW SMG 7-speed since 2008
Dual clutch
Four-speed
transmission
Diagram from the patent specification by Rudolf
Franke 1940 Ford/Volvo since 2008
Powershift 6DCT450 6-speed
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Dual clutch transmission (DCT or DKG)
VW DSG 6-speed since 2003 VW DSG 7-speed since 2007
BMW SMG 7-speed since 2008
Dual clutch
Four-speed
transmission
Diagram from the patent specification by Rudolf
Franke 1940 Ford/Volvo since 2008
Powershift 6DCT450 6-speed
35
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Dual clutch transmission - Functional principle
Basic design similar to shift transmission
Two clutches
Toothed wheels supported on three shafts
Pre-selection of the gears by two counter shafts
Automatic actuation of clutches and switching elements by the ECU and the actuators
Partial transmission 1
Partial transmission
2
Clutch 1
Clutch 2
1
24
35
6
R
Dual clutch transmission (DCT or DKG)
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Dual clutch transmission - Functional principle
Basic design similar to shift transmission
Two clutches
Toothed wheels supported on three shafts
Pre-selection of the gears by two counter shafts
Automatic actuation of clutches and switching elements by the ECU and the actuators
Partial transmission 1
Partial transmission
2
Clutch 1
Clutch 2
1
24
35
6
R
Dual clutch transmission (DCT or DKG)
36
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Dual clutch transmission - Characteristics
Advantage
Comfort same as stepped transmission
High efficiency
Individual transmission selection
Lower fuel consumption against automated shift transmission
No interruption in traction force while switching (possible up to 7 gears)
Torque transmission up to (500 Nm)
Disadvantage
Larger installation space than ASG
High bearing forces
Massive design
Complex construction (multi-shaft transmission, sensor, switching mechanism)
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Dual clutch transmission - Characteristics
Advantage
Comfort same as stepped transmission
High efficiency
Individual transmission selection
Lower fuel consumption against automated shift transmission
No interruption in traction force while switching (possible up to 7 gears)
Torque transmission up to (500 Nm)
Disadvantage
Larger installation space than ASG
High bearing forces
Massive design
Complex construction (multi-shaft transmission, sensor, switching mechanism)
37
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
6-speed Ford PowerShift 6DCT450
1.How does the dual clutch system work?
Two gears can always be engaged at the same time.
One of the clutches operates the odd gears (1,3,5 and
R) while the other clutch operates the even gears
(2,4,6).
1.Clutch 1
2.Clutch 2
3.Input shaft (hollow shaft)
4.Claw toothing
5.Input shaft (core shaft)
1 2
3
4
5
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
6-speed Ford PowerShift 6DCT450
1.How does the dual clutch system work?
Two gears can always be engaged at the same time.
One of the clutches operates the odd gears (1,3,5 and
R) while the other clutch operates the even gears
(2,4,6).
1.Clutch 1
2.Clutch 2
3.Input shaft (hollow shaft)
4.Claw toothing
5.Input shaft (core shaft)
1 2
3
4
5
38
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
6-speed VW DSG Type: 02E
1.How does this system work?
Functionality is similar to the Ford-System. Two
multi-disc-wet-clutches for which a gear is shifted
and a gear is pre-selected.
1.Clutch 1
2.Outer disk carrier clutch 1
3.Clutch 2
4.Outer disk carrier Clutch 2
5.Main hub
6.Drive shaft 2
7.Drive shaft for ATF pump
8.Drive shaft 1
8.Rotary unions
9. Pressure compensating room Clutch 1
10. Oil pressure room Clutch 1
11. Piston 1
12. Oil pressure room Clutch 2
13. Piston 2
14. Pressure compensating room Clutch 2
15. Input hub with driver disc
16. Inner disc carrier Clutch 2
17. Inner disc carrier Clutch 1
18. Housing cover
19. Driver disc
1
3
20
19
16
5
6
8
7
9
17
18
2
4
10
11
12
13
14
15
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
6-speed VW DSG Type: 02E
1.How does this system work?
Functionality is similar to the Ford-System. Two
multi-disc-wet-clutches for which a gear is shifted
and a gear is pre-selected.
1.Clutch 1
2.Outer disk carrier clutch 1
3.Clutch 2
4.Outer disk carrier Clutch 2
5.Main hub
6.Drive shaft 2
7.Drive shaft for ATF pump
8.Drive shaft 1
8.Rotary unions
9. Pressure compensating room Clutch 1
10. Oil pressure room Clutch 1
11. Piston 1
12. Oil pressure room Clutch 2
13. Piston 2
14. Pressure compensating room Clutch 2
15. Input hub with driver disc
16. Inner disc carrier Clutch 2
17. Inner disc carrier Clutch 1
18. Housing cover
19. Driver disc
1
3
20
19
16
5
6
8
7
9
17
18
2
4
10
11
12
13
14
15
39
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Pressure compensation
1.What is the function of the pressure
compensating rooms?
It enables a defined closing and opening of
the clutches 1 and 2. A dynamic pressure
compensation takes place when the engine
speed is increased.
2.May the dual clutches be dismantled?
No! Laminated disc packs are pre-defined by
the factory.
1.Clutch 1
2.Piston 1
3.Pressure
compensating room 1
4.Pressure chamber 1
5.Pressure oil feed
Clutch 1
6.Cooling oil feed
Clutch 1 in the upper half and clutch 2 in the lower
half are displayed as force-closed.
1
3
2
4
5
6
8
7
10
9
11
7.Main hub with rotary
unions
8.Pressure chamber 2
9.Piston 2
10.Pressure compensating
room 2
11.Clutch 2
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Pressure compensation
1.What is the function of the pressure
compensating rooms?
It enables a defined closing and opening of
the clutches 1 and 2. A dynamic pressure
compensation takes place when the engine
speed is increased.
2.May the dual clutches be dismantled?
No! Laminated disc packs are pre-defined by
the factory.
1.Clutch 1
2.Piston 1
3.Pressure
compensating room 1
4.Pressure chamber 1
5.Pressure oil feed
Clutch 1
6.Cooling oil feed
Clutch 1 in the upper half and clutch 2 in the lower
half are displayed as force-closed.
1
3
2
4
5
6
8
7
10
9
11
7.Main hub with rotary
unions
8.Pressure chamber 2
9.Piston 2
10.Pressure compensating
room 2
11.Clutch 2
40
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
7-speed VW DSG Type: 0AM
1.What type of clutch is used here?
The dual clutch consists of two conventional dry clutches which are
combined to one dual clutch.
1.Tie rod
2.Pressure plate Clutch 1
3.Dual-mass flywheel (ZMS)
4.Clutch disc Clutch 1
5.Crankshaft
6.Drive shaft 1
7.Support bearing
8.Central plate
9.Disc spring Clutch 1
10.Clutch disc Clutch 2
11.Drive shaft 2
12.Ball cam Clutch 1
13.Ball cam Clutch 2
14. Disc spring Clutch 2
15.Pressure plate Clutch 2
2
3
4
5
6
7
1
8
13
9
12
11
10
1
14
15
1
Dual-
mass
flywh
eel
Dual clutch
Engaging system
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
7-speed VW DSG Type: 0AM
1.What type of clutch is used here?
The dual clutch consists of two conventional dry clutches which are
combined to one dual clutch.
1.Tie rod
2.Pressure plate Clutch 1
3.Dual-mass flywheel (ZMS)
4.Clutch disc Clutch 1
5.Crankshaft
6.Drive shaft 1
7.Support bearing
8.Central plate
9.Disc spring Clutch 1
10.Clutch disc Clutch 2
11.Drive shaft 2
12.Ball cam Clutch 1
13.Ball cam Clutch 2
14. Disc spring Clutch 2
15.Pressure plate Clutch 2
2
3
4
5
6
7
1
8
13
9
12
11
10
1
14
15
1
Dual-
mass
flywh
eel
Dual clutch
Engaging system
41
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Multi-disk clutch VW DSG Type: 02E (7-speed)
The pressing movement of the large shift lever [1] is
reversed by re-routing points in a pulling movement.
