Manual Skoda Octavia - Gearbox m5 02J

Service
Workshop Manual OCTAVIA

5-Speed Manual Gearbox 02J
Service Department. Technical Information

S00.5114.50.20 Edition 08.96
The Workshop Manual is intended only for use within the KODA Organisation; it is not permitted to pass it on to third parties. 1996 KODA, automobilov a.s.
Printed in Czech Republic
Service
List of Supplements to OCTAVIA Workshop Manual
5-Speed Manual Gearbox 02J
Replaces List of Supplements - Edition: 11.00
Supplement
Edition: 08.02
Edition 08.96 10.96 03.97 07.97 12.97 03.98 09.98 05.99 02.00 11.00 08.02
Subject
Basic Edition of Workshop Manual Supplement to Basic Edition Modifications to Special Tools Supplement with New Manual Gearbox Types Two-Mass Flywheel Supplement of New Manual Gearbox Type Supplement of New Manual Gearbox Types New Shift Mechanism Modifications to Repair Groups 00, 34, 35, 39 Modifications to synchromesh of 1st gear Removal of 5-Speed Manual Gearbox
Article Number S00.5114.50.20 S00.5114.51.20 S00.5114.52.20 S00.5114.53.20 S00.5114.54.20 S00.5114.55.20 S00.5114.56.20 S00.5114.57.20 S00.5114.58.20 S00.5114.59.20 S00.5114.60.20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Contents next page.
This Service Manual is intended only for use within the koda Organisation; it is not permitted to pass it on to third persons. 2002 KODA AUTO a. s.
Printed in CR S00.5114.60.20
OCTAVIA
00 Technical Data
Contents
Service
00-1 00-2 00-4 00-3
General repair information .........................................................................................................
Survey of power transmission ...................................................................................................
Identification of gearbox ............................................................................................................. - Code letters, component assignment, ratios, capacities ..........................................................
Page
30
Clutch
Servicing clutch release mechanism ........................................................................................ Servicing clutch ...........................................................................................................................
Servicing clutch mechanism ...................................................................................................... - Survey of components of pedal assembly ............................................................................... - Removing and installing over-centre spring (left-hand steering models) ................................. - Removing and installing over-centre spring (right-hand steering models) ............................... - Removing and installing clutch pedal (left-hand steering models) ........................................... - Survey of components of hydraulic system .............................................................................. - Removing and installing master cylinder .................................................................................. - Bleeding clutch system .............................................................................................................
30-1 30-1 30-3 30-4 30-4 30-5 30-6 30-8 30-9
Page
30-10
34
Shift Mechanism/Housing
Servicing shift mechanism 04.99 .......................................................................................... - Installation position of shift mechanism .................................................................................... - Removing and installing operating cables ................................................................................ - Removing and installing shift housing ...................................................................................... - Removing and installing shift lever ........................................................................................... - Setting shift mechanism ...........................................................................................................
Removing and installing gearbox .............................................................................................. - Inspecting gearbox oil ..............................................................................................................
Servicing shift mechanism 05.99 .......................................................................................... - Installation position of shift mechanism .................................................................................... - Removing and installing gearshift knob and cover ................................................................... - Servicing shift lever and shift housing ...................................................................................... - Removing and installing shift housing ...................................................................................... - Removing and installing operating cables- survey of components .......................................... - Setting shift mechanism ...........................................................................................................
34-14.1 34-14.1 34-14.2 34-14.4 34-14.6 34-14.10 34-14.12 34-15 34-23
34-1 34-1 34-2 34-5 34-10 34-12
Page
Servicing gearbox housing and clutch housing ...................................................................... Disassembling and assembling shift mechanism at gearbox side 04.99 ......................... Disassembling and assembling shift mechanism at gearbox side 05.99 .........................
Disassembling and assembling gearbox .................................................................................. - Removing and installing cover for gearbox housing and 5th gear ............................................ - Removing and installing gearbox housing and shift mechanism ............................................. - Removing and installing input shaft, output shaft (drive pinion), differential and shift forks ..... - Sequence of removal and installations .....................................................................................
34-24 34-25 34-31 34-32 34-34 34-46 34-48 34-41
Disassembling and assembling shift forks ..............................................................................
34-50
Edition 08.02 S00.5114.60.20
------------1 ------------
35
Service
Gears/Shafts
Disassembling and assembling input shaft ............................................................................. Setting input shaft ....................................................................................................................... m
Disassembling and assembling reverse idler shaft .................................................................
Setting output shaft ....................................................................................................................
Disassembling and assembling input shaft (drive pinion) .....................................................
39
Final Drive/Differential
Replacing seals for flange (gearbox installed ..........................................................................
Setting differential .......................................................................................................................
Disassembling and assembling differential ............................................................................. -
------------11 ------------
) ( ! # ' % ! " & # # $# # "#
OCTAVIA
Page
35-1 35-9 35-26 35-14 35-29 39-1
Page
39-3
39-12
Edition 08.02 S00.5114.60.20
OCTAVIA
Technical Data
00
Identification of gearbox
Assignment page 00-2. K Location on gearbox Code letters and date of manufacture (arrow 1) Manual gearbox 02J (arrow 2)
K Manual gearbox 02J (arrow 2)
K Code letters and date of manufacture of gearbox Example: CZM l Code letters 15 l Day 10 l Month 6 l Year (1996) of manufacture
Additional data are production-related.
Note: The code letters of the gearbox are also listed in the data stickers of the vehicle.
------------ 00-1 ------------
Edition 07.97 S00.5114.53.20
00
Technical Data
OCTAVIA
Code letters, component assignment, ratios, capacities

Code letters Assignment: Ratio: Z2:Z1 Engine Final drive 1st gear 2nd gear 3rd gear 4th gear 5th gear Reverse Speedo Capacity Specification Engine oil change interval Clutch control Clutch plate Drive shaft flange 215 mm 100 mm CZM 1.8-ltr./92 kW 72 : 17 = 4.235 33 : 10 = 3.300 35 : 18 = 1.944 34 : 26 = 1.308 35 : 34 = 1.029 36 : 43 = 0.837 DTK 1.8-ltr./110 kW 70 : 19 = 3.684 33 : 10 = 3.300 35 : 18 = 1.944 34 : 26 = 1.308 35 : 34 = 1.029 36 : 43 = 0.837 17 : 10 x 36 : 20 = 3.060 13 : 22 = 0.591 1.9 + 0.1 litres Gear oil G50 SAE 75W90 (synthetic oil) filled for life hydraulic 219 mm (TMF)1) DBZ 1.8-ltr./110 kW 70 : 19 = 3.684 33 : 10 = 3.300 35 : 18 = 1.944 34 : 26 = 1.308 35 : 34 = 1.029 36 : 43 = 0.837
Code letters Assignment Ratio: Z2:Z1 Engine Final drive 1st gear 2nd gear 3rd gear 4th gear 5th gear Reverse Speedo Capacity Specification
ECW 1.8-ltr./110 kW 70 : 19 = 3.684 33 : 10 = 3.300 35 : 18 = 1.944 34 : 26 = 1.308 35 : 34 = 1.029 36 : 43 = 0.837
ENJ 1.8-ltr./110 kW 70 : 19 = 3.684 33 : 10 = 3.300 35 : 18 = 1.944 34 : 26 = 1.308 35 : 34 = 1.029 36 : 43 = 0.837 17 : 10 x 36 : 20 = 3.060 13 : 22 = 0.591 1.9 + 0.1 litres
EBN 1.8-ltr./110 kW 70 : 19 = 3.684 33 : 10 = 3.300 35 : 18 = 1.944 34 : 26 = 1.308 35 : 34 = 1.029 36 : 43 = 0.837
Gear oil G51 SAE 75W90 (synthetic oil)
Gear oil G50 SAE 75W90 (synthetic oil) filled for life hydraulic 219 mm (TMF)1) 108 mm
Engine oil change interval Clutch control Clutch plate Drive shaft flange
1)
08.97 TMF = two-mass flywheel
------------ 00-2 ------------
Edition 02.00 S00.5114.58.20
OCTAVIA
Technical Data
00
EVS2) EHA2)
Code letters Assignment: Ratio: Z2:Z1
Final drive 2nd gear 3rd gear 4th gear 5th gear 1st gear
Engine
EGY2)
33 : 10 = 3.300 34 : 26 = 1.308
70 : 19 = 3.684
1.8-ltr./110 kW
35 : 18 = 1.944
33 : 10 = 3.300 34 : 26 = 1.308
70 : 19 = 3.684
35 : 18 = 1.944
33 : 10 = 3.300 34 : 26 = 1.308 30 : 29 = 1.034 31 : 37 = 0.838
62 : 17 = 3.647
1.8-ltr./132 kW
35 : 18 = 1.944
35 : 34 = 1.029 36 : 43 = 0.837
35 : 34 = 1.029 36 : 43 = 0.837
Reverse Capacity
Speedo Gear oil G51 SAE 75W90 (synthetic oil)
17 : 10 x 36 : 20 = 3.060 13 : 22 = 0.591 1.9 + 0.1 litres
Specification Gear oil change interval Clutch mechanism Clutch plate
Gear oil G50 SAE 75W90 (synthetic oil) filled for life
Drive shaft flange
225 mm (TMF)1) 108 mm
hydraulic
Final drive 2nd gear 3rd gear 4th gear 5th gear 1st gear
Engine
EMR
33 : 10 = 3.300 34 : 26 = 1.308
71 : 18 = 3.994
2.0-ltr./85 kW
EGU2)
35 : 18 = 1.944
33 : 10 = 3.300 34 : 26 = 1.308
71 : 18 = 3.994
1.9-ltr./66 kW TDI 33 : 10 = 3.300 34 : 26 = 1.308 33 : 36 = 0.917 33 : 46 = 0.717 62 : 17 = 3.647
CZL
35 : 18 = 1.944
35 : 18 = 1.944
35 : 34 = 1.029 36 : 43 = 0.837
35 : 34 = 1.029 36 : 43 = 0.837
Reverse Capacity
Speedo
17 : 10 x 36 : 20 = 3.060 13 : 22 = 0.591 1.9 + 0.1 litres filled for life hydraulic 100 mm
Specification
Gear oil change interval Clutch mechanism Clutch plate
Drive shaft flange

1) 2)
215 mm
228 mm
TMF = two-mass flywheel
Gearbox with modified synchromesh for 1st gear
Edition 11.00 S00.5114.59.20
------------ 00-2.1 ------------
00
Technical Data
OCTAVIA
Final drive 2nd gear 1st gear
Engine
DQY 61 : 18 = 3.389 36 : 17 = 2.118
1.9-ltr./66 kW TDI 34 : 09 = 3.778 34 : 25 = 1.360 36 : 17 = 2.118 61 : 18 = 3.389
EBJ
EGR2) 61 : 18 = 3.389 36 : 17 = 2.118
34 : 09 = 3.778 34 : 25 = 1.360
34 : 09 = 3.778 34 : 25 = 1.360 34 : 35 = 0.971 34 : 45 = 0.756
3rd gear
4th gear 5th gear
34 : 35 = 0.971 34 : 45 = 0.756
34 : 35 = 0.971 34 : 45 = 0.756
Reverse Capacity
Speedo
18 : 09 x 36 : 20 = 3.600 13 : 22 = 0.591 1.9 + 0.1 litres filled for life hydraulic
Specification
Drive shaft flange
228 mm (219 mm TMF)1)
219 mm (TMF) 100 mm
225 mm (TMF)
Code letters Assignment Ratio: Z2:Z1
Final drive 2nd gear 1st gear
Engine
DEA 61 : 18 = 3.389 33 : 16 = 2.063 34 : 9 = 3.778
1.9-ltr./81 kW TDI 61 : 18 = 3.389 34 : 9 = 3.778
EBF
EGS2) 61 : 18 = 3.389 33 : 16 = 2.063 34 : 9 = 3.778
3rd gear
4th gear 5th gear
31 : 23 = 1.348
29 : 30 = 0.967 30 : 39 = 0.769
31 : 23 = 1.348
33 : 16 = 2.063
29 : 30 = 0.967 30 : 39 = 0.769
31 : 23 = 1.348 29 : 30 = 0.967 30 : 39 = 0.769
Reverse Capacity
Speedo
18 : 09 x 36 : 20 = 3.600 13 : 22 = 0.591 1.9 + 0.1 litres filled for life hydraulic 100 mm
Specification
Drive shaft flange