The pressing plate 1 [2] is drawn in the direction of
the central plate and thus, closes the clutch 1 [blue].
1
2
3
Even gears
The small shift lever [4] presses
the pressure plate 2 [5] against
the clutch 2 [green] and closes
the clutch 2 .
4
5
Odd gears
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Multi-disk clutch VW DSG Type: 02E (7-speed)
The pressing movement of the large shift lever [1] is
reversed by re-routing points in a pulling movement.
The pressing plate 1 [2] is drawn in the direction of
the central plate and thus, closes the clutch 1 [blue].
1
2
3
Even gears
The small shift lever [4] presses
the pressure plate 2 [5] against
the clutch 2 [green] and closes
the clutch 2 .
4
5
Odd gears
42
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Dual-mass flywheel and engaging system
1.What is the function of the adjusting discs in the engaging system?
The adjusting discs compensate the axial tolerances of different components.
2.How is a wrong axial play (clearance) noticeable?
Separation problems and clutch slipping.
1.Primary mass with bow springs
2.Flange with internal tooth for supporting the driver
rim of the dual clutch
3.Clamping ring
4.Cover for primary mass with starter rim
5.Guide sleeve for ball cam Clutch 1
6.Large shift lever
7.Ball cam for clutch 1
8.Adjusting disc Clutch 1
9.Small shift lever with guide piston for clutch 2
10. Adjusting disc Clutch 2
11. Ball cam for clutch 2
Engaging system
5 6 7 8 9 10 11
Dual-mass flywheel
2
3 4
1
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Dual-mass flywheel and engaging system
1.What is the function of the adjusting discs in the engaging system?
The adjusting discs compensate the axial tolerances of different components.
2.How is a wrong axial play (clearance) noticeable?
Separation problems and clutch slipping.
1.Primary mass with bow springs
2.Flange with internal tooth for supporting the driver
rim of the dual clutch
3.Clamping ring
4.Cover for primary mass with starter rim
5.Guide sleeve for ball cam Clutch 1
6.Large shift lever
7.Ball cam for clutch 1
8.Adjusting disc Clutch 1
9.Small shift lever with guide piston for clutch 2
10. Adjusting disc Clutch 2
11. Ball cam for clutch 2
Engaging system
5 6 7 8 9 10 11
Dual-mass flywheel
2
3 4
1
43
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
DSG – Gearbox unit
1.What must be considered while repairing the
transmitter wheel?
The strong magnet can destroy the transmitter
wheel.
1.Drive shaft 2
2.ZMS (dual-mass flywheel)
3.Clutch 2
4.Clutch 1
5.Pump shaft
6.Spur gear of axle drive
7.Transmitter wheel Drive shaft
2
8.Transmitter wheel Drive shaft
1
1
2
3 456 8 910
11
12
13
14
15
2
. 4
.
3
.
1
.
5.
6
.
7
16
9.Pump shaft
10.Output shaft 1
11.Oil pump
12.Transmitter wheel Output
shaft 2
13.Output shaft 2
14.Reverse gear shaft
15.Dual clutch
16.Drive shaft 1
17
18 19
20
21
22
17.Hydraulic cylinder
18.Shift fork 2/4
19.Shift fork 3/1
20.Shift fork N/5
21.Shift fork R/6
22.Magnet for path
sensors
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
DSG – Gearbox unit
1.What must be considered while repairing the
transmitter wheel?
The strong magnet can destroy the transmitter
wheel.
1.Drive shaft 2
2.ZMS (dual-mass flywheel)
3.Clutch 2
4.Clutch 1
5.Pump shaft
6.Spur gear of axle drive
7.Transmitter wheel Drive shaft
2
8.Transmitter wheel Drive shaft
1
1
2
3 456 8 910
11
12
13
14
15
2
. 4
.
3
.
1
.
5.
6
.
7
16
9.Pump shaft
10.Output shaft 1
11.Oil pump
12.Transmitter wheel Output
shaft 2
13.Output shaft 2
14.Reverse gear shaft
15.Dual clutch
16.Drive shaft 1
17
18 19
20
21
22
17.Hydraulic cylinder
18.Shift fork 2/4
19.Shift fork 3/1
20.Shift fork N/5
21.Shift fork R/6
22.Magnet for path
sensors
44
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Transmission - Power transmission (DSG 02E)
1st gear 3rd gear2nd gear
4th gear
Reverse gear
5th gear 6th gear
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Transmission - Power transmission (DSG 02E)
1st gear 3rd gear2nd gear
4th gear
Reverse gear
5th gear 6th gear
45
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Oil circuit
Oil sump
Oil cooler
Oil pump
Mechatronics
Gear actuator
Oil spray
tube for
cooling the
toothed
wheels
Pressure oil filter
VW DSG System
Oil filter unit
Oil
pump
Ford Powershift System
Housing gear
pump
Drive
-gear
Oil intake
Impeller
wheels of the
toothed
wheels
Oil return
Oil pressure
tube for
hydraulic unit
BMW SMG system
Suction oil filter
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Oil circuit
Oil sump
Oil cooler
Oil pump
Mechatronics
Gear actuator
Oil spray
tube for
cooling the
toothed
wheels
Pressure oil filter
VW DSG System
Oil filter unit
Oil
pump
Ford Powershift System
Housing gear
pump
Drive
-gear
Oil intake
Impeller
wheels of the
toothed
wheels
Oil return
Oil pressure
tube for
hydraulic unit
BMW SMG system
Suction oil filter
46
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Oil circuit – Function for VW DSG system
1.What is the size of the working pressure?
3-20 bar. (Depending on the engine torque and ATF-temperature).
2.At what pressure does the pressure relief valve open?
32 bar.
1.Oil pump
2.Pressure relief valve
3.Principle pressure slide
4.Pressure control valve
5.Clutch cooling oil-slide
6.Clutch cooling oil - Pressure control
valve
7.Oil cooler
8.Oil spray tube
9.Oil sump
10. Lubrication / cooling of toothed wheels
11. Pressure oil filter
12. Suction filter
13. Return to the oil pump
1
8
12
9
11
3
2
7
4
13
5
10
6
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Oil circuit – Function for VW DSG system
1.What is the size of the working pressure?
3-20 bar. (Depending on the engine torque and ATF-temperature).
2.At what pressure does the pressure relief valve open?
32 bar.
1.Oil pump
2.Pressure relief valve
3.Principle pressure slide
4.Pressure control valve
5.Clutch cooling oil-slide
6.Clutch cooling oil - Pressure control
valve
7.Oil cooler
8.Oil spray tube
9.Oil sump
10. Lubrication / cooling of toothed wheels
11. Pressure oil filter
12. Suction filter
13. Return to the oil pump
1
8
12
9
11
3
2
7
4
13
5
10
6
47
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics unit – Ford (Powershift)
1.What must be considered while changing the electronic transmission
control unit?
The sealing must be changed under the electronic transmission control
unit, it must be installed in the correct position and it must be programmed
with the diagnostic device.
1.Hydraulics module
2.Valve block
3.Electronic transmission control unit
4.Sensor for shift fork positions 1st and 3rd gear
5.Sensor for shift fork position 2nd and 4th gear
6.Speed sensor of the input shaft for the even
shafts
7.Sensor for shift fork position 6 as also speed
sensor of the input shaft for uneven shafts
8.Sensor for the shift fork position 5th gear and
reverse gear
1 2
3
4
6
5
7
89
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics unit – Ford (Powershift)
1.What must be considered while changing the electronic transmission
control unit?
The sealing must be changed under the electronic transmission control
unit, it must be installed in the correct position and it must be programmed
with the diagnostic device.
1.Hydraulics module
2.Valve block
3.Electronic transmission control unit
4.Sensor for shift fork positions 1st and 3rd gear
5.Sensor for shift fork position 2nd and 4th gear
6.Speed sensor of the input shaft for the even
shafts
7.Sensor for shift fork position 6 as also speed
sensor of the input shaft for uneven shafts
8.Sensor for the shift fork position 5th gear and
reverse gear
1 2
3
4
6
5
7
89
48
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics unit – BMW
1.How does the transmission control
unit record the temperature of the
oil container?
The ECU records the oil
temperature from the clutch- and
SMG-housing. The transmission
control unit calculates this data
with the help of a specific
mathematical model.
1.Hydraulics module
2.Record shift valves
3.Switching cylinder
4.Integrated speed sensors
5.Shift gear path sensors
6.Integrated parking lock sensors
7.Electronic control unit
2
1
3
7
4
5
6
5
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics unit – BMW
1.How does the transmission control
unit record the temperature of the
oil container?
The ECU records the oil
temperature from the clutch- and
SMG-housing. The transmission
control unit calculates this data
with the help of a specific
mathematical model.
1.Hydraulics module
2.Record shift valves
3.Switching cylinder
4.Integrated speed sensors
5.Shift gear path sensors
6.Integrated parking lock sensors
7.Electronic control unit
2
1
3
7
4
5
6
5
49
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics unit – VW (DSG 6-speed)
1.Which temperature sensors are obstructed in the transmission control unit?
Transmission oil sensor and control unit temperature sensor.
2.What is the function of transmission output-speed sensors?
The speed sensors measure the vehicle speed and the driving direction.
1.Central plug
2.Path sensors for gear actuators
3.Transmission control unit
4.Transmission output speed sensors
(2 units)
5.Drive shafts Speed sensors
6.Channel plate
7.Pressure limiting valve
8.Multiplexer spool valve
9.Hydraulic control unit
10. Safety valve 1
11. Gear actuators
12. Safety valve 2
13. Cooling oil valve
14. Clutch valves
15. System pressure control valve
16. Hydraulic pressure sensors
13
14
12
11
10
8
1
6
7
3
9
15
4
16
1
2
2
5
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics unit – VW (DSG 6-speed)
1.Which temperature sensors are obstructed in the transmission control unit?
Transmission oil sensor and control unit temperature sensor.
2.What is the function of transmission output-speed sensors?
The speed sensors measure the vehicle speed and the driving direction.
1.Central plug
2.Path sensors for gear actuators
3.Transmission control unit
4.Transmission output speed sensors
(2 units)
5.Drive shafts Speed sensors
6.Channel plate
7.Pressure limiting valve
8.Multiplexer spool valve
9.Hydraulic control unit
10. Safety valve 1
11. Gear actuators
12. Safety valve 2
13. Cooling oil valve
14. Clutch valves
15. System pressure control valve
16. Hydraulic pressure sensors
13
14
12
11
10
8
1
6
7
3
9
15
4
16
1
2
2
5
50
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics unit – VW (DSG 6-speed)
1.What type of transmitter is used?
All transmitters are hall sensors.
1.Transmission input speed transmitter
2.Drive shaft transmitter (1 and 2)
3.Transmission output speed transmitter (2
units)
4.Transmitter for transmission oil temperature
restricted to multi-disk clutch
5.Hydraulic pressure sensor
6.ECU temperature transmitter in ECU
7.Transmission oil temperature transmitter in
ECU
8.Gear switch in the steering wheel
9.Gear switch - path sensor
10. ECU for selector lever
11. Selector lever lock (magnet)
12. Principle pressure valve
13. Clutch valves
14. Cooling oil valves
15. Gear actuator valves
16. Multiplexer valve
17. Safety valves
18. Transmission control unit
1
2
3
4
5
6
7
8
9
18
10
11
12
13
14
15
16
17
CANCAN
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics unit – VW (DSG 6-speed)
1.What type of transmitter is used?
All transmitters are hall sensors.
1.Transmission input speed transmitter
2.Drive shaft transmitter (1 and 2)
3.Transmission output speed transmitter (2
units)
4.Transmitter for transmission oil temperature
restricted to multi-disk clutch
5.Hydraulic pressure sensor
6.ECU temperature transmitter in ECU
7.Transmission oil temperature transmitter in
ECU
8.Gear switch in the steering wheel
9.Gear switch - path sensor
10. ECU for selector lever
11. Selector lever lock (magnet)
12. Principle pressure valve
13. Clutch valves
14. Cooling oil valves
15. Gear actuator valves
16. Multiplexer valve
17. Safety valves
18. Transmission control unit
1
2
3
4
5
6
7
8
9
18
10
11
12
13
14
15
16
17
CANCAN
51
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Hydraulic control
1.What is the function of the Multiplexer valve?
The Multiplexer enables controlling of eight hydraulic cylinders with four
solenoid valves.
1.Principle pressure
2.Pressure control valve 1
3.Safety valve 1
4.Pressure control valve 2
5.Safety valve 2
6.Hydraulic sensor 1
7.Hydraulic sensor 1
8.Clutch valve 1
9.Gear actuator valves 1-4
10.Clutch valve 2
11.Multiplexer valve
12.Solenoid valve
13.Shift fork
1
31N5R642
2
4
3
7
9
9
9
12
10
8
11
13
5
6
9
A
C
B
D
xY
xyxyxy
12
xY
xyxyxy
12
Solenoid valve without
current
Solenoid valve with
current
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Hydraulic control
1.What is the function of the Multiplexer valve?
The Multiplexer enables controlling of eight hydraulic cylinders with four
solenoid valves.
1.Principle pressure
2.Pressure control valve 1
3.Safety valve 1
4.Pressure control valve 2
5.Safety valve 2
6.Hydraulic sensor 1
7.Hydraulic sensor 1
8.Clutch valve 1
9.Gear actuator valves 1-4
10.Clutch valve 2
11.Multiplexer valve
12.Solenoid valve
13.Shift fork
1
31N5R642
2
4
3
7
9
9
9
12
10
8
11
13
5
6
9
A
C
B
D
xY
xyxyxy
12
xY
xyxyxy
12
Solenoid valve without
current
Solenoid valve with
current
52
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics unit – VW (DSG 7-speed)
1.How much is the system pressure?
Approx. 70 bar, the system pressure controls the transmission control unit
with the help of a hydraulic pressure sensor.
2.How much is the storage volume of the hydraulic accumulator?
0.2 litre.
1.Oil pressure accumulator
2.Hydraulic oil pump
3.Engine for hydraulic oil
pump
4.Valve block
5.Transmission input speed
6.Clutch actuator
7.Clutch servo sensor
8.Vehicle plug
9.Gear actuator
9
1
3
2
4
5
6
7
8
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Mechatronics unit – VW (DSG 7-speed)
1.How much is the system pressure?
Approx. 70 bar, the system pressure controls the transmission control unit
with the help of a hydraulic pressure sensor.
2.How much is the storage volume of the hydraulic accumulator?
0.2 litre.
1.Oil pressure accumulator
2.Hydraulic oil pump
3.Engine for hydraulic oil
pump
4.Valve block
5.Transmission input speed
6.Clutch actuator
7.Clutch servo sensor
8.Vehicle plug
9.Gear actuator
9
1
3
2
4
5
6
7
8
53
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
42
Maintenance / Diagnosis – Oil level check (VW)
1.Oil level
2.Overflow pipe
3.Locking screw
4.Sealing plug
Pre-requisite (s) for test:
Transmission oil temperature: 35...50 °C
Engine in idling condition
Selector lever position P.
Check oil level:
Unscrew the locking screw [3]. After unscrewing the locking screw, the transmission oil must flow from the
overflow pipe [2] till the overflow pipe is emptied. In case of a correctly filled automatic transmission, approx. 1
drop drops from the overflow pipe per second. Screw the locking screw with a new sealing.
1 2
3
4
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
42
Maintenance / Diagnosis – Oil level check (VW)
1.Oil level
2.Overflow pipe
3.Locking screw
4.Sealing plug
Pre-requisite (s) for test:
Transmission oil temperature: 35...50 °C
Engine in idling condition
Selector lever position P.