1) 2)
219 mm (TMF)
225 mm (TMF)
08.97 TMF = two-mass flywheel
Gearbox with modified synchromesh for 1st gear
------------ 00-2.2 ------------
Edition 11.00 S00.5114.59.20
OCTAVIA
Technical Data
00
Survey of power transmission
Designation 1 - Engine 2 - Clutch 3 - Manual gearbox 4 - Input shaft 5 - Output shaft/Drive pinion 6 - Differential Arrows face in direction of travel Ratios I 1st gear 2nd gear 3rd gear 4th gear 5th gear Reverse Final drive Speedometer drive
II III IV V R A T -
Edition 10.96 S00.5114.51.20
------------ 00-3 ------------
00
Technical Data
OCTAVIA
General repair information

Scrupulous care and cleanliness, as well as proper tools are essential requirements for carrying out proper and successful gearbox repairs. The generally valid basic rules of safety naturally also apply when carrying out repair work. A number of generally applicable notes for individual repair operations - which are otherwise listed several times at many points through the Workshop Manual - are summarised here. They apply to this Workshop Manual. Gearbox When installing the gearbox, ensure that the dowel sleeves between engine and gearbox are correctly located. When replacing the gearbox, fill the gearbox with gear oil up to the lower edge of the filler hole. Capacity and specification page 00-2. Gaskets, seals Thoroughly clean the contact surfaces and apply sealant AMV 188 200 03. Apply an even film of sealant - not too thick. Replace O-rings. Replace radial shaft seals. Before installing: K Lightly oil the outer diameter and pack the space between the sealing lips (arrow) with grease. After installing: Inspect gear oil level; top up, if necessary, to lower edge of filler hole; specification page 00-2.
------------

------------
Edition 10.96 S00.5114.51.20
OCTAVIA
Technical Data
00
Locking elements Replace circlips. Do not over-tension circlips. Circlips must be positioned in the base of the groove. K Replace tensioning sleeves. Fitting location: slot parallel to direction of force. Nuts, bolts Slacken and tighten nuts and bolts for attaching covers and housings diagonally opposite. Do not twist particularly sensitive parts - e.g. clutch pressure plates - and slacken and tighten in stages diagonally opposite. The tightening torques stated apply to unoiled nuts and bolts. Always replace self-locking nuts and bolts. Bearings Do not treat new taper roller bearings for the output shaft and differential additionally with gear oil in order to measure the friction torque. The bearings are already factorytreated with a special oil for this purpose. Insert all bearings in the gearbox with gear oil. Always replace all the taper roller bearings which are fitted to a shaft. Use the same makes, if possible. Heat inner races to about 100 C for installing. Do not mix up the outer and inner races of bearings of equal size. Bearings are matched. Position the inscribed side of the needle bearing (larger metal thickness) facing toward the insertion drift.
Edition 10.96 S00.5114.51.20
------------

------------
00
Technical Data
OCTAVIA
Shims Re-gauge shims at several points with a micrometer. The different tolerances make it possible to exactly gauge the required thickness of shim. Inspect the shims for burrs or damage. Only install shims which are in proper condition. Synchroniser rings Do not mix up. Assign synchroniser rings to the same gearwheel when re-using. Inspect for signs of wear; replace if necessary. Insert with gear oil. Gearwheels Clean and heat on a heating plate to about 100 C before pressing on. The temperature can be checked with a temperature measuring instrument (e.g. V.A.G 1558).
------------

------------
Edition 10.96 S00.5114.51.20
OCTAVIA
Clutch
30
Servicing clutch mechanism

List of pedal assembly components
Special tools, testers and aids required Polycarbamide grease G 052 142 A2
Disconnect earth strap from the battery. Pay attention to the code of the radio set on models fitted with coded radio. Grease all bearing and contact surfaces with polycarbamide grease G 052 142 A2. Remove the shelf on the drivers side before carrying out work on the pedal assembly: General Body Repairs; Repair Group 70; Removing and installing dash panel.
Notes:
List of components of hydraulic system page 30-5
Edition 10.96 S00.5114.51.20
------------ 30-1 ------------
30
Clutch
OCTAVIA
2 - Gasket Always replace 3 - Bearing bracket 4 - Hexagon bolt
5 - Accelerator/brake pedal assembly 6 - Self-locking hexagon nut, 25 Nm Always replace
------------

------------
1 - Bulk head mount For master cylinder and bearing brakket
7 - Connecting plate 8 - Self-locking hexagon nut, 20 Nm Always replace 9 - Spacer bushes
10 - Bearing bush 11 - Clutch pedal Removing and installing page 30-4
12 - Mount Removing and installing page 30-5
Edition 10.96 S00.5114.51.20
OCTAVIA
13 - Self-locking hexagon nut, 25 Nm Always replace 14 - Master cylinder Removing and installing page 30-5 15 - Feed hose 16 - Overcentre spring Removing and installing page 30-3
Clutch 17 - Mounting of overcentre spring Insert in bearing bracket Always replace 18 - Pedal stop 19 - Self-locking hexagon nut, 25 Nm Always replace
30
Removing and installing overcentre spring (LHD models)

Special tools, testers and aids required Assembly clamp 3317 Removing Remove stowage area in bottom left of drivers side: General Body Repairs; Repair Group 70; Removing and installing dash panel. KTension overcentre spring with the clutch pedal and press on assembly clamp 3317 from above.
Note: The hole (arrow) faces toward clutch pedal.

Move clutch pedal into rest position and take off overcentre spring together with assembly clamp 3317.
Installing KMove clutch pedal into rest position. First of all fit on overcentre spring in the overcentre spring mounting -B-, then depress clutch pedal until the mounting journal of the clutch pedal -A- is resting against the overcentre spring. Tension overcentre spring with the clutch pedal and remove assembly clamp 3317.
Edition 03.97 S00.5114.52.20
------------ 30-3 ------------
30
Clutch
OCTAVIA
Removing and installing overcentre spring (RHD models)

Removing - Remove shelf on bottom left of drivers side: General Body Repairs; Repair Group 70; Removing and installing dash panel KPosition screwdriver between clutch pedal and over-centre spring. Operate clutch pedal and lift over-centre spring off pedal in direction of arrow.
Installing Installation is performed in the reverse order; pay attention to the following points: Depress clutch pedal. Insert over-centre spring in mounting of overcentre spring and press onto the stud of the clutch pedal.
Removing and installing clutch pedal (LHD models)

Removing Remove over-centre spring page 30-3. Separate clutch pedal from master cylinder page 30-6 and press operating rod toward engine compartment as far as the stop. Unscrew hexagon nut item 19, page 30-3. Pull hexagon bolt out of bearing bracket item 4, page 30-2. Take off clutch pedal.
Installing
------------

------------
Installation is performed in the reverse order.
Edition 10.96 S00.5114.51.20
OCTAVIA
Clutch
30
Survey of components of hydraulic system

9 - Support bracket 10 - Dust cap 11 - Bleeder valve Bleeding clutch system page 30-8 12 - Slave cylinder Can be removed without taking off shift mechanism parts 13 - Collar bolt, 25 Nm 14 - Gearbox 15 - Securing clip Removing page 30-6 16 - Clip Attach to body 17 - Pipe-hose line Refer to parts list for assigning to LHD and RHD models 18 - Pipe connection/Plug connection 1 - Brake fluid reservoir 2 - Feed hose 3 - Master cylinder Removing and installing on left-hand drive models page 30-6 4 - Mount Replace only if master cylinder removed Removing Fig. 1 Pressing on Fig. 2 5 - Clutch pedal Removing and installing on left-hand drive models page 30-4 6 - Self-locking hexagon nut, 25 Nm Always replace 7 - Bracket Attach to supporting bracket item 9 8 - Pipe-hose line Refer to parts list for assigning to LHD and RHD models 19 - O-rings Cannot be replaced If O-ring damaged, pipe-hose line has to be replaced complete 20 - Securing clip Removing page 30-6
Edition 03.98 S00.5114.55.20
---------- 30-5 ----------
30
Clutch
OCTAVIA
K Fig. 1
Levering off mount -A- in direction of arrow
K Fig. 2
Pressing master cylinder operating rod into mount -A- (direction of arrow)
Removing and installing master cylinder

Special tools, testers and aids required Release tool 3309 Pliers 10-208 A Removing
Note: Unbolt master cylinder from the passenger compartment.

KDetach feed hose -A- to the brake fluid reservoir and seal. Pull out locking clip -B- of master cylinder. Pull out pipe -C- from master cylinder and seal.
------------ 30-6 ------------
Edition 03.97 S00.5114.52.20
OCTAVIA
Clutch
30
Remove stowage area in bottom left of drivers side: General Body Repairs; Repair Group 70; Removing and installing dash panel.
Note: The clutch pedal assembly is removed complete in order to take out the master cylinder. The master cylinder has to be separated from the clutch pedal first of all, however, before removing.
K Release master cylinder operating rod from the clutch pedal as follows: Insert release tool 3309 into the recesses of the clutch pedal for releasing (arrows A). The inscription top/oben (arrow B) faces toward the dash panel. Insert pliers 10-208 A into the recesses -arrows C- and in this way press together the release tool 3309. Pull clutch pedal toward passenger compartment and separate in this way from the master cylinder.
K-
Unscrew hexagon nuts -arrows 1- and take off connecting plate -arrow A-. Unscrew hexagon nuts -arrows 2- and remove clutch pedal assembly -arrow Bcomplete with master cylinder. Remove overcentre spring page 30-3. Turn mounting of overcentre spring through 90 and pull out page 30-3 item 17. Remove master cylinder.
Edition 03.97 S00.5114.52.20
------------

------------
30
Clutch Installing
OCTAVIA
Installation is carried out in the reverse order. Pay attention to the following points. KThe support -A- must be located on the actuator rod -B- of the master cylinder. To click in the support push the clutch pedal toward the front wall (in direction of arrow) and make sure it catches correctly. After installing the master cylinder bleed the clutch system page 30-8.
Bleeding the clutch system

Special tools, testers and aids required Brake filling and bleeding device Romess S15 Bleeder hose 670 mm Bleed the clutch system with brake filling and bleeding device Romess S15. Use bleeder hose 670 mm to bleed the clutch system. Fit bleeder hose onto the connection of the collecting bottle of the brake bleeding appliance. Insert the bleeder hose on the slave cylinder (arrow) and open the bleeder device. After completing the bleeding procedure activate the clutch pedal repeatedly.
K-
------------ 30-8 ------------
Edition 08.02 S00.5114.60.20
OCTAVIA
Clutch
Servicing clutch release mechanism
30
8 - Clutch release bearing Do not wash the bearing, just wipe clean Replace noise bearing Grease contact points at release lever with MoS2 grease 9 - Collar screw, 20 Nm 10 - Slave cylinder Removing and installing page 30-5 11 - Tappet Grease tappet end with MoS2 grease 12 - Mounting bolt Secures the clutch release lever when installing the gearbox page 34-21 Unscrew after the gearbox has been fitted Note: If a mounting bolt (item 12) is not provided, use bolt M8 x 35 Special tools, testers and aids required MoS2 grease 1 - Gearbox 2 - Ball stud, 25 Nm Grease with MoS2 Grease 3 - Gasket ring for drive shaft Replacing page 34-41 4 - Guide Bushing with O-ring O-ring is fitted to guide bushing Replace guide bushing if damaged Grease clutch release bearing with MoS2 grease 5 - Retaining spring Attach to clutch releaser 6 - Fillister head screw, 20 Nm 7 - Clutch release lever
Edition 08.02 S00.5114.60.20
------------