Check oil level:
Unscrew the locking screw [3]. After unscrewing the locking screw, the transmission oil must flow from the
overflow pipe [2] till the overflow pipe is emptied. In case of a correctly filled automatic transmission, approx. 1
drop drops from the overflow pipe per second. Screw the locking screw with a new sealing.
1 2
3
4
54
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Maintenance / Diagnosis – Adjustment
The function 'Adjustments' means programming of different components and functions of the automatic
transmission control unit. Following adjustments can be carried out:
Programming the transmission - and clutch parameters:
Changing the mechatronics module
Changing the clutch
Error entry: Mechatronics module malfunction, basic setting faulty
The adjustment contains:
Basic setting of gear actuator and path sensors
Program synchronous points
Program clutch scanning points
Reset principle pressure output values
Reset steering wheel key for Tiptronic
Reset ESP and Tempomat
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Maintenance / Diagnosis – Adjustment
The function 'Adjustments' means programming of different components and functions of the automatic
transmission control unit. Following adjustments can be carried out:
Programming the transmission - and clutch parameters:
Changing the mechatronics module
Changing the clutch
Error entry: Mechatronics module malfunction, basic setting faulty
The adjustment contains:
Basic setting of gear actuator and path sensors
Program synchronous points
Program clutch scanning points
Reset principle pressure output values
Reset steering wheel key for Tiptronic
Reset ESP and Tempomat
55
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Summary
1.How does the wet dual clutch system work?
Two gears can always be engaged at the same time. One of the clutches operates the
odd gears (1, 3, 5 and R), the other operates the even gears (2, 4, 6).
2.What must be considered while repairing the transmitter wheel?
The strong magnet can destroy the transmitter wheel.
3.May the wet dual clutches be fragmented?
No! Laminated disk packs are preset by the factory.
4.At what pressure does the pressure relief valve open?
32-bar.
5.What is the function of the Multiplexer valve?
The Multiplexer enables the controlling eight hydraulic cylinders with four solenoid
valves.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Summary
1.How does the wet dual clutch system work?
Two gears can always be engaged at the same time. One of the clutches operates the
odd gears (1, 3, 5 and R), the other operates the even gears (2, 4, 6).
2.What must be considered while repairing the transmitter wheel?
The strong magnet can destroy the transmitter wheel.
3.May the wet dual clutches be fragmented?
No! Laminated disk packs are preset by the factory.
4.At what pressure does the pressure relief valve open?
32-bar.
5.What is the function of the Multiplexer valve?
The Multiplexer enables the controlling eight hydraulic cylinders with four solenoid
valves.
56
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• Maintenance / diagnosis
• AUTOMATED SHIFT
TRANSMISSION (AST)
• Clutch actuator
• Selecting and engaging a gear
• Mechatronics module
• Summary
• Overview / Design
• Clutch adjustment
• Maintenance
• Summary
• CONTINOUSLY VARIABLE
TRANSMISSION (CVT)
• Overview / Design
• Transmission sensors
• Components
• Maintenance
• Summary
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• Maintenance / diagnosis
• AUTOMATED SHIFT
TRANSMISSION (AST)
• Clutch actuator
• Selecting and engaging a gear
• Mechatronics module
• Summary
• Overview / Design
• Clutch adjustment
• Maintenance
• Summary
• CONTINOUSLY VARIABLE
TRANSMISSION (CVT)
• Overview / Design
• Transmission sensors
• Components
• Maintenance
• Summary
57
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automated Shift Transmission (AST) - historical overview
LuK
Opel Corsa C
Easytronic (2001)
Opel Astra G
Easytronic (2004)
Opel Astra H
Easytronic (2004)
Toyota Corolla
MultiMode (2004)
Toyota Yaris
MultiMode (2004)
Toyota Corolla Verso
MultiMode (2004)
Aisin
Ford Fusion
Durashift EST (2006)
Ford Fiesta Durashift
EST (2002)
Getrag
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automated Shift Transmission (AST) - historical overview
LuK
Opel Corsa C
Easytronic (2001)
Opel Astra G
Easytronic (2004)
Opel Astra H
Easytronic (2004)
Toyota Corolla
MultiMode (2004)
Toyota Yaris
MultiMode (2004)
Toyota Corolla Verso
MultiMode (2004)
Aisin
Ford Fusion
Durashift EST (2006)
Ford Fiesta Durashift
EST (2002)
Getrag
58
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automated Shift Transmission (AST) – Characteristics
1.Which functions must be changed so that the shift transmission is adapted
to the automated shift transmission?
-Clutch actuation
-Gear switch movement in the direction X and Y.
2.How are these functions triggered?
Pneumatically, hydraulically, electrically, electro-hydraulically.
The important characteristics of the automated shift transmission
are:
•Compact design,
•High efficiency,
•Adjusting the available transmission is possible
•More cost-effective than the stepped automatic transmission or
continuously variable transmission,
•Easy operation,
•Suitable switching strategies in order to achieve an optimal fuel
consumption
or best consumption values and
•interruption in traction force while switching.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automated Shift Transmission (AST) – Characteristics
1.Which functions must be changed so that the shift transmission is adapted
to the automated shift transmission?
-Clutch actuation
-Gear switch movement in the direction X and Y.
2.How are these functions triggered?
Pneumatically, hydraulically, electrically, electro-hydraulically.
The important characteristics of the automated shift transmission
are:
•Compact design,
•High efficiency,
•Adjusting the available transmission is possible
•More cost-effective than the stepped automatic transmission or
continuously variable transmission,
•Easy operation,
•Suitable switching strategies in order to achieve an optimal fuel
consumption
or best consumption values and
•interruption in traction force while switching.
59
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automated Shift Transmission (AST) - system overview
1.Can the AST transmission be manually switched?
Yes, sequentially.
Gasoline injection
Diesel injection
Instrument cluster
DLC3
CAN
Brake light switch
S
h
if
t
L
e
v
e
r
T
r
a
n
s
m
i
s
s
io
n
Engine ECU
AMT ECU
Selecting and engaging a
gear
Neutral switch
Clutch actuator
Speed sensor
Gear main switch
Reverse gear switch
Transmission lock
(Solenoid)
Kick down switch
Position sensor for
gear switch
Tone
Function selection
Hand brake switch
Accelerator pedal
sensor
Engine speed
Crankshaft sensor
Engine speed
E
n
g
i
n
e
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Automated Shift Transmission (AST) - system overview
1.Can the AST transmission be manually switched?
Yes, sequentially.
Gasoline injection
Diesel injection
Instrument cluster
DLC3
CAN
Brake light switch
S
h
if
t
L
e
v
e
r
T
r
a
n
s
m
i
s
s
io
n
Engine ECU
AMT ECU
Selecting and engaging a
gear
Neutral switch
Clutch actuator
Speed sensor
Gear main switch
Reverse gear switch
Transmission lock
(Solenoid)
Kick down switch
Position sensor for
gear switch
Tone
Function selection
Hand brake switch
Accelerator pedal
sensor
Engine speed
Crankshaft sensor
Engine speed
E
n
g
i
n
e
60
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
9
AST components – electrical components
1.Clutch actuator
2.Clutch movement sensor
3.Engine 1
4.Movement sensor 1
5.Engine 2
6.Movement sensor 2
7.Transmission speed
sensor
8.Tip lever
9.Transmission control
unit
3 & 5
1 & 9
7
3
1
2
64
5
8
Toyota MultiMode
Manual Transmission
Opel Easytronic
MTA
1.Which components have been fitted at the ECU-housing?
Clutch actuation unit, gear switch and gear engaging module.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
9
AST components – electrical components
1.Clutch actuator
2.Clutch movement sensor
3.Engine 1
4.Movement sensor 1
5.Engine 2
6.Movement sensor 2
7.Transmission speed
sensor
8.Tip lever
9.Transmission control
unit
3 & 5
1 & 9
7
3
1
2
64
5
8
Toyota MultiMode
Manual Transmission
Opel Easytronic
MTA
1.Which components have been fitted at the ECU-housing?
Clutch actuation unit, gear switch and gear engaging module.
61
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
AST components – clutch actuator (Opel – Bosch)
1.Where is the transmission control unit of Opel
Easytronic located?
It is integrated in the clutch actuator.
2.How does the clutch actuator actuate the clutch?
With oil pressure.
1.Actuator - engine
2.Electronic Control
Unit
3.Worm
4.Worm gear
5.Worm gear shaft
6.Pins
7.Position sensor
8.Compensation spring
9.Lifter
10.Master cylinder
1 2 3 4
5
6789
10
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
AST components – clutch actuator (Opel – Bosch)
1.Where is the transmission control unit of Opel
Easytronic located?
It is integrated in the clutch actuator.
2.How does the clutch actuator actuate the clutch?
With oil pressure.
1.Actuator - engine
2.Electronic Control
Unit
3.Worm
4.Worm gear
5.Worm gear shaft
6.Pins
7.Position sensor
8.Compensation spring
9.Lifter
10.Master cylinder
1 2 3 4
5
6789
10
62
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
AST components – clutch actuator (Toyota – Aisin)
1.Where is the transmission control unit of Toyota Yaris MMT located?
In the engine compartment behind the instrument cluster.
2.How does the clutch actuator actuate the clutch?
With the pushrod.
1.Clutch movement
sensor
2.Clutch actuator
3.Release lever
4.Worm shaft
5.Worm gear
6.Pushrod
7.Rotation point
8.Return spring
1
3
2
8
3
45
1
6
7Source: Toyota
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
AST components – clutch actuator (Toyota – Aisin)
1.Where is the transmission control unit of Toyota Yaris MMT located?
In the engine compartment behind the instrument cluster.
2.How does the clutch actuator actuate the clutch?
With the pushrod.
1.Clutch movement
sensor
2.Clutch actuator
3.Release lever
4.Worm shaft
5.Worm gear
6.Pushrod
7.Rotation point
8.Return spring
1
3
2
8
3
45
1
6
7Source: Toyota
63
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
AST components – DC-motors for selecting and engaging gear
1.Thin armature form for
high dynamics
2.Vibration-resistant
winding
3.20-pole ring magnet and
dual hall sensor
4.Armature bearing with
pressed ball bearing
(axial securing with
clamping collar)
5.Massive pinion for gear
transmission
intervention
512 34
Shift fork shafts
Direction of
switching
Direction of
selection
Gear selection
and gear
engaging module
Opel (Bosch) Toyota (Aisin)
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
AST components – DC-motors for selecting and engaging gear
1.Thin armature form for
high dynamics
2.Vibration-resistant
winding
3.20-pole ring magnet and
dual hall sensor
4.Armature bearing with
pressed ball bearing
(axial securing with
clamping collar)
5.Massive pinion for gear
transmission
intervention
512 34
Shift fork shafts
Direction of
switching
Direction of
selection
Gear selection
and gear
engaging module
Opel (Bosch) Toyota (Aisin)
64
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Speed sensors for transmission control
1.How does the sensor react after coming in contact with oil?
It does not react, the sensors are oil-proof.
2.Does the sensor send a signal without voltage supply?
No, the hall sensor requires voltage supply
3.Starting from what speed does the hall sensor send a signal?
The sensor can generate one speed signal from zero (1/min).
IS – Sensor current (supply and signal)
RM – Measuring resistor (in ECU)
URM – Signal voltage
UV – Supply voltage
US – Sensor voltage
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Speed sensors for transmission control
1.How does the sensor react after coming in contact with oil?
It does not react, the sensors are oil-proof.
2.Does the sensor send a signal without voltage supply?
No, the hall sensor requires voltage supply
3.Starting from what speed does the hall sensor send a signal?
The sensor can generate one speed signal from zero (1/min).
IS – Sensor current (supply and signal)
RM – Measuring resistor (in ECU)
URM – Signal voltage
UV – Supply voltage
US – Sensor voltage
65
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Linear position recording
1.Linear position sensor functions using which principle?
Hall principle.
2.Where else is the sensor used?
In automatic transmission (AT).
1.Oil-resistant housing
2.Electrical connection via stamping
grid
3.Printed circuit board with cat-in hall
elements
4.Slides with permanent magnet
5.Locating pin
Front view Rear view
1
2
3
5
4
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Linear position recording
1.Linear position sensor functions using which principle?
Hall principle.
2.Where else is the sensor used?
In automatic transmission (AT).
1.Oil-resistant housing
2.Electrical connection via stamping
grid
3.Printed circuit board with cat-in hall
elements
4.Slides with permanent magnet
5.Locating pin
Front view Rear view
1
2
3
5
4
66
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Rotary position recording
1.With which sensor is this sensor
comparable?
Hall sensor.
Hall IC
Hall ICHall IC
Short-circuit ring
Sensor output characteristic
-55
55
0
0-55 55
0.5
2.5
4.5
Degree of rotation of sensor ()
O
u
t
p
u
t
v
o
lt
a
g
e
(
V
)
Clutch dow
nw
ards
Clutch upw
ards
Switching 2., 4., R1., 3., 5.,
Selecting5., R 1., 2.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Rotary position recording
1.With which sensor is this sensor
comparable?
Hall sensor.
Hall IC
Hall ICHall IC
Short-circuit ring
Sensor output characteristic
-55
55
0
0-55 55
0.5
2.5
4.5
Degree of rotation of sensor ()
O
u
t
p
u
t
v
o
lt
a
g
e
(
V
)
Clutch dow
nw
ards
Clutch upw
ards
Switching 2., 4., R1., 3., 5.,
Selecting5., R 1., 2.
67
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Clutch adjustment
1.Why is the automatic
adjustment necessary?
Actuation force changes
(increases) if the force of the
clutch disc decreases.
Steering rack (upper pressure plate Upper steering rack
lower steering rack
(lower pressure plate)
Spring
lower pressure plate
upper
pressure plate
Adjusting
wedge
DST
Clutch cover
Before the adjustment After the adjustment
Pressure plate
below above
Adjusting
wedge
Upper pressure
plate rotated
Spring seat
1
Conventional
clutch
3
5
6
Adjusting
clutch
1.Pivot ring
2.Helical spring
3.Setting ring
4.Cover
5.Sensor DS
6.Cover stop
2
3
4
Source: LuK
Source: Toyota
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Clutch adjustment
1.Why is the automatic
adjustment necessary?
Actuation force changes
(increases) if the force of the
clutch disc decreases.
Steering rack (upper pressure plate Upper steering rack
lower steering rack
(lower pressure plate)
Spring
lower pressure plate
upper
pressure plate
Adjusting
wedge
DST
Clutch cover
Before the adjustment After the adjustment
Pressure plate
below above
Adjusting
wedge
Upper pressure
plate rotated
Spring seat
1
Conventional
clutch
3
5
6
Adjusting
clutch
1.Pivot ring
2.Helical spring
3.Setting ring
4.Cover
5.Sensor DS
6.Cover stop
2
3
4
Source: LuK
Source: Toyota
68
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Selector lever
1.Which operating modes can be
executed by the system?
-Automatic
-Manual (sequential)
1.Gearshift lever
2.Gear response
3.Gear - main switch
4.Transmission lock signal
5.Shift lever position sensor
6.Transmission lock Solenoid
7.Transmission lock Unlocking
button
1
7
6
5
3 2
4
–
+
R N E, M
Link 2
Link 1
Link 2
Link 1
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Selector lever
1.Which operating modes can be
executed by the system?
-Automatic
-Manual (sequential)
1.Gearshift lever
2.Gear response
3.Gear - main switch
4.Transmission lock signal
5.Shift lever position sensor
6.Transmission lock Solenoid
7.Transmission lock Unlocking
button
1
7
6
5
3 2
4
–
+
R N E, M
Link 2
Link 1
Link 2
Link 1
69
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Adjustments, programming (Opel Easytronic)
1.The adjustment must be carried out after which
servicing activities?