------------
30
Clutch
OCTAVIA
Servicing clutch
2 - Clutch plate Diameter page 00-2 Pay attention to installation position; spring cage faces toward pressure plate Centering Fig. 1 Grease splines lightly
Note: Clean splines of input shaft and, in the case of used clutch plates, splines of hub; remove corrosion and apply only a very thin film of grease Part No. G 000 100 to the splines of the input shaft. After this, move clutch plate back and forward on the input shaft until the hub on the shaft moves freely. It is essential to remove excess grease.
3 - Pressure plate Removing and installing Fig. 1 Inspecting ends of diaphragm spring Fig. 2
Note: Pressure plates are protected against corrosion and greased. They must be cleaned only at the contact surface otherwise the life of the clutch will be considerably reduced.
4 - Twelve-point bolts, 20 Nm Slacken and tighten in stages diagonally opposite
Special tools, testers and aids required Grease G 000 100 Locking device MP 1-223 Centering drift MP 3-475 (Gearbox removed)
Notes:
Replace clutch plates and pressure plates which have damaged or loose riveted connections. Assign clutch plate and pressure plate according to Parts Catalogue and engine code. 1 - Flywheel Ensure the centering pins are tight Contact surface for clutch lining free of grooves, oil and grease Removing and installing 4-Cyl. Engine, Mechanical Components; Repair Group 13; Removing and installing sealing flanges and flywheel
------------ 30-10 ------------
Edition 10.96 S00.5114.51.20
OCTAVIA
Clutch
30
K Fig. 1 -
Centering clutch plate and removing and installing pressure plate
Slacken or tighten the bolts in stages diagonally opposite. Turn over counterholder MP 1-223 when removing.
Note: Contact surface of pressure plate and lining of clutch plate must be making proper contact all round with flywheel. Do not tighten securing bolts until this is the case. On no account pull on pressure plate. Centering holes of the pressure plate and the centering pins of the flywheel would otherwise be damaged.
K Fig. 2
Inspecting ends of diaphragm spring
l Wear down to half the thickness of the diaphragm spring is permissible.
Edition 12.97 S00.5114.54.20
------------ 30-11 ------------
30
Grease G 000100
Pressure pad MP 1-223
Centering mandrel MP 3-475 (Gearbox removed) Notes:
Replace the clutch discs and pressure plates if the riveting is damaged or loose.
Make the clutch disc and pressure plate coincide in accordance with the spare part catalogue and engine identification characters.
------------
B$ F9 0$ ) E@ D8 C 3( # ' % 1( 0 $ 0 1 5$ " & A'2& #(5) $7&)( 7$)( '6 $5 11 14 $' 31 3$ )23 ($3 % 1 5 & !
Clutch
OCTAVIA
2 - Clutch Diameter page 00-2 Pay attention to the fitting position, curved side pointing toward the pressure plate Centering Fig. 1 Slightly grease the serration
Note:
Clean the serration on the drive shaft and if the clutch discs have been used clean the hub serration, remove corrosion and only apply a very thin layer of grease SP No.: G 000 100 on the drive shaft serration. Subsequently move the clutch disc up and down on the drive shaft until the hub fits smoothly on the shaft. Remove all excess grease. 3 Removing and installing Fig. 1 Check the extremities of the membrane spring Fig. 2
Note:
The pressure plates are protected against corrosion and are greased. Only clean the thrust surface as otherwise the life of the clutch may be considerably reduced. 4 Loosen or tighten gradually in a cross pattern
1-F Make sure the centering pins are tight. The locating face for the clutch lining must be free from grooves, oil and grease. Removing and installing: Engine, Mechanical Components; Repair Group 13; removing and installing sealing flanges and flywheel.
------------
Edition 08.02 S00.5114.60.20
OCTAVIA
Clutch
K Fig. 1 -
K Fig. 2 l
Edition 12.97 S00.5114.54.20
& & @ 7 % 9 8 3 4 ) 6 50 ' & "8 %2 ( $ # # ! 1 ( )

30
Centering clutch plate and removing and installing pressure plate Slacken or tighten in Note: Contact surface of pressure plate and lining of clutch plate must be making proper contact all round with flywheel. ighten securing bolts diagonally opposite in order to damaging centering holes of the pressure plate in the centering pins of the flywheel. Inspecting ends of diaphragm spring to the ear the
------------ 30-13 ------------
OCTAVIA
Servicing shift mechanism 04.99
34
Installation position of shift mechanism

A - Shift cable for shift movement B - Selector cable for selector movement C - Heat shield Take off before removing shift mechanism Arrow -A- shift movement Arrow -B- selector movement 1 - Gearbox shift lever 2 - Relay lever with follower/selector cable Notes: Pay attention to coding of models fitted with coded radio set. Disconnect earth strap from battery when carrying out work on shift mechanism in engine compartment. Remove shift mechanism complete in order to replace operating cables page 34-7.
Do not kink operating cables.
Grease all bearing and contact surfaces with poly resin grease G 052 142 A2. Setting shift mechanism page 34-12.
Edition 05.99 S00.5114.57.20
------------ 34-1 ------------
34
OCTAVIA
Removing and Installing operating cables
Special tools, testers and aids required Polycarbamide G 052 142 A2 MoS2 grease Note: Grease bearing and friction surfaces with polycarbamide grease G 052 142 A2. 1 - Shift cable Fitting position page 34-1
2 - Selector cable Disconnect from driver (item 18) and pull peg in direction of arrow. Fitting location page 34-1 Assemble before installing shift cable 3 - Lock washer Do not damage bellows when removing 4 - Hexagon collar bolt, 25 Nm Shift cable at gearbox shift lever
------------ 34-2 -----------34-6
Edition 08.02 S00.5114.60.20
OCTAVIA
5 - Insulation For shift cable/gearbox shift lever
Shift Mechanism/Housing 16 - Reversing lever Take off before removing servicing clutch mechanism Fitting location page 34-4 Servicing page 34-46 17 - Hexagon nut, self-locking, 20 Nm For bell crank/driver Release setting shift mechanism 18 - Driver With spindle for mounting of the reversing lever Fitting location page 34-4 Servicing 34-46 19 - Insulation For selector cable Press in and press out with drift 20 - Hexagon bolt 20 Nm + 90 For balancing weight 21 - Balancing weight Remove when setting shift mechanism page 34-12 22 - Hexagon nut, self-locking, 20 Nm For shift cable at shift housing 23 - Rubber washer 24 - Insulation For shift cable/shift lever Press in and press out with drift 25 - Insulation For selector cable/selector angle plate Press in and press out with drift
34
6 - Washer Insert between shift cable and gearbox shift lever 7 - Gearbox shift lever Fits in one position only After installing set shift mechanism 34-12 Fitting location page 34-4 8 - Square nut Insert in gearbox shift lever 9 - Hexagon nut, self-locking, 20 Nm For gearbox shift lever 10 - Bellow Carefully pull over shift cable/end part Use MoS2 grease 11 - Hexagon screw, 25 Nm For release bearing 12 - Support 13 - Spacer 14 - Grommet Mounting of support to gearbox 15 - Bellow Carefully pull over selector cable/end part Use MoS2 grease
Edition 08.02 S00.5114.60.20
------------ 34-3 ------------
34
OCTAVIA
K Installation position of gearshift lever/relay lever Driver/balancing weight 1 - Gearshift lever 2 - Relay lever Engages over sliding shoe into guide rail of gearshift lever (arrow -A-); grease with MoS2 grease 3 - Driver Flats (arrow -B-) of shaft for mounting relay lever fit only in one position 4 - Balancing weight Bolt to gearshift lever
Note: Shift mechanism and reversing light switch are shown removed to simplify illustration.
------------ 34-4 ------------
Edition 10.96 S00.5114.51.20
OCTAVIA
34
Removing and installing shift housing
1 - Gearshift knob When removing, also take off cover item 2 Removing page 34-7 2 - Cover When removing, also take off gearshift knob item 1 Removing page 34-7 Separate cover from gearshift knob page 34-9
Edition 03.98 S00.5114.55.20
3 - Connection part Connects cover to gearshift knob Removing page 34-9 4 - Clamp For attaching gearshift knob to shift lever 5 - Hexagon bolt, 25 Nm 6 - Cover panel
---------- 34-5 ----------
34
OCTAVIA
8 - Shift housing
9 - Gasket Between operating cables and shift housing 10 - Gasket Between shift housing and floor Self-adhesive Stick onto shift housing
----------

----------
7 - Gasket Self-adhesive Stick onto cover panel
11 - Bracket of shift housing Welded to body
12 - Body 13 - Self-locking hexagon nut, 25 Nm
Edition 03.98 S00.5114.55.20
OCTAVIA
Shift Mechanism/Housing Removing shift housing KRemove air filter housing completely page 34-15. Remove shift cable from gearbox shift lever, by unscrewing bolt -B-. Take off shift cable with washer and square nut. Pull off selector cable -C- from driver/circlip, by raising lug in direction of arrow.
34
K-
Unclip hose line of slave cylinder at cable support. Remove cable support from gearbox (arrow) and lay aside.
Remove gearshift knob and collar KLift off collar upwards -arrow- and pull out toward rear.
Edition 08.02 S00.5114.60.20
34-7 ------------ 34-9 ------------
34
Shift Mechanism/Housing KPull cover up and over gearshift knob.
OCTAVIA
Open clamp -arrow- and pull off gearshift knob together with cover.
K-
Unscrew securing nuts -arrows-.
K-
Slacken double clamp -arrow A- and separate exhaust system. Unbolt cross member -arrow B-. Remove heat shields -arrows C and D- for operating cables. Unscrew securing bolts page 34-5, item 5.
----------

----------
Lower shift housing and pull out to the rear complete with cables.
Edition 03.98 S00.5114.55.20
c e f d C % % $ # ' 2 % Y 9 # h i W @ B Cq # 2 % Y 9 # % 2 h% iA W# B I C% C C # # hB i% W2 ( I B ! S CB # P ' h" i# W! ( B g # S CP # P h9 i# W! ( B g b a ` C) %@ ' 2 P ' % ' % Y # ! @ @ 7# C !6 !! 2@ 9" !# # % $ 6 # 2 6 ! U V ( U X W H 7B C@ #( 69 #@ 2 ! 2 " % " % ! 9 ! % IB S @ Q I % 2 6 ! 8 !' # %)p %' 9' #5 2 6 ! # % ! ! # " % % # )9 )! @B 46 &% 8 !6 2" #@ !2 2 % 9 '4# % # 2 6 $ ! # % " (! B# @)' A52 %$ #4') #&))) !)5 $4 " # ! 2 % 9 ' ! B @ 4&r ))4 # % ! % # ! $ ( C %) # % $ # @ 2'&5 %&A) ") !p 2 %)) # # ' # ! % 9 ! @%)& (' ( (&@ B A @ 84 0") 2T5))& % 9&)&)&" '45P # 2 6 ! # % ! ! # " %%5& %') $% )' @' 3 # 2 1 2! 6# 3 #)0 % % $ 2 % ' ' !' #' %' !" !)5' #A " %) "" % # $R )2 )" ( &&2 5" 0 ))7&)44 #5&T) % ! % ' # $ " ( '&4&)07454GD4 0"E&E4 ) "0 &&)&) ))F) 47 ! &' 5)05 5&)&&&&&&&) 0 )
Align exhaust system: Notes: Adjust shift mechanism page 34-12. If the gasket between shift housing and floor is damaged, replace. ightening
-------------------
OCTAVIA
Edition 03.98 S00.5114.55.20
34
34
OCTAVIA
Removing and installing shift lever
1 - Selector cable At selector angle bracket 2 - Shift cable At shift lever 3 - Hexagon bolt, 15 Nm For bearing bolt at bearing plate 4 - Bearing bolt 5 - Bearing plate
------------ 34-10 ------------
6 - Self-locking hexagon nut, 25 Nm For bearing plate at shift housing 7 - Cap Installing Fig. 1 8 - Bearing bush 9 - Selector housing Insert into bearing plate after assembling complete shift lever
Edition 09.98 S00.5114.56.20
OCTAVIA
10 - Bush 11 - Dog-leg spring 12 - Guide bush Lock onto bearing bush item 8 13 - Lock washer Removing and installing Fig. 2 14 - Spacer bush 15 - Compression spring 16 - Shift lever guide
Shift Mechanism/Housing 17 - Lock washer Removing Fig. 3 18 - Damper washer 19 - Bearing bush Fits only in one position 20 - Selector angle bracket 21 - Split pin 22 - Shift lever 23 - Shock absorber Installing Fig. 4
34
K Fig. 1 -
Installing cap
Press on from the side (arrow). Press opening together to form a slot.
Note: Heat cap if necessary (e.g. in hot water).
K Fig. 2 -
Removing and installing lock washer
To remove and install the lock washer, pull shift lever in direction of arrow -A- and at the same time use a screwdriver to press down spacer bush in direction of arrow -B- as far as the stop.
Note: Do not twist spacer bush when pressing it down. Carefully release tension of mounting slot in shift lever for the lock washer.
Edition 09.98 S00.5114.56.20
------------ 34-11 ------------
34
OCTAVIA
K Fig. 3
Removing lock washer for selector angle bracket and shift lever guide/ selector housing
Raise clip in direction of arrow.
K Fig. 4
Installing shock absorber
Installation position: The stud (arrow) on the shock absorber -1points toward the shift lever guide -2-.
Setting shift mechanism