- After replacing the components - transmission
adjusting element and transmission control unit.
- After working on the component manual
transmission.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Adjustments, programming (Opel Easytronic)
1.The adjustment must be carried out after which
servicing activities?
- After replacing the components - transmission
adjusting element and transmission control unit.
- After working on the component manual
transmission.
70
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Summary
1.How does the speed transmitter react when it comes in contact with oil?
It does not react, the transmitters are oil-proof.
2.The adjustment must be carried out after which servicing activities?
After replacing the components - transmission adjusting element and
transmission control unit. After working on the component manual
transmission.
3.Where is the transmission control unit of Opel Easytronic located?
It is integrated in the clutch actuator.
4.Why is the automatic adjustment necessary?
Actuation force changes (increases) if the force of the clutch disc decreases.
5.Which functions must be changed so that the shift transmission is adapted
to the automated shift transmission?
-Clutch actuation
-Gear switch movement in the direction X and Y.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Summary
1.How does the speed transmitter react when it comes in contact with oil?
It does not react, the transmitters are oil-proof.
2.The adjustment must be carried out after which servicing activities?
After replacing the components - transmission adjusting element and
transmission control unit. After working on the component manual
transmission.
3.Where is the transmission control unit of Opel Easytronic located?
It is integrated in the clutch actuator.
4.Why is the automatic adjustment necessary?
Actuation force changes (increases) if the force of the clutch disc decreases.
5.Which functions must be changed so that the shift transmission is adapted
to the automated shift transmission?
-Clutch actuation
-Gear switch movement in the direction X and Y.
71
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• Maintenance / diagnosis
• AUTOMATIC SHIFT
TRANSMISSION (AST)
• Clutch actuator
• Selecting and engaging a gear
• Mechatronics module
• Summary
• Overview / Design
• Clutch adjustment
• Maintenance
• Summary
• CONTINOUSLY VARIABLE
TRANSMISSION (CVT)
• Overview / Design
• Transmission sensors
• Components
• Maintenance
• Summary
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Table of contents
• Maintenance / diagnosis
• AUTOMATIC SHIFT
TRANSMISSION (AST)
• Clutch actuator
• Selecting and engaging a gear
• Mechatronics module
• Summary
• Overview / Design
• Clutch adjustment
• Maintenance
• Summary
• CONTINOUSLY VARIABLE
TRANSMISSION (CVT)
• Overview / Design
• Transmission sensors
• Components
• Maintenance
• Summary
72
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Jatco (JP)
Continuously Variable Transmission (CVT) - historical overview
Nissan Murano 3.5
V6 (2008)
Mercedes A/B class 2.0
(2004/2005)
Citroën C-Crosser
Peugeot 4007
(2008)
Nissan Maxima 3.5 V6
(2008)
Dodge Caliber 2.0
(2008)
Renault Megane III
Scenic / Grand Scenic
(2009)
Toyota Avensis 1.8/2.0
(2009)
Toyota iQ 1.0
(2008)
Nissan Qashqai
(2008) Audi Multitronic
A4/A6
(2000)
VDT (NL/DE)
(alias Bosch GS-CT)
LuK (DE)
Seat Exeo Multitronic
(2008)
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Jatco (JP)
Continuously Variable Transmission (CVT) - historical overview
Nissan Murano 3.5
V6 (2008)
Mercedes A/B class 2.0
(2004/2005)
Citroën C-Crosser
Peugeot 4007
(2008)
Nissan Maxima 3.5 V6
(2008)
Dodge Caliber 2.0
(2008)
Renault Megane III
Scenic / Grand Scenic
(2009)
Toyota Avensis 1.8/2.0
(2009)
Toyota iQ 1.0
(2008)
Nissan Qashqai
(2008) Audi Multitronic
A4/A6
(2000)
VDT (NL/DE)
(alias Bosch GS-CT)
LuK (DE)
Seat Exeo Multitronic
(2008)
73
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Continuously Variable Transmission (CVT)
• Hydrodynamic converter or
multi-disk clutch as drive-off element
• Direct transmission with cone pulley
and steel thrust belt (variator)
• High pressure hydraulics (expensive)
• Electrohydraulic control
• Predominant in the Asian market
• Jatco global market leader (CVT)
Disadvantage
- Still less customer acceptance
- Expensive
Advantage
- No interruption in the traction force
- Torque transmission up to (380 Nm)
- Spread angle up to 6.25
- Best driving comfort
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Continuously Variable Transmission (CVT)
• Hydrodynamic converter or
multi-disk clutch as drive-off element
• Direct transmission with cone pulley
and steel thrust belt (variator)
• High pressure hydraulics (expensive)
• Electrohydraulic control
• Predominant in the Asian market
• Jatco global market leader (CVT)
Disadvantage
- Still less customer acceptance
- Expensive
Advantage
- No interruption in the traction force
- Torque transmission up to (380 Nm)
- Spread angle up to 6.25
- Best driving comfort
74
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Continuously Variable Transmission (CVT) - Functional principle
1.How does the distance between the discs change?
With the help of the oil pressure.
Engine
Wheel
Overdrive Low ratio
Primary
Secondary
Engine
speed
Torque
Engine
speed
Torque
Animation
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Continuously Variable Transmission (CVT) - Functional principle
1.How does the distance between the discs change?
With the help of the oil pressure.
Engine
Wheel
Overdrive Low ratio
Primary
Secondary
Engine
speed
Torque
Engine
speed
Torque
Animation
75
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Continuously Variable Transmission (CVT) - System overview
1.What is the function of the
planetary wheel set?
It indicates the reverse gear.
1.Engine
2.Pump
3.Converter
4.Planetary gear
5.Steel thrust belt
6.Drive disk (primary
pulley)
7.Output disk (secondary
pulley)
8.Differential
9.Electronic engine
control
10. Electrohydraulic
module (hydraulic
valves,
sensors, actuators)
11. Automobile cable
harness
1
2
3
5
6
11
4
9
7
8
10
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Continuously Variable Transmission (CVT) - System overview
1.What is the function of the
planetary wheel set?
It indicates the reverse gear.
1.Engine
2.Pump
3.Converter
4.Planetary gear
5.Steel thrust belt
6.Drive disk (primary
pulley)
7.Output disk (secondary
pulley)
8.Differential
9.Electronic engine
control
10. Electrohydraulic
module (hydraulic
valves,
sensors, actuators)
11. Automobile cable
harness
1
2
3
5
6
11
4
9
7
8
10
76
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
7
4
CVT variants – Mercedes-Benz Autotronic
1.What is the function of the two clutches?
The torque converter connects the engine to the gear.
The multi-disk clutch ensures that the gears are changed (front and reverse).
1.Primary belt pulley set
2.Slip band
3.Secondary belt pulley
set
4.Automatic transmission
control unit
5.Torque converter
6.Transmission oil pump
7.Simple planetary wheel
set with multi-disk
clutch
6
5
3
2
1
Source: Mercedes-Benz
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
7
4
CVT variants – Mercedes-Benz Autotronic
1.What is the function of the two clutches?
The torque converter connects the engine to the gear.
The multi-disk clutch ensures that the gears are changed (front and reverse).
1.Primary belt pulley set
2.Slip band
3.Secondary belt pulley
set
4.Automatic transmission
control unit
5.Torque converter
6.Transmission oil pump
7.Simple planetary wheel
set with multi-disk
clutch
6
5
3
2
1
Source: Mercedes-Benz
77
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
CVT variants – Audi Multitronic
1.What is the special feature of the Audi CVT transmission?
Audi uses a chain instead of a belt.
2.What is the advantage of this solution?
The torque can be larger (Max:300Nm).
3
4
5
6
8
7
21
1. Reverse gear clutch 5. Hydraulic
2. Gearing level control unit
3. Variator 6. Transmission control unit
4. Plate link chain 7. Planetary wheel set
8. Forward clutch
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
CVT variants – Audi Multitronic
1.What is the special feature of the Audi CVT transmission?
Audi uses a chain instead of a belt.
2.What is the advantage of this solution?
The torque can be larger (Max:300Nm).
3
4
5
6
8
7
21
1. Reverse gear clutch 5. Hydraulic
2. Gearing level control unit
3. Variator 6. Transmission control unit
4. Plate link chain 7. Planetary wheel set
8. Forward clutch
78
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
CVT components – Variator
1.What is the function of the hydraulic piston?
The friction of the belt pulley ensures the
torque transmission, the value of friction
depends on oil pressure which presses the
hydraulic piston.
1.Movable pulley
2.Fixed pulley
3.Steel thrust belt
4.Spring
5.'p' side pressure of
the transmission oil.
2
3
5
4
1
p
Video
2
3
5
4
1
p
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
CVT components – Variator
1.What is the function of the hydraulic piston?
The friction of the belt pulley ensures the
torque transmission, the value of friction
depends on oil pressure which presses the
hydraulic piston.
1.Movable pulley
2.Fixed pulley
3.Steel thrust belt
4.Spring
5.'p' side pressure of
the transmission oil.
2
3
5
4
1
p
Video
2
3
5
4
1
p
79
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
CVT components – Variator
1.What is the function of the
pressure sensor?
The pressure sensor regulates
the contact pressure of the
discs.
Underdrive Overdrive
6
1
5
4
3
2
1
7
3
8
9
10
11
4
8
Source: Audi
1. Torque sensor 7. Adjustable cone pulley
2. Chain 8. Adjusting cylinder
3. Disk set 1 9. Pressure spring
4. Disk set 2 10. Pressing cylinder
5. Pressing cylinder 11. Adjustable cone pulley
6. Disc spring
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
CVT components – Variator
1.What is the function of the
pressure sensor?
The pressure sensor regulates
the contact pressure of the
discs.
Underdrive Overdrive
6
1
5
4
3
2
1
7
3
8
9
10
11
4
8
Source: Audi
1. Torque sensor 7. Adjustable cone pulley
2. Chain 8. Adjusting cylinder
3. Disk set 1 9. Pressure spring
4. Disk set 2 10. Pressing cylinder
5. Pressing cylinder 11. Adjustable cone pulley
6. Disc spring
80
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
CVT components – Steel thrust belt
Steel band packageThrust belt
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
CVT components – Steel thrust belt
Steel band packageThrust belt
81
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
CVT components – Plate link chain
Cradle pressure pieces
Plates
Cone pulleys of the
variator
Source: Audi
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
CVT components – Plate link chain
Cradle pressure pieces
Plates
Cone pulleys of the
variator
Source: Audi
82
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
1
2 2
CVT components – CVT oil pump
1.Why is an efficient oil pump required?
Because the adjustment of the pulley requires a high oil pressure in CVT
and it must also lie at low speeds.
1.Oil pump housing
2.Axial washer
3.Driver
4.Outer segment
5.Inner segment
6.Segment springs
7.Seal role
8.Bar spring
9.Stop pin
10. Crescent
11. Pinion
12. Hollow wheel
1
2
3
9
8
7
6
5
4
4
5
10
1112
Source: Audi
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
1
2 2
CVT components – CVT oil pump
1.Why is an efficient oil pump required?
Because the adjustment of the pulley requires a high oil pressure in CVT
and it must also lie at low speeds.
1.Oil pump housing
2.Axial washer
3.Driver
4.Outer segment
5.Inner segment
6.Segment springs
7.Seal role
8.Bar spring
9.Stop pin
10. Crescent
11. Pinion
12. Hollow wheel
1
2
3
9
8
7
6
5
4
4
5
10
1112
Source: Audi
83
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
1.What is the special feature of the ECU?
The ECU along with the sensors forms a unit; checking is possible only via
diagnosis of ECUs.
2.Which sensors are integrated in the ECU?
Sensor for transmission input speed; sensor for transmission output speed
multi-function switch; sensor for transmission oil temperature.
1.Sensor for transmission
output speed
2.Multi-function switch
3.Sensor for transmission
input speed
4.Sensor -1- for hydraulic
pressure (clutch pressure)
5.Sensor -2- for hydraulic
pressure (contact pressure)
6.Sensor for transmission oil
temperature
Source: Audi
4
5
3
2
1
6
ECU and sensors
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
1.What is the special feature of the ECU?
The ECU along with the sensors forms a unit; checking is possible only via
diagnosis of ECUs.
2.Which sensors are integrated in the ECU?
Sensor for transmission input speed; sensor for transmission output speed
multi-function switch; sensor for transmission oil temperature.
1.Sensor for transmission
output speed
2.Multi-function switch
3.Sensor for transmission
input speed
4.Sensor -1- for hydraulic
pressure (clutch pressure)
5.Sensor -2- for hydraulic
pressure (contact pressure)
6.Sensor for transmission oil
temperature
Source: Audi
4
5
3
2
1
6
ECU and sensors
84
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Maintenance / diagnosis
1.What must be considered while changing the ATF?
The oil temperature must be controlled from actual values.
1.Oil pan
2.Overflow pipe
3.Combined oil filling- /
oil level plug
4.Locking screw
5.Oil level
5
4
3
2
1
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Maintenance / diagnosis
1.What must be considered while changing the ATF?
The oil temperature must be controlled from actual values.
1.Oil pan
2.Overflow pipe
3.Combined oil filling- /
oil level plug
4.Locking screw
5.Oil level
5
4
3
2
1
85
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Summary
1.What is the function of the two clutches?
The torque converter connects the engine to the gear.
The multi-disk clutches ensure that the gears are changed (front and
reverse).
2.What is the special feature of the ECU?
The ECU along with the sensors forms a unit; checking is possible
only via diagnosis of ECUs.
3.Why is an efficient oil pump required?
Because the adjustment of the pulley requires a high oil pressure in CVT
and it must also lie at low speeds.
4.What is the function of the hydraulic piston?
The friction of the belt pulley ensures the torque transmission,
the value of friction depends on oil pressure which presses the hydraulic
piston.
5.What is the special feature of the Audi CVT transmission?
Audi uses a chain instead of a belt.
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Summary
1.What is the function of the two clutches?
The torque converter connects the engine to the gear.
The multi-disk clutches ensure that the gears are changed (front and
reverse).
2.What is the special feature of the ECU?
The ECU along with the sensors forms a unit; checking is possible
only via diagnosis of ECUs.
3.Why is an efficient oil pump required?
Because the adjustment of the pulley requires a high oil pressure in CVT
and it must also lie at low speeds.
4.What is the function of the hydraulic piston?
The friction of the belt pulley ensures the torque transmission,
the value of friction depends on oil pressure which presses the hydraulic
piston.
5.What is the special feature of the Audi CVT transmission?
Audi uses a chain instead of a belt.
86
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right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Advantages of attending Bosch Training...
• Maximum 16 participants in the training.
• Focus on practical work
• Small working groups for practising
with real error detection
• Training on different systems about all
brands
• The technical know-how of the largest original
equipment manufacturer
worldwide.
Customer-oriented trainings as per your requirements....
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Advantages of attending Bosch Training...
• Maximum 16 participants in the training.
• Focus on practical work
• Small working groups for practising
with real error detection
• Training on different systems about all
brands
• The technical know-how of the largest original
equipment manufacturer
worldwide.
Customer-oriented trainings as per your requirements....