Special tools, testers and aids required Wedge 3192/1 Shift lever gauge 3422 Gearbox in Neutral. KTake off gearshift knob with cover page 34-7. Remove air filter housing complete page 34-15. Take off balancing weight page 34-3. Slacken bolt -A- and nut -B- until the shift cable and selector cable driver move freely in the slots.
------------ 34-12 ------------
Edition 09.98 S00.5114.56.20
% E F & % ' ' ' ! % & C & # & B $ 5 # " 1 @ " ! A ' @ " ' C 3 '$ ' ' ) %4 & % 8 5 $ 6 5 " ' 4 & % ' 3 % ) D0 & ' ' 0 % % 2 ' % 7 & 9 '' ' 1 ) % ! ' ' ) ' ( ! & ' % % ! ! $ $ # " 1 04
------------ 34-13 ------------
OCTAVIA
Edition 09.98 S00.5114.56.20
K-
K-
K-
Wedge must not raise gearbox shift lever when this is done. Note:
34
34
l Shift lever should be in Neutral in gate of 3rd/ 4th gear. -
If sticking occurs when repeatedly engaging a gear, check the clearance (lift) of the shift shaft as follows: Engage 1st gear.
K-
K-
Notes:
Requirements for correct setting:
In addition, gearbox, clutch and clutch mechanism should be in proper operating condition.
------------ 34-14 ------------

OCTAVIA
Depress clutch, start engine, wait about 3 ... 6 seconds to allow the input shaft of the gearbox to come to a stop. Shift through all the gears several times. Pay particular attention to proper operation of the reverse gear lock. Press shift lever fully to the left and release again. At the same time observe the shift shaft at the gearbox (2nd mechanic). When the shift lever is moved, the shift shaft should make a stroke of about 1 mm (direction of arrow). If this is not the case, disengage 1st gear and once again slacken nut -A- for the mounting stud of the selector cable driver. (The selector cable has slight play at the mounting stud as a result of the transmission elements). Eliminate the play of the selector cable by pressing it slightly towards the bulkhead with the mounting stud (direction of arrow). Re-tighten nut -A- in this position. The operating and transmission elements of the shift mechanism should be in proper condition. The insulating pieces for mounting the shift and selector cables at all the operating elements should be in proper condition (not worn). Shift cable and selector cable should operate freely.
Edition 09.98 S00.5114.56.20
OCTAVIA
Servicing shift mechanism 05.99
34
Installation position of shift mechanism

A - Shift cable for shift movement B - Selector cable for selector movement C - Heat shield Take off before removing shift mechanism Arrow -A- shift movement Arrow -B- selector movement 1 - Gearbox shift lever 2 - Relay lever with follower/selector cable Notes: Pay attention to coding of models fitted with coded radio set. Disconnect earth strap from battery when carrying out work on shift mechanism in engine compartment. Remove shift mechanism complete in order to replace operating cables page 34-14.6.
Do not kick operating cables.
Grease all bearing and contact surfaces with poly resin grease G 052 142 A2. Setting shift mechanism page 34-14.12.
Edition 08.02 S00.5114.60.20
------------ 34-14.1 ----------------------- 34-11
34
OCTAVIA
Removing and installing gearshift knob and cover
1 - Gearshift knob Remove together with cover item 2 Fig. 1 2 - Cover Remove together with gearshift knob item 1 Fig. 1 Separating cover from gearshift knob Fig. 2
3 - Connection part 4 - Collar clamp For attaching gearshift knob to gearshift lever 5 - Surround 6 - Shift insulation Fitted only to certain models
------------ 34-14.2 ------------
Edition 11.00 S00.5114.59.20
4 7 6 8 1 U 2 B 1 8 ) 7 6 8 2 4 8 8 2 1 4 6 1 B B 2 5 4 2 3 @ @ @ S Y 0 H 0 H 8 7 2 8 7 4 R B 4 2 7 6 3 8 2 4 8 8 2 1 5 ) 5 1 B @ 9 T Q S ( Q P 4 2 2 8 3 1 2 8 7 4 R 5 B 4 8 B T Q S ) 2 4 8 4 B 2 8 ) 3 1 9 G 4 2 3 2 8 U1 2@ 4 7 7 6 4 8 7 B ) 2 5 5 7 4 R B 8 ) @ T Q S G 9 P 4@C 4@0 35 7@ 45 RH B@ 4C 2 7 6 5@H 8 2 4 8 8 5 2 1 ) 1 @ @ Q@H QH ( PH 0 H A 2 7 B A 25 4" 4' 2 4 3@ 4 3 7 1 B 5H 5 5 7P' 6PH 8C' 2@' 45 85 8P 2X 15 15 55W 4 B @HP @H 9 0 I H@ P5 P5 )' 2 4 8 4 B 2 8 ) 3 1 5 9 G H H $ # %' ' 5 C 5V @ @0 ' H 0 H @' F 5 C "1 " E !5W !5 D C ' ' A 2 7 B ) 2 8 7 6 ) 4 2 3 5 5 1 ) 9 ( %@' & 0 0 " $5 # !
I . . and
3
OCTAVIA
Edition 05.99 S00.5114.57.20
K ig.
34
' $ # & " (! (! % T T T Q 1 0 T t y) ) T) 3 r u ) ) R p 1 1 T TRq) R ) Y) ` X a) i) T Q R f' cU b) e) g)) TV d) ss dbh)) UUc) URV RS S )) yR Tcbi)R SW xs RcbR dT) ve)) v wV2 P AE @ I C @ C 5 B D D H 85 BG6 8688 78 D 5 A C F @ 5 9 4 E7 6 A F
Grease bearing points and contact surfaces with poly resin grease G 052 142 A2. Note: 1
S00.5114.57.20
OCTAVIA
I # & $ # # ' I # # # & # 2 & ' ' s I 1! 1 1 #! & w $ 3 % ) $ ) " " " ( s I S !" ( #) & $1 # # ) ) # '1 r ' I I H %!) ) S &y #" % # # 3 ) ) (! W! h)! c! g!1 c(" C g! 1 C! ( Di B!( B h c c 8( 5 8) I # & ! I 1 1 & & # & # # ) 3 $ ) ) & 3 ' " r " I @ # H H # 2 $ 3 ) ) & ) ' ' s@ 1 18 & & # & # # 3 ) 2 ) ) ' ' I) y $) ( ! H & # 3 & )( & # 2 # ( ( 4 ' v B 7 W C h! D"1 c c! ) S h c C A ! 8 x @ 8( @) @! 8 v C D B 7 u d 5 I p !( #!! #" ! ! # # w ) ` a Y 7 5 W U V 5 X 5 v C D B 5 7 u I I S 1 % & # # # & & R" Q! RW Q P( t ! 8 $ ! % ( 2 # # ) ' ! ( (i D E ! F 5 I@ B I S( 1 1! (( 5 %W & ! F #i X #a # & & B S( R!!! Q( 2 Rp Q!! P!( U !8 sd c &C % 3 ) & 4h8 r% ( ( c Cf D D ` C B& D B B I 57 Eg 6g @ e I H!V %E )7 #@C 2H #@Q & $Q E ` )iE )@% A B ` r% !P " 7 5 ' gY & C0 R C6 B % qb 5C 5c %! $! #8 # # 3 4 " ! ! 0 7 & V ' 5# " # #! &9 % @ # )S ' "1 ( " ! ! c$8 ( D'! & BT 52 Y6 G @ @
9 5 3 Shift housing 2 Shift Mechanism/Housing K Fig. K Fig. Do not twist spacer bush when pressing down. Carefully relieve stress at locating slot in shift lever for lock washer. Note: T 5 3 0 Shift 5 m and
3
OCTAVIA
Edition 05.99 S00.5114.57.20
34
34
OCTAVIA
Removing and installing shift housing

Remove Shift mechanism up to 12.00 KUse an open-end wrench -1- to lever off selector cable -A- and shift cable -B- at gearbox.
Shift mechanism from 01.01 KRemove lock washer -3- for the shift cable at gearbox shift lever -1-. Remove lock washer -4- for the selector cable at circlip -2-. Pull off selector cable and shift cable from stud -arrow-.
Continued for all shift mechanisms KRemove cable support from gearbox -arrow, if necessary, first unclip hose line at cable support.
------------ 34-14.6 -----------------------
Edition 08.02 S00.5114.60.20
) 3 1 4 0 2 0 ' " ( % $ $ $ !& " ! "!! # $ !

------------ 34-13 -----------------------
OCTAVIA
Edition 08.02 S00.5114.60.20
KKK-
34
" $ ) F # b " ) 2 c e e 5 1 e d & " qp i (g % f h b g T W V U 8 9 A S R Q a a Y X I " % ) ( % I % $ % F " 6 "H 8 " ) D 9 % 2 5 1 5 ( ) " ) 2 14 0 G $ '%%(% &( ! (`@% " % # C@C P %C%%@%%(%%%%%%((B%BE7 3 % A 8 9
Shift Mechanism/Housing KKKNotes: The seals -arrows- on the outer ball head must be free of grease.
Edition 08.02 S00.5114.60.20
------------ 34-14 -----------------------
34
OCTAVIA
OCTAVIA
Shift Mechanism/Housing Shift mechanism from 01.01 The holes in the cable locks have different diameters. K Assignment Cable lock for: Shift cable at gearbox shift lever Selector cable at relay lever
34
Dimension -a10 mm 8 mm
The cable locks do not have to be replaced after disassembling. KCoat with thin film of grease G 052 142 A2 pin -arrows- of gearbox shift lever -1- and relay lever -2-. Replace the lock washers -3- and -4- after each disassembling Secure the shift cable with the lock washer -3- and the selector cable with the lock washer -4-
Continued for all shift mechanisms Align shift housing parallel to body.
Notes: Replace gasket between shift housing and floor if damaged Aligning exhaust system: Engine, Mechanical Components; Repair Group 26; Removing and installing parts of the exhaust system Tightening torques Shift housing to body Cross member to body 25 Nm 25 Nm 25 Nm Setting shift mechanism page 34-14.12.
Cable support to gearbox
Edition 08.02 S00.5114.60.20
------------ 34-14.9 ----------------------- 34-15
34
OCTAVIA
Removing and installing operating cables - list of components
Note:
Grease bearing points and contact surfaces with poly resin grease G 052 142 A2 1 - Shift cable Press onto shift lever guide Installation position page 34-14.1 2 - Selector Cable At bell crank Installation position page 34-14.1
------------

6 - Support
-----------------------
3 - Lock washer 4 - Lock washer Do not damage cables when removing 5 - Shift housing
7 - Grommet
Edition 08.02 S00.5114.60.20
OCTAVIA
8 - Spacer 9 - 20 Nm 10 - Cable lock For selector cable 01.01 with through hole page 34-14.6 11 - Cable lock For shift cable 01.01 with through hole page 34-14.6 12 - Lock washer
Shift Mechanism/Housing 13 - Bush 14 - Relay lever Installation position page 34-14.11 15 - Sliding shoe 16 - Gearbox shift lever With balancing weight Insert so that interrupted tooth spacing matches the shift shaft After installing, set shift mechanism page 34-14.12 Installation position page 34-14.11 17 - 20 Nm
34
K Installation position of gearbox shift lever/ relay lever 1 - Gearbox shift lever with balancing weight 2 - Relay lever - fits over sliding shoe to engage in sliding rail of gearbox shift lever -arrow-
Edition 08.02 S00.5114.60.20
------------ 34-14.11 ----------------------- 34-17
34
OCTAVIA
Setting shift mechanism

Special tools, testers and aids required T 10027 Locking pin Notes: Pay attention to the following points to ensure correct setting of the shift mechanism: Operating and transmission elements of the shift mechanism in proper condition Shift mechanism operates easily
In addition, gearbox, clutch and clutch mechanism must be in proper condition l Gearbox in Neutral KPull locking mechanism at shift cable and at selector cable forward as far as the stop (arrow -1-) and then lock to the left (arrow -2-)
K Position the shift shaft as follows: Press the shift shaft down (direction of arrow -1-). When pressing down the shift shaft, turn the locking pin -A- in direction of arrow -2-.
------------ 34-18 -----------34-14.12 ------------
Edition 08.02 S00.5114.60.20
OCTAVIA
34
K-
Lift up cover -arrows- and pull out to the rear. Pull rubber cover, if fitted, toward shift knob.
K Now position the shift lever as follows; Insert the locking pin T 10027 through the hole -A- into the hole -B-.
Edition 08.02 S00.5114.60.20
------------ 34-14.13 -----------------------
) " % 4 2 % 3 7 "% "7 & 8 ! 0 6 !5 & % !! 11 1 1 & # 21 ) & 1 ! " " & " " & 0 " ! & % ( ) ! !" " !' ! " ! " ! ! " ## $ #) % !" "( !' " $ ) # !
-----------------------
------------
34
K-
K-
K-
10027
Edition 08.02 S00.5114.60.20
OCTAVIA
OCTAVIA
Shift Mechanism/Housing Operation l Shift lever must be in gate of 3rd/4th gear in Neutral. Depress clutch and shift through all gears several times. Pay particular attention to proper operation of the reverse gear lock.
34
If the gearshift lever catches when repeatedly engaging gear, inspect the play (lift) of this shift shaft as follows: KEngage 1st gear. Press shift lever fully to the left and release again. At the same time, observe the shift shaft at the gearbox (2 nd mechanic). When the gearshift lever is moved, the shift shaft must make a stroke of approx. 1 mm (direction of arrow). If this is not the case, set shift mechanism page 34-14.12.
Edition 08.02 S00.5114.60.20
------------ 3 ------------

------------
34
OCTAVIA
------------

-----------------------
Edition 08.02 S00.5114.60.20
OCTAVIA
Removing and installing gearbox

Special tools, testers and aids required Grease G 000 100 Supporting device MP 9-200 Removal device MP 3-470 Mounting rails MP 3-457 Gearbox mount MP 3-476 Adjusting plate MP 3-476/8 Transporting device MP 3-478 Removing KPay attention to coding on models fitted with coded radio set. Disconnect earth strap from battery. Detach air guide hose -1- and unplug connector -2- from the air mass meter. Remove air filter housing complete by taking out screws -4- and -5-. Detach vent hose -3- (only on models with TDI engine).
34
Models 04.99 KUnplug connector from the speedometer sender -1- and reversing light switch -2-.
Edition 05.99 S00.5114.57.20
------------ 34-15 ------------
' $ # & " (! (! % 5 5 E3 590 5 7 R 5 8 5 8 5 I B 7 5 5 6 6 95 1 96 @ 9 H ` E2 R9) 7 5 T D 5 5 7 8 5 Q b I W 5 @U 9 9 @ 9 9 E E R 7 W B D B 5 B W 8 I 5 Q Q 5 V r @ 4 E R7 7 5 TB D 5 5 D R 5 Q9 7 8 7 6 @5 9 X 9 @ 9 9 YY E7 RI 76 QU QQ S E 56 7 IF R D B 8 R 5 U Q 5 5 V U rq qV 9I aC6 @ 4 E6C6Q 5QP6s 5AC6AQ 56CPP DCQ R6P 5AQ 7 R 5 8 5 QF 8 I 6Q 6CC8 95 9U GA66 9I @6 9 h p6CA pCAAAC e g E R5 7V RQQ BQ R 5 B 8 D W D B Q5 Q6 7 I 5 7 H @ PF 4 F 5 7 R 5 8 5 8 SQiAA E8 57 5FAC R6 R R Q5 Q cA6A6 @ dI 9 W B B R b ` Ef E BW 7Q 5F 7 I 5 5 D R 5 7 QR 8 R 5 7 Q H7 9Aa 9 9 @ 9 X EA D6 B8 S 5 B W 8 I 5 V 5 U R I 7 Q 5 T RI 6D 9P @ CCQ @PC66CF @6F A5 4 F F 5AVY 7R E6A6 8FCQ BCQP 7YQ IV DAQ 5F DCC B B 7 7 8 7 5 8 6U @QC6PCA6 GPAC6P 9PQC H6CAQ 9A6 @ 9 P6 P A A
------------
------------
K-
K-
S00.5114.57.20
OCTAVIA
" ! % D ! E ! " ! ! C C % G F ! ! ! $ ! B # ' C $ % @'$ )1 A62 49 ) 8 3 0 0 4 ) 7 5 ( 5 99$ " ! & # " ! $ % ' ! $
1------------ 3 ------------
OCTAVIA
Edition 05.99 S00.5114.57.20
KK-
34
' $ # & " (! (! % c I 8 B 6 P B Y F @ B B C 8 6 H R X 6Q ) P 6 8 @ 6 B I F C B 8 B 6 G ' R G c 6U` 4 8C2 I@0 8H 1 6 B P 6 8 6 B 6 C QF RB3 R d G R X WQ I 8 B 8 b 5 `8 BQQAQ 6F YX 6C FE@ 7 YA F 6 Y F 6 F F 8 C HH 8 C 6 @ B 6 6 9 X R a` IH 8 B 8 B 6 b 6 F Y H X `Y FBE 6QQAWQAQ YQQQH FEC 6EH` F@ FHAQ 8Eà CQHQ CQAA 7HQ 8QH 8EAH IU B B 6 @ 6 QQQ QQ Q Q XHQ V R R 7 6@ F@ PEAS FHEEAQ 6@ I@ P 8UQ 8A F 8 6 6 T 6 6 C Q VHU R G R 5 P9 86 F6 7 6@ B I C F B 6 F 6 B D C 6 9 8 8H QEA6 G G GD Q E
------------
------------
K-
K-
Do not depress clutch pedal.
Note:
-1-.
-2-.
S00.5114.57.20
OCTAVIA
OCTAVIA
K-
K-
Edition 05.99 S00.5114.57.20
0 0 P Q R ( 3 A G H G 8 6 8 E 8 6 @ 8 I 5 D 7 ) ' 2FB 4 0 # 9 BC # C 9 & 3 ) ) ) &( #& ! % % $1 "
34
Note: When fitting on the hooks of the supporting device, pay attention to the hose and cable connections in the area of the lifting eyes of the engine to ensure that these are not damaged. ------------ 3 ------------
34
OCTAVIA
Models with TDI engine: KRemove noise insulation panel by unscrewing bolts -arrows-.
Continued for all models: - Remove starter: Electrical System; Repair Group 27; Removing and installing starter. Unbolt bracket for cable of PAS from gearbox. If fitted, take protective cap for inner righthand CV joint off the engine.
K-
Remove small cover plate -A- for flywheel behind the right-hand flange shaft (arrows). Detach the drive shafts from the flange shafts, turn steering to full left lock and tie up drive shafts as far as possible. Do not damage surface protection when doing this.
Separate exhaust system downstream of catalytic converter: 4-Cylinder Engine, Mechanical Components; Repair Group 26; Removing and installing parts of the exhaust system.
Note:
On models with TDI engine, the exhaust pipe bracket on the subframe has to be removed. KUnbolt pendulum support -arrows-.
------------ 34-18 ------------
Edition 10.96 S00.5114.51.20
OCTAVIA
34
K-
Unbolt support -A-. Unscrew the securing bolts -arrows- from the left gearbox mount -B-.
K-
Take gearbox supporting bracket -A- off the gearbox.
Unscrew the securing bolts -arrows- for the gearbox supporting bracket as follows: Lower engine/gearbox assembly with the two spindles sufficiently far until the securing bolts of the gearbox supporting bracket -Aare accessible from the left wheelhouse.
Note: Pay attention to the PAS pipe when altering the position of the engine/gearbox assembly.
A - Forcing device MP 3-470 B - M8 x 25 bolt C -Mounting rails MP 3-457 K-
Attach special tool -C- to subframe (attachment of pendulum support) with bolt -B-. Insert forcing device -A- and tighten bolts -arrows-. Press engine/gearbox forward.
Note: Pay attention to PAS pipe.
Edition 10.96 S00.5114.51.20
------------

------------
34
OCTAVIA
Fit together the gearbox jack with gearbox mount 3282, adjusting plate 3282/8 for gearbox 02A and mounting elements as follows: Fit adjusting plate 3282/8 onto gearbox mount 3282 (adjusting plate fits only in one position). Align the arms of the gearbox mount to match the holes in the adjusting plate. Screw in the mounting elements -A-, as shown on the adjusting plate.
K-
K-
Position gearbox jack below vehicle; arrow symbol -B- ( Fig. V34-2670 on page 34-20) on adjusting plate faces in direction of travel/ vehicle. Align adjusting plate parallel to gearbox and fix locking mount in place at gearbox. Remove the bottom bolts for attaching engine/gearbox.
K-
Press gearbox off the engine and turn toward the subframe. Carefully lower gearbox; adjust the position constantly at the spindles of the gearbox jack.
Note: Pay attention to PAS pipe when lowering the gearbox.
------------ 34-16 -----------34-20
Edition 03.97 S00.5114.52.20
OCTAVIA
34
K-
Bolt gearbox suspension device MP 3-478 to clutch housing.
K-
Set supporting arm at slide with locking bolt (arrow).
Number of holes visible = 5 Take up gearbox using workshop crane and gearbox suspension device MP 3-478. Place down gearbox, e.g. in container.
Installing Installation of the gearbox is carried out in the reverse order. Install engine/gearbox mounts free of stress: 4-Cylinder Engine, Mechanical Components; Repair Group 10; Removing and installing engine.
Notes:
K Press clutch release lever toward gearbox housing before installing the gearbox and secure with assembly bolt or M8 x 35 bolt. After installing gearbox, remove bolt. Hole is then sealed by the 3rd securing bolt for supporting bracket/operating cables. Clean splines of input shaft and apply a light film of G 000 100 grease.
Edition 10.96 S00.5114.51.20
------------

------------
34
OCTAVIA
K If the gearbox is replaced, use existing speedometer sender (Fig.), gearbox shift lever (item 7 page 34-3) and relay lever, if fitted. If the gearbox is replaced, ensure the intermediate plate is correctly installed.
Check whether dowel sleeves for centring engine/gearbox are present in the cylinder block; insert if necessary. Replacing seal of drive shaft Running Gear; Repair Group 40; Servicing drive shaft
Installing starter and cables Electrical System; Repair Group 27; Removing and installing starter. Inspecting gear oil page 34-23. Setting shift mechanism 04.99 page 34-12.
Setting shift mechanism 05.99 page 34-14.11.
Tightening torques K Gearbox to engine Item 21) 31) 41) 5 6 7 8

1)
M 12 x 55 M 12 x 150 M 12 x 150 M 10 x 50 M 10 x 50 M 10 x 50 M 12 x 55 M 12 x 55
Bolt
Qty. 1 1
Nm 80 80
1 1
80 80
1 1 1 1
45 45 45 80
M8 bolt with threaded pin
A: Dowel sleeves for centring Drive shaft to flange shaft: Running Gear; Repair Group 40; Installation overview of wheel location, suspension strut, drive shaft, brake
------------ 34-22 ------------
Edition 11.00 S00.5114.59.20
OCTAVIA
34
Tightening torques 25 Nm 25 Nm
Components Support to gearbox M8
Support to gearbox mounting bracket M8 Cable to gearbox shift lever
Cable support bracket to gearbox Balancing weight to gearbox shift lever 04.99
20 Nm
20 Nm + 90 20 Nm
25 Nm
Gearbox shift lever with balancing weight 05.99
Inspect gear oil

Gear oil specification page 00-2. KUnscrew gear oil filter plug -arrow-.
The oil is at correct level if the gearbox is filled up to the lower edge of the oil filler hole. Screw in plug -arrow- - 25 Nm.
Pay attention to the following points when refilling: Unscrew plug -arrow-. Pour in gearbox oil up to lower edge of filler hole and screw in plug. Screw in plug -arrowStart engine, engage gear and allow gearbox to rotate for about 2 minutes. Switch off engine, unscrew plug -arrow- and once again fill up gear oil to lower edge of filler hole. Screw in plug -arrow- - 25 Nm.
Edition 08.02 S00.5114.60.20
------------ 34-23 ------------
34
OCTAVIA
Disassembling and assembling gearbox
Mounting sequence page 34-34 I - Disassembling and assembling gearbox housing and 5th gear page 34-25 II - Disassembling and assembling gearbox housing and shift mechanism page 34-31 III - Disassembling and assembling drive shaft, output shaft, differential and gearshift forks page 34-32
------------ 34-24 ------------
Edition 08.02 S00.5114.60.20
OCTAVIA
34
Removing and installing cover for gearbox housing and 5th gear
1 - Hexagon screw, 14 Nm For cover at gearbox housing 2 - Cover for gearbox housing Note: If the gearbox housing cover is fitted with the gearbox mounted, inspect the oil level: Pour in oil up to lower edge of filler hole and plug filler hole with screw plug. Start engine, engage gear and allow gearbox to rotate for about 2 minutes. Switch off engine and once again fill up gear oil to lower edge of filler hole.
3 - Seal 4 - Inside Torx screw M10, 80 Nm Holds disc spring in position with sleeve socket on screw head 5 - Pressure plate Install page 34-30 6 - Filister head screw, 25 Nm For bearing pins on the gearbox housing 7 - Bearing pins 8 - Shift fork for 5 th gear Disassembling and assembling page 34-50 Setting page 34-30 9 - Sliding sleeve for 5th gear Fitting location page 34-29 Setting page 34-30 10 - Synchroniser body with sliding gear and synchroniser ring for 5th gear Disassembling and assembling page 34-28 11 - Needle bearing 12 - Gear pinion for 5th gear Fitting location page 34-28
Edition 08.02 S00.5114.60.20
------------ 34-25 ------------
34
Shift Mechanism/Housing Disassembling Special tools, testers and aids required
OCTAVIA
Two-arm extractor for example Kukko 20/10 with hook Matra V/170 Raise vehicle. Remove left front wheel.
- Remove wheelhouse liner. Body Work; Repair Group 66; remove and install front wheelhouse liner. Vehicles equipped for bad road conditions Remove steel sheet under engine compartment.
Vehicles with xenon headlights - Remove front left vehicle level sensor. Electrical installation; Repair group 94; remove and install front sensor. Continued for all vehicles KKDrain out gear oil, by unscrewing oil drain plug. Unscrew fixing screw -arrow- for cable of power steering. Press down carefully cable of power steering. Position catch pan underneath. Unscrew fixing screws for cover of gearbox housing and remove gearbox cover. Remove shift fork for 5th gear -arrow-
Note: Take off spring and locking pieces before pulling upward sliding sleeve. Then secure sliding sleeve without shift forks again on the synchroniser body.
------------

------------
Edition 08.02 S00.5114.60.20
OCTAVIA
34
K-
Release nuts -A- for synchroniser body and 5th gear pinion, while engaging the 5th gear (arrow 1) and 1st gear (arrow 2 and 3) When engaging both gears, the drive shaft and output shaft are blocked, synchroniser body and speed gear cannot rotate. Now it is possible to release the two bolts.
K-
Remove the 5th gear sliding sleeve. Pull off synchroniser body with 5th speed sliding gear and remove with needle bearing. A - Two-arm extractor for example Kukko 20/10 with hook Matra V/170 B - Hexagon screw M10 x 20
Notes: When pulling off gear pinion, make sure the hooks do not bend outward, if necessary tighten screw (arrow). Check 5th gear for damages after removing. KPull off 5th speed sliding gear.
A - Two-arm extractor for example Kukko 20/10 with hook Matra V/170 B - Hexagon screws M10 x 20
Mounting sequence: Set up two-arm extractor and centre by turning the screw (arrow). If necessary heat pinion with hot-air blower (e.g. V.A.G 1416) and remove with two-arm extractor.
Edition 08.02 S00.5114.60.20
------------

------------
34
------------
% % ' $ ! & ! ! # " !

OCTAVIA
The circular nut (arrow) points toward the gearbox housing.
Warm up 5th speed gear up to 100 C. Install 5th speed gear.
K-
gear
ring
K-
Before refitting the 5th sliding gear and synchroniser ring press the synchroniser ring on the cone of the sliding gear and measure clearance -a- with a feeler gauge. Fitting measure 1.1 ... 1.7 mm
Measure clearance -a-
Determining wear thickness 0.5 mm
Set up 5th speed sliding gear with needle bearing
Set 5th gear synchroniser ring on sliding gear
Assemble before installing 5th gear synchroniser body/sliding sleeve page 35-8
------------
Edition 08.02 S00.5114.60.20
2 & & & 9 8 3 F 2 8 3 8 E ( 2 F 9 8 ) W 7 7 G ' h ' e 3 0 0 ( P 3 2 g X X C & & & 9) 8662 3 F 2 8 3 8 E ( 2 F 9 W 765 7 G ' d ' e b b1H )) 2 & 6)6 @ @ 2 6 "265 a I ` V & H B 9 8 3 ( 9 8 2 8 3 W U Y C X2 X V T & & & S 2) 3' 2 2 ( 2 ( 9 2 8 2 ( ) 2 8 ) ( 1 '2 7 ' 4( & & & 8 3( 2 ( 3 F) 2 8 3 8 2 E ) F 3 3 0 ) 0 Q 7 G ' ' & R 98 8 Q& 3& B 3) ( 2 P 9 2 B ( 3 8 3 0 ) 3 'c G1 ' 7 &6 & H 2E 86) 3) 8 2 E F 3 ( 3 )) 9 E ) (2 3@ F& )f '6) '61 ' ' 6 4 77 G( A1& &)1 &c & 2& 2) 25 @R6 3 0 ( BI 30 ()11 9 811 2 )8 ))R 2 2 C 7641 D2 ' ' A ' 5) 65 %D5 16 5H 66 " " ! 5R)R 2 21 9 11) 6F A1# 14 D ' ) 6 ) $ $51 1 6 H1 '
Pay attention to the free travel of the synchroniser ring during the driving in operation. Note: The The
-----------------------
OCTAVIA
Edition 08.02 S00.5114.60.20
K K K
34
! F E E ! X F F " " E F E H E ! D I H E ! ! ! # F FE F E R h F F E F f R a HH H ! P c F " S H H !g c !S S## ! Q I I# # E # # S e ac c 9 A ( 5 A % 5 5 4 4 d #S c ! b V Y T a ` R U X T R U T P b " ' IS # " 6 ! ' ! Q 0 S S ' S R IG ' I I F D G S I E H !S P 1 B % 1 5 & % @ 8 4 9 A#P ( 5b 2I 56 5' & 6# 1 & @ 4W 8 3 & 5 & ( % 6' 1 1 2 % & 1 % ( & 4C #6 ' " !0 G ! 1 ( B & S #6 0' ) 7 ) 0 !"$ ' 0 )
------------
------------
34
K-
K-
attaching
of the dished
and
Edition 08.02 S00.5114.60.20
OCTAVIA
OCTAVIA
34
Removing and installing gearbox housing and shift mechanism
Special tools, testers and aids required Sealant AMV 188 200 03 1 - Tapered screw, 25 Nm 2 - Flange shaft with compression spring Remove and install page 39-12 Fit remaining parts page 39-5, from item 18 3 - Hexagon torque screw, 30 Nm For reverse idler shaft support Self-locking Always replace 4 - O-ring Always replace 5 - Bearing journal 6 - Bolt, 22 Nm 7 - Bolt, 22 Nm 8 - End cover 9 - Gearbox housing Servicing page 34-41 10 - Clutch housing Servicing page 34-41 11 - Hexagon bolt. 25 Nm and torque a further 90 12 - Shift mechanism 05.99 Disassembling and assembling page 34-48 13 - Shift mechanism 04.99 Disassembling and assembling page 34-46 14 - Hexagon bolt, 22 Nm
Edition 08.02 S00.5114.60.20
------------ 34-31 ------------
34
OCTAVIA
Disassembling and assembling input shaft, output shaft (drive pinion), differential and shift forks
1 - Differential Disassembling and assembling page 39-3 2 - Seals 4 pieces Always replace
3 - Output shaft Disassembling and assembling page 35-14
------------

------------
4 - Reverse shaft support Disassembling and assembling page 35-29 5 - Reverse shaft Disassembling and assembling page 35-29 6 - Input shaft Disassembling and assembling page 35-1
Edition 08.02 S00.5114.60.20
$ S $ F $ S " ` F B p " $ i S S B h 8 3 2 ' 2 6 7 I 5 e H d d S $ ` S S S ` " 8 G f % U c d1 $ S F2 S# " S T F" 'H 3" bD ) Q Q bF ' B # G 9 'T RE aH ( "C!%!( `DP `!4( YD F " Y D F 2 8@6C& 'DD (0 Q3@ '7 'I A ' A 1" $ 6!(PC 0 7D0 )!C5D WFU4 9C0CgD 5P X40 R R V H HR
0 8 Shift mechanism Disassembling and assembling page Shift Disassembling and assembling page page housing page Shift Mechanism/Housing 3 2 shaft and in bearing page 39-2 pressure
------------ 34-33 ------------
OCTAVIA
Edition 08.02 S00.5114.60.20
34
34
Mounting
housing c shaft
Gearbox mount MP 3-501
Two-arm extractor Kukko 20/10 Extractor hook Matra V/170 Drive bushing MP 3-402
(Hot-air blower e.g. V.A.G 1416)
K-
K-
Note:
Before the first gearbox mounting, the gearbox mount has to be reworked according to specified measures.
------------ 34-34 ------------
$ 2 ( 1 0 " # $ # $ % ( ( & % $& #% ! %# % "! " & % & )' & % % %
OCTAVIA
and shift the and and aids Drain gear oil, to this end unscrew oil drain plug -arrowClamp the gearbox into the assembly support.
Edition 08.02 S00.5114.60.20
OCTAVIA
34
K-
Attach additional hole in gearbox mount. A B C = 118.5 mm = 23.5 mm = 11.0 mm
K-
Remove clutch release lever and clutch release bearing page 30-9 Unscrew guide bushing page 30-9 Unscrew gearbox housing cover -arrow-. Remove 5th speed gear page 34-25
K-
Remove left flange shaft, use drift to secure against turning and unscrew conical screw -arrow-.
Edition 08.02 S00.5114.60.20
------------

------------
2 " & " & & 4 3 % " & 2 " " & 0 1 ( & # & ) % ( # & # # &( ' " # % ' # $ ###$# " % ## !
------------
------------
34
K-
K-
K-
Edition 08.02 S00.5114.60.20
OCTAVIA
$ ' $ ' ! % 1 ' ! ! 4 3 0 ! ' # ' " )$ ( '"(2 ) ' $ $ ' (( '5 %(" $ $ $ ' # ' ' $ %( ) $" # " # ! &( " ! " " ( ( ! "#
-----------------------
OCTAVIA
Edition 08.02 S00.5114.60.20
K-
K-
K-
Do not release nuts -B- for the output shaft bearing support. Note:
34
) % $ T 1 ) 3 S R R 4 3 $" $ $ B "% ' ) ' ) ) ' $ ' $ $ & 4 ( S $ ' ) ' % B3 B ' ) ' ) ) ' $ 3 ( 0" $ ) % 9 ) 0" 9 $!! F Q P E D D C G ' $ $ B $ ' ' ! " @ ' ) ' $ A B B A $ ' % @ 2 8 3 4 1 !! ! ) 7% 2& 3 6 5I 4! 3 ' ) '$ ) ) '" ! $H ! ' % $ & % (! # 9 " " $ 3 % $ " ! ! & 0 %
------------
------------
34
K-
K-
K-
Identical when removing left flange shaft page 34-35.
Note:
The Fig. only shows 3 of the 4 gasket rings.
Note:
-B-
-B-
-C-
Edition 08.02 S00.5114.60.20
-B-.
OCTAVIA
( ' I G H 7 ( ' G 5 A F ! # E # ) 7 ) ( $ # ' ! ! !7 6 0 # A 4 5 B A D C A B A ' ! ) ' ' # 0 ' 4 @ 0 0 6 0 0 9 H 0 $ #0 0 7 0 1 3 0 0 # 3 # )8 76 7 # ! # % ) ( 0 9 8 ' 3 # % 1 5 5 4@%% 2 ) ' # & % $ # ! !% ! #0 " % 0 ! % 6
T The shift segments must be positioned in the slots of the sliding sleeves. Note:
-----------------------
OCTAVIA
Edition 08.02 S00.5114.60.20
KKK
34
B A 9 ) & & ( ) ' B A 9 $ ) & & ) ' 3 4 9 @ 9 8 7 @ 9 ) 3 & 5 8 ' ' ( & ' 3 ( & 6 ) 7 & 5 " " ) $" # 3 1 ) $$ & & ) $ 4 3 1 3 $ 3$ ) 2 $$$$ $ $ & ) " & ( $ %" % 0$ &$ & ' " ($ ' " ) $ # ! $
------------
------------
34
K-
When assembling pay attention to the note on page 34-25
Note:
Edition 08.02 S00.5114.60.20
OCTAVIA
9 a T p D R T T F p y Y y T G r 8 p Y D R E ) w a F D T C p p Y Y T T D R T E 2 e W v p Y F b p I F ` 7 # ! $ ) $ T T R U # $ w 9 x T p D R D Y Y D U T F T ` Ay 8 8 X u t ) $ s g 0 ` r D I R Y U T Y p Y U D R T E T pY D8 R W w 9 x T p D R D Y Y D U T F T y ` b 8 X v D I R Y U F W # # ) u t ! ' & g 9 a T T F p y Y T p D R G4 r 8 v D I R I U F F W u $ t ! ) $ ' 0 ` b c TT pI D RU D I R I U F T Y p Y U D R T W w 95 x D Y Y D U T F T y T p D R `52 X b8 GE 8 v D I R I U F F W53iR #354@ #T dA2P2 65 )q2P3&"7 !ec u8 T t7 !T I U 'U 9 ' & gD `9 rV 8 D5436 I8 RT YW UD TU YI pW YU U D R T E Ty72 pTa DEA25 REb W53@ wP 9 9 T' U p I DW RU x3T D Y Y D U T F T y `523 D 8dW 85 V X v D5PP72 Ia R`2 Y` U@ F8 W365 #&6 #R 'e7533 dA )'` !d@ u&8 7 tY !T T E '5 U 9 ' & gF U 9 p Y T a3X T' V p5 X DD RT TW TU F9 y G4' F rX 8dT v9 D6 Ie@2 R8 Y@ F8 W""72 72P2 @ u8 $T t7 !D )R $I 'T 3P5P65 G 0T I9 F x"i72 Te8 YH pI DQ W P63P3 uA5 )@ D tC ! D s9G2 89 R 0S v1 T64 I82 TA Y8 E D U p54q2753 X@ wE v335'P334 C xB p T F y G5P' 9 v D5655 IG9 RA2 I@ U8 FF FD W2372 u"e753 t"64 !A 8 s1 gA2 0@ 925 D535" T"" p5333 D Y T T T542 p59 D9 R' G5223 r'55 8'55 9U0 Y3T43"4P55i3355P"54P3"e$ D4'3543252i& Dd'! I2q&e$ R2q&e Y5'e# U2'' T'$ Yq2 p2Pe Y32 U354P555P54P'e D R T 2' 5' XE5) X34"3i3('%"" W5'3%523e 4y3P542 4 #3352 h ! f# g
Edition 08.02 S00.5114.60.20
Sealant AMV 188 200 03
OCTAVIA
and aids
housing and
housing
2 C
housing
housing
------------ 34-41 ------------
34
34
------------
9 ( ! 8 % % ( 0 ' ) ( & ## $ 2$ $ (& 1 25 1 1 %# ( ( 8 7! % 2 ( 2 4 3 1 (2 ' 8 7" 6'
OCTAVIA
O-ring attached to guide sleeve. If damaged, replace guide sleeve With seal Remove seal Fig. 3 Insert seal Fig. 4 Remove guide sleeve in order to replace seal 20
ace For differential Remove and install page 39-3 If replaced, set differential page 39-12
20 Magnet Is held by contact surface of housing ace For differential Remove and install page 39-3 If replaced, set differential page 39-12
head Self-locking Always replace
For right flange shaft Replace page 39-1
S For right seal (item 15) Remove Fig. 7 Install Fig. 8
22 Shim For differential List of settings page 39-11 23 For left flange shaft Replace page 39-1
Without magnet
Knock out
------------
Edition 08.02 S00.5114.60.20
D 9 A A B C @ 9 A 9 9 8 B 2 0# 1 % 0 0 # # ( ! ! 50 4) 3 ( 6 ' ( # # # % # $ # # "& # # " ( ' @!7 "" ""

2 4 3 ing up to the stop stop in into guide up to the
------------ 34-43 ------------
OCTAVIA
Edition 08.02 S00.5114.60.20
K K K
34
34
------------ 34-44 ------------
# # $ " %!
OCTAVIA
off
Edition 08.02 S00.5114.60.20
OCTAVIA
Edition 08.02 S00.5114.60.20

34
8 A - Screw threaded rod MP 3-434 from assembly device into the threaded part of the differential. B - Nut M12 with washer. By turning the nut -B- insert the bushing over the pressure plate MP 3-420 up to the stop. Note: If the gearbox is disassembled press the bushing with pressure plate MP 3-420 up to the stop.
-----------------------
34
Disassembling and assembling shift mechanism at
Thrust washer MP 3-455 Guide piece MP 3-454 Thrust plate MP 3-407
Pressure die MP 3-448
Internal extractor Kukko 21/3 Fitting tool MP 1-212 Shift shaft
------------
# 2 5 & W ) % F! # 3 2 # " E1 I1 R V U G H 0 & T 0 1 3 2 $ & A 0 1 # 9 8 0 @ # # & 6 S 0 ! % F! ( 6 E E 0 0 & 5 !1 1 & 01 "5" 5" 12 # $! C$ &14 & "1 Q! 413 R 0# 71 !1 & 0 51 0 0 1 P I 0 # 9 H & " G 9 F'"! (1&"! 2% 2$ ## 3 C# & A$ 6( "1 E) B$" D! @ # 9 8 ! # ! 5! & 6 4 7 1 %1 & 1 1 " "
OCTAVIA
side
Lug points toward Brush the nose lightly with MoS 2 grease Self-locking Always replace
With reversing light
a For gearbox ventilation
S Insert as stop
and aids
Insert so that interrupted tooth spacing matches the shift shaft Can be replaced with shift mechanism Installation position page 34-4
3 Relay Installation position page 34-4 4
With shaft for mounting relay lever Installation position page 34-4 Press into follower
O Fit onto shaft of follower Press into relay lever
2 3
Remove Fig. 1 Insert Fig. 2
4 Seal Use screwdriver to lever out Install Fig. 3
20
------------
Edition 08.02 S00.5114.60.20
OCTAVIA
Disassembling and assembling shift mechanism at gearbox side 05.99

1 - Shift shaft Ensure correctly assigned Parts List 2 - Stop ring 3 - Conical sleeve Removing Fig. 1 Inserting Fig. 2 4 - Shift cover With interference-fit sleeve for lock Ensure correctly assigned Parts List 5 - Relay lever Fitting location page 34-14.10 6 - Bearing bush 7 - Seal Use screwdriver to lever out Installing Fig. 3 8 - Cap For gearbox breather 9 - 20 Nm Special tools, testers and aids required Thrust disc MP 3-456 Guide piece MP 3-454 Thrust plate MP 3-406 Thrust plunger MP 3-448 Internal extractor Kukko 21/3 Insertion tool MP 1-212 10 - Gearbox shift lever Insert so that interrupted tooth spacing matches shift shaft Fitting location page 34-14.10 11 - Lock washer 12 - 15 Nm Secures shift shaft Take out before removing shift shaft 13 - Reve rsing light switch, 20 Nm 20 Nm Apply a thin film of MoS 2 grease (Molykote) to lug 14 - End cover
34
Edition 11.00 S00.5114.59.20
------------ 34-46.1 ------------
' $ # & " (! (! % 4 9x3 2 0 ) 1 ' @ 0 8 u 4 @ 8A 9 @ @y5 v w A t t s E W C V W Q Q E H R C h r p i b b e d W H T E C W Q W C R W c ` b B YA EC CV ag CII TG C C X W C T G V H Fq E R T Q H G C E SC `r U 8 4 S FSPID V5 AdS 8SFIIP PYF FF IS S 9S @A@ 8 W 7 @ T Yi 6 AId f 5 I d
------------
------------
18.5 ...
S00.5114.57.20
OCTAVIA
d d X c Y Y W à aa b X a Y V A A U U S P Q G $ ' 1 " $ 5 " @ $ 0 H S Q P I I C B A " $ " 7 0 5 " 1 5 & 5G " 6 8 4 3 ! "a " " 7 6 ' $ 1 0 ' & " $ " " $@ "B 9@ 66 5 " % 2 2T 3" 8 4 3 D R(2%) F2( 5 (2(%)2 # 2B (%B B2() 2( (% E % %
3 2 s into
-----------------------
OCTAVIA
Edition 08.02 S00.5114.60.20
K K K
34
34
Disassembling and assembling shift mechanism at
Thrust disc MP 3-456
Guide piece MP 3-454 Thrust plate MP 3-406
Thrust plunger MP 3-448
Internal extractor Kukko 21/3 Insertion tool MP 1-212
------------
T # 0 3 ) E& % H& S 1 $ 1 0 $ 3 " G" 4 F 4 8 6 G Q S $ # & 4 R I ! 3 # $ P & & " 4 B 5 ! E H ) G F D 2 C A 1 0 & ( $ & 4 B @ 3 9 & 6 8 # ! 3 & & 4 2# 0 # (% 3' 7& $ $ 1"! 0$" #$ &# &"! 5 " " ! ! !
OCTAVIA
side
1 - Shift shaft Ensure correctly assigned Parts List 2-
3-
Removing Fig. 1 Inserting Fig. 2
4-
With interference-fit sleeve for lock Ensure correctly assigned Parts List Fitting location page 34-14.10
- Seal Use screwdriver to lever out Installing Fig. 3
8- a For gearbox breather Self-locking Always replace
and aids
10 -
Insert so that interrupted tooth spacing matches shift shaft Fitting location page 34-14.10
11 -
12 - 1 m Secures shift shaft Take out before removing shift shaft 13 -
Apply a thin film of MoS 2 grease (Molykote) to lug
14 -
------------
Edition 08.02 S00.5114.60.20
d d X c a Y Y W à aa b X Y V A A U U R I S $ ' 1 " $ 5 " @ $ 0 G R P I H H C Q B A " $ " 7 0 5 " 1 5 5 5 " 6( 8 4a 3 ! "((2 " " 7 6 ' $ 1 0 ' & " $ " " $@ " 9@ 6P 5 " %T 2" 2 3F 8(2(2 4 3 %2(#( 2 6 & % % %E B%) %)2 BB 2B () D B
3 2 s . into
-----------------------
OCTAVIA
Edition 08.02 S00.5114.60.20
K K K
34
34
Disassembling and assembling shift
Pressure plate MP 3-407 Driver MP 3-423
Pressure spindle MP 3-448 Pressure plate MP 3-453 Thrust washer MP 3-455
------------
& ! ' & % # " ! ! ! $

OCTAVIA
and aids
Pressure lever MP 8-506
Distance sleeve MP 3-458
Shift segment Identification Fig. 1 It must still be possible to rotate the segment freely once the circlip has been fitted. Lift off with e.g. pressure lever MP 8-506 Replace Fig. 2 Always replace
------------
Edition 08.02 S00.5114.60.20
OCTAVIA
34
Edition 08.02 S00.5114.60.20
! ' ) $ 6 5 % " 4 3! " " " & 2# )( " 3 3 1 " "0
3 Setting page 34-30 4 Press out Fig. 3 Press in Fig. 4 shift 0 a With shift segment Fig. 5 2 8 Shift segment Identification Fig. 1 It must still be possible to rotate the segment freely once the circlip has been fitted With shift segment Fig. 5 3 Shift segment Identification Fig. 1 It must still be possible to rotate the segment freely once the circlip has been fitted,
-----------------------
D T U F G F X q p a a T F T V g F G P V F P F V U I I i h e c aEQ V F ` F F I I TEH XW VF Td VG FHQfd PbrH F V U U S I IP W I QF A E 9 bGR uA a' aU iX sP hI b` u aHw a' a Vw FH ` F G U F ` G xW yE s I I W Y bF ui aD aI vV hU hX i i t bF uP aG av ii sI hHE i t i aH VG FG `RQHQHR FQEQ GYQRE U F#H `H GE V V U E HG H IHQY W s W h h Y ) %B % C A E " !H 7 )d '2 "H @d 9 & ! % % ) ) " b 6' $ 0 # !" ## ! 8 % ( 1 d $ 5H $ 4 B3 #b
4 S
------------
------------
34
It must still be possible to rotate the shift segment freely once the circlip has been fitted.
Notes:
20
Shift segment identification
Edition 08.02 S00.5114.60.20
OCTAVIA
OCTAVIA
Edition 08.02 S00.5114.60.20
E 9 D 7 @ 9 5 7A 68B C ( $ ) 4 ! #0 '1 &"" (" 3 (3 ) ' $ % 8 00 &8 ! ! & & " ) &12
34
3 inner race bearing Note: Do not 4 ress inner race bearing to Shift fitted shift segments 1st and 2nd gear shift fork 08.00 08.00 Dimension -a- (mm) 87.2..87.9 88.4..89.1 96.0.96.7 3rd and 4th gear shift fork Assignment of shift segment Fig. 1
-----------------------
OCTAVIA
Gears/Shafts
35
Disassembling and assembling input shaft
Special tools, testers and aids required Thrust plate MP 3-406 Plunger MP 3-408 Thrust piece MP 3-411 Thrust washer MP 3-413
Driver MP 3-423 Plunger MP 3-448 Pipe section MP 3-451 Thrust washer MP 3-455 Thrust washer MP 3-456 Pipe section MP 3-4013
Edition 10.96 S00.5114.51.20
------------ 35-1 ------------
35
Gears/Shafts
OCTAVIA
Notes: Pay attention to technical data when installing new gears page 00-2. If the position of the taper roller bearings is affected as a result of replacing parts, it is then necessary to re-set the input shaft. List of settings page 39-11 1 - Clutch housing 2 - Taper roller bearing outer race Remove Fig 1 Insert Fig. 2
3 - Taper roller bearing inner race Remove Fig. 14 Insert Fig. 3 4 - Input shaft Setting page 35-9 5 - 3 rd speed gear Shoulder points toward 4th gear Press off Fig. 5 Press on Fig. 6 6 - Circlip Always replace
------------ 35-2 ------------
Edition 08.02 S00.5114.60.20
OCTAVIA
7 - 4th speed gear Press off with taper roller bearing outer race and sleeve Fig. 4 Press on Fig. 7 Collar points toward 3rd gear 8 - Taper roller bearing inner race Press off with 4th speed gear and sleeve Fig. 4 Press on Fig. 8 9 - Thrust washer Dimensions 29.2x49x2.5 10 - Taper roller bearing outer race Press out Fig. 10 Press in Fig. 11 11 - Shim Determining thickness Setting input shaft, page 35-9 12 - Gearbox housing 13 - Sleeve For needle bearing Press off together with 4th speed gear and taper roller bearing inner race Fig. 4 Press on Fig. 9 Fit on thrust washer (item 9) before installing Dimensions 29x35x24.1
Gears/Shafts 14 - Needle bearing Dimensions 35x40x23.8 15 - 5th gear sliding gear Pull off 5th speed synchroniser body page 34-25 16 - 5th speed synchroniser ring With cast locking pieces page 34-29, Fig. N35-0018 Inspect for wear page 34-28 17 - Spring Fitting location Fig. 14 18 - Locking pieces (3x) Fitting location Fig. 12 19 - 5th speed synchroniser body Remove and install page 34-25 20 - 5th speed sliding sleeve Remove and install page 34-25 21 - Dished washer Fitting location page 34-30 22 - 80 Nm Holds dished washer in position with fit piece at bolt head page 34-30
35
K Fig. 1
Press out taper roller bearing outer race
Edition 08.02 S00.5114.60.20
------------ 35-3 ------------
35
Gears/Shafts
OCTAVIA
K Fig. 2
Inserting outer race of taper roller bearing
K Fig. 3
Pressing on inner race of taper roller bearing
K Fig. 4
Pressing off 4th speed gearwheel with taper roller bearing and sleeve
------------

------------
Edition 10.96 S00.5114.51.20
OCTAVIA
Gears/Shafts
35
K Fig. 5
Pressing off 3rd speed gearwheel
K Fig. 6
Pressing on 3rd speed gearwheel
K Fig. 7
Pressing on 4th speed gearwheel
Shoulder faces toward 3rd gear.
Edition 10.96 S00.5114.51.20
------------ 35-5 ------------
35
Gears/Shafts
OCTAVIA
K Fig. 8
Pressing on inner race of taper roller bearing
K Fig. 9
Pressing on sleeve for needle bearing
K Fig. 10
Removing outer race of taper roller bearing
------------

------------
Edition 10.96 S00.5114.51.20
OCTAVIA
Gears/Shafts
35
K Fig. 11 -
Press in taper roller bearing outer race
Replace shim after setting input shaft.
K Fig. 12
1 - Springs for locking pieces
5th speed synchroniser
2 - Sliding sleeve with 3 recesses (arrow A) for the locking pieces (item 4) 3 - Synchroniser body 4 - Locking pieces Fitting location: The leg (arrows B) points to the sharp teeth of the sliding sleeve (item 2).
K Fig. 13
Press off taper roller bearing inner race
A - Separating device, e.g. Kukko 17/1
Edition 08.02 S00.5114.60.20
------------ 35-7 ------------
% ' 6 1 % % ' ' ' ' & "$ " " ' 1 ' ( % ' "$ " 1 % ' & # ! D % & 9 5 4 @ & & ' 3 5 4 3 6 % % ' " 1 % ' 2 ' ' & 1$ ! ' A & $ 3 " 1 ' & ' ! ') " 1 1 &7 ' ' ' ' 1 '$ & $ ) # ! ) % ' 3 $ & ' ' 0 6 2 " 1 ) &$ ' & ! )' " " % & ' 5 4A 8 9$ @ & ' " % ' & 3 5 4 ) ' & & 32 57 4$ 6 1 ' 0 &C & " " 0 ! & $ $ ( 2 %B 2$$ '$" & ) ' $ $ & # ! ) 6 $ " " " $ ) $7 7
------------
------------
35
Gears/Shafts
K Springs for 5th gear synchroniser body 05.01
K Fig. 14
Assemble 5th gear sliding sleeve with synchroniser body
Edition 08.02 S00.5114.60.20
OCTAVIA
OCTAVIA
Gears/Shafts
35
Setting input shaft

(Determining shim for input shaft) Special tools, testers and aids required Gauge block MP 3-405/17 Thrust washer MP 3-413 Clamp MP 3-416 Plunger MP 3-423 Universal dial gauge holder MP 3-447 Thrust washer MP 3-456 Gearbox holder MP 3-501 Commercially available torque gauge It is necessary to re-set the input shaft if gearbox housing clutch housing input shaft 4th speed gear or the taper roller bearings are replaced. List of settings page 39-11 Press outer race of taper roller bearing into clutch housing as far as stop page 35-4 Fig. 2. Use MP 3-413 to press outer race of taper roller bearing into gearbox housing as far as the stop without shim.
K-
Edition 10.96 S00.5114.51.20
------------

------------
35
Gears/Shafts
OCTAVIA
Place input shaft into the clutch housing and fit on gearbox housing. Tighten hexagon bolts to 25 Nm and torque a further 90. Install measuring device and dial gauge in clutch housing. Before carrying out measurement, rotate input shaft several times so that the taper roller bearings settle. Zero dial gauge with a preload of 1 mm.
K-
Note: This procedure should be repeated for each additional measurement for the dial gauge moves back into the initial position (0 position) without once again turning in the bearings.
Press input shaft in direction of dial gauge (direction of arrow). Read off play on dial gauge and note (example 1.21).
Note: Dial gauge does not move back into initial position.
Determine thickness of shim from table page 35-11 (example 1.175). Remove input shaft and use MP 3-456 to press outer race of taper roller bearing out of gearbox housing. Use MP 3-413 to press outer race of taper roller bearing into gearbox housing together with 1.175 shim. Fit on gearbox housing and tighten hexagon bolt to 25 Nm and torque a further 90.
------------

------------
Edition 10.96 S00.5114.51.20
OCTAVIA
Gears/Shafts
35
Table of shims
Bearing play Measurement obtained (mm) 0.671 ... 0.699 0.700 ... 0.724 0.725 ... 0.749 0.750 ... 0.744 0.775 ... 0.799 0.800 ... 0.824 0.825 ... 0.849 0.850 ... 0.874 0.875 ... 0.899 0.900 ... 0.924 0.925 ... 0.949 0.950 ... 0.974 0.975 ... 0.999 1.000 ... 1.024 1.025 ... 1.049 1.050 ... 1.074 1.075 ... 1.099 1.100 ... 1.124 1.125 ... 1.149 1.150 ... 1.174 1.175 ... 1.199 1.200 ... 1.224 1.225 ... 1.249 1.250 ... 1.274 1.275 ... 1.229 1.300 ... 1.324 1.325 ... 1.349 1.350 ... 1.374 1.375 ... 1.399 1.400 ... 1.424 1.425 ... 1.449 1.450 ... 1.474 1.475 ... 1.499 1.500 ... 1.524 Thickness (mm) 0.650 0.675 0.700 0.725 0.750 0.775 0.800 0.825 0.850 0.875 0.900 0.925 0.950 0.975 1.000 1.025 1.050 1.075 1.100 1.125 1.150 1.175 1.200 1.225 1.250 1.275 1.300 1.325 1.350 1.375 1.400 1.425 1.450 1.475 Shim Part No. 02A 311 140 02A 311 140 A 02A 311 140 B 02A 311 140 C 02A 311 140 D 02A 311 140 E 02A 311 140 F 02A 311 140 G 02A 311 140 H 02A 311 140 J 02A 311 140 K 02A 311 140 L 02A 311 140 M 02A 311 140 N 02A 311 140 P 02A 311 140 Q 02A 311 140 R 02A 311 140 S 02A 311 140 T 02A 311 140 AA 02A 311 140 AB 02A 311 140 AC 02A 311 140 AD 02A 311 140 AE 02A 311 140 AF 02A 311 140 AG 02A 311 140 02A 311 140 02A 311 140 02A 311 140 A 02A 311 140 A 02A 311 140 A 02A 311 140 A 02A 311 140 B 02A 311 140 B 02A 311 140 B
02A 311 140 B 02A 311 140 C 02A 311 140 C 02A 311 140 C 02A 311 140 C 02A 311 140 D
Edition 10.96 S00.5114.51.20
------------

------------
35
Gears/Shafts
OCTAVIA
Bearing play Measurement obtained (mm) 1.525 ... 1.549 1.550 ... 1.574 1.575 ... 1.599 1.600 ... 1.624 1.625 ... 1.649 1.650 ... 1.674 1.675 ... 1.699 1.700 ... 1.724 1.725 ... 1.749 1.750 ... 1.774 1.775 ... 1.791 Thickness (mm) 1.500 1.525 1.550 1.575 1.600 1.625 1.650 1.675 1.700 1.725 1.750
Shim Part No. 02A 311 140 D 02A 311 140 D 02A 311 140 D 02A 311 140 E 02A 311 140 E 02A 311 140 E 02A 311 140 E 02A 311 140 F 02A 311 140 F 02A 311 140 F 02A 311 140 F 02A 311 140 G 02A 311 140 G 02A 311 140 G 02A 311 140 G 02A 311 140 H 02A 311 140 H 02A 311 140 H 02A 311 140 H 02A 311 140 J 02A 311 140 J 02A 311 140 J
Carrying out a check measurement

KInstall measuring device and dial gauge. Rotate input shaft several times so that the taper roller bearings settle. Press input shaft in direction of arrow. The bearing play should be min. 0.01 ... max. 0.09 mm.
------------

Note:
------------
If no bearing play can be measured, but the input shaft has perceptible rock and can be easily rotated, the setting is also correct.
Edition 10.96 S00.5114.51.20
OCTAVIA
Gears/Shafts