87
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Service Training Center
We offer seminars for you on the following topics:
- Automobile-Electrical System /Electronic System
- Gasolene injection
- Diesel injection
- Brake systems
- Mechanics
Multimedia training:
- Web Based Training
•Diesel technology
•Electrical/Electronic systems
•Gasoline direct injection
•Active brake safety systems
- eLearning Multimedia presentations for automotive technology
Training series:
Bosch diesel automobile engineers
Bosch diesel aggregate engineers
Bosch automobile engineers for gasoline injection
Bosch automobile engineers for brake systems
Bosch automobile engineers for electrical systems
Bosch automobile engineers for electronic systems
Additional information about us can be found in the Internet:
http://rb-aa.bosch.com/diagnostics/de/start/index_flash.htm
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Service Training Center
We offer seminars for you on the following topics:
- Automobile-Electrical System /Electronic System
- Gasolene injection
- Diesel injection
- Brake systems
- Mechanics
Multimedia training:
- Web Based Training
•Diesel technology
•Electrical/Electronic systems
•Gasoline direct injection
•Active brake safety systems
- eLearning Multimedia presentations for automotive technology
Training series:
Bosch diesel automobile engineers
Bosch diesel aggregate engineers
Bosch automobile engineers for gasoline injection
Bosch automobile engineers for brake systems
Bosch automobile engineers for electrical systems
Bosch automobile engineers for electronic systems
Additional information about us can be found in the Internet:
http://rb-aa.bosch.com/diagnostics/de/start/index_flash.htm
88
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Additional Information
Additional information on the topics
handled in this training program as
well as other topics of interest can
be found in the following
publications by Robert Bosch
GmbH. They can be procured from
publishing houses.
Reference books ISBN Order number
Automotive handbook) (25th edition) 978-38348-01388 1 987 723 001
Automobile electricals,Automobile electronics (4th edition)) 978-35282-38728 1 987 723 501
Gasoline engine management 978-38348-00376 1 987 723 504
Safety systems and comfort
and convenience system (3rd edition)) 978-35282-38735 1 987 723 503
Diesel engine management 978-35281-38752 1 987 723 502
Gasoline engine management
Emission technique for spark-ignition engines 978-3-86522-000-4 1 987 722 020
Gasoline injection system K-Jetronic 978-3-86522-001-1 1 987 722 009
Gasoline injection system KE-Jetronic 978-3-86522-002-8 1 987 722 021
Gasoline injection system L-Jetronic 978-3-86522-003-5 1 987 722 010
Gasoline injection system Mono-Jetronic 978-3-86522-028-8 1 987 722 033
Ignition in spark-ignition engine 978-3-86522-006-6 1 987 722 030
Gasoline engine management –
basic principles and components) 978-3-86522-004-2 1
987 722 036
Gasoline engine management - Motronic Systems 978-3-86522-005-9 1 987 722 029
Diesel engine management
Diesel in-line fuel-injection pumps 978-3-86522-013-4 1
987 722 057
Diesel engine management at a glance 978-3-86522-007-3 1 987 722 058
Helix-controlled diesel distributor-type injection pumps 978-3-86522-012-7 1 987 722 014
Solenoid-controlled diesel distributor-type injection pumps978-3-86522-008-0 1 987 722 059
Diesel injection system) Unit injector / Unit pump system 978-3-86522-009-7 1 987 722 056
Electronic diesel control EDC 978-3-86522-011-0 1 987 722 035
Diesel-Accumulator Common Rail (CR) injection system 978-3-86522-010-3 1 987 722 062
Exhaust-gas technology for diesel engines 978-3-86522-082-0 1 987 722 061
Safety systems and comfort and convenience systems)
Conventional and electronic brake systems 978-3-86522-014-1 1 987 722 023
Driving stability systems 978-3-86522-015-8 1 987 722 026
Safety systems and comfort and convenience systems) 978-3-86522-019-6 1 987 722 037
Audio, Navigation and Telematics 978-3-86522-020-2 1
987 722 032
Adaptive cruise control ACC 978-3-86522-018-9 1 987 722 034
+Electronic transmission Control EGS 978-3-86522-026-4 1 987 722 027
Commercial vehicle compressed air systems(1): Fundamentals,
systems and drawings 978-3-86522-016-5 1 987 722 015
Commercial vehicle compressed air systems(2): Devices 978-3-86522-017-2 1 987 722 016
Automobile electricals / automobile electronics
Batteries and vehicle electrical systems 978-3-86522-024-0 1 987 722 003
Generators and starting systems 978-3-86522-025-7 1 987 722 028
Lighting technology and wind shield and rear-window cleaning 978-3-86522-023-3 1 987 722 039
Micro-electronics in the automobile 978-3-86522-022-6 1 987 722 022
Sensors in the automobile 978-3-86522-021-9 1 987 722 031
Networking in automobile 978-3-86522-276-3 1 987 722 067
Hybrid drives, fuel cells and alternative fuels 978-3-86522-277-0 1 987 722 065
Department AA-DG/TSS12| © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve every
right of disposal such as copying and passing on to third parties.
Automotive Aftermarket
Automatic transmission control
Additional Information
Additional information on the topics
handled in this training program as
well as other topics of interest can
be found in the following
publications by Robert Bosch
GmbH. They can be procured from
publishing houses.
Reference books ISBN Order number
Automotive handbook) (25th edition) 978-38348-01388 1 987 723 001
Automobile electricals,Automobile electronics (4th edition)) 978-35282-38728 1 987 723 501
Gasoline engine management 978-38348-00376 1 987 723 504
Safety systems and comfort
and convenience system (3rd edition)) 978-35282-38735 1 987 723 503
Diesel engine management 978-35281-38752 1 987 723 502
Gasoline engine management
Emission technique for spark-ignition engines 978-3-86522-000-4 1 987 722 020
Gasoline injection system K-Jetronic 978-3-86522-001-1 1 987 722 009
Gasoline injection system KE-Jetronic 978-3-86522-002-8 1 987 722 021
Gasoline injection system L-Jetronic 978-3-86522-003-5 1 987 722 010
Gasoline injection system Mono-Jetronic 978-3-86522-028-8 1 987 722 033
Ignition in spark-ignition engine 978-3-86522-006-6 1 987 722 030
Gasoline engine management –
basic principles and components) 978-3-86522-004-2 1
987 722 036
Gasoline engine management - Motronic Systems 978-3-86522-005-9 1 987 722 029
Diesel engine management
Diesel in-line fuel-injection pumps 978-3-86522-013-4 1
987 722 057
Diesel engine management at a glance 978-3-86522-007-3 1 987 722 058
Helix-controlled diesel distributor-type injection pumps 978-3-86522-012-7 1 987 722 014
Solenoid-controlled diesel distributor-type injection pumps978-3-86522-008-0 1 987 722 059
Diesel injection system) Unit injector / Unit pump system 978-3-86522-009-7 1 987 722 056
Electronic diesel control EDC 978-3-86522-011-0 1 987 722 035
Diesel-Accumulator Common Rail (CR) injection system 978-3-86522-010-3 1 987 722 062
Exhaust-gas technology for diesel engines 978-3-86522-082-0 1 987 722 061
Safety systems and comfort and convenience systems)
Conventional and electronic brake systems 978-3-86522-014-1 1 987 722 023
Driving stability systems 978-3-86522-015-8 1 987 722 026
Safety systems and comfort and convenience systems) 978-3-86522-019-6 1 987 722 037
Audio, Navigation and Telematics 978-3-86522-020-2 1
987 722 032
Adaptive cruise control ACC 978-3-86522-018-9 1 987 722 034
+Electronic transmission Control EGS 978-3-86522-026-4 1 987 722 027
Commercial vehicle compressed air systems(1): Fundamentals,
systems and drawings 978-3-86522-016-5 1 987 722 015
Commercial vehicle compressed air systems(2): Devices 978-3-86522-017-2 1 987 722 016
Automobile electricals / automobile electronics
Batteries and vehicle electrical systems 978-3-86522-024-0 1 987 722 003
Generators and starting systems 978-3-86522-025-7 1 987 722 028
Lighting technology and wind shield and rear-window cleaning 978-3-86522-023-3 1 987 722 039
Micro-electronics in the automobile 978-3-86522-022-6 1 987 722 022
Sensors in the automobile 978-3-86522-021-9 1 987 722 031
Networking in automobile 978-3-86522-276-3 1 987 722 067
Hybrid drives, fuel cells and alternative fuels 978-3-86522-277-0 1 987 722 065
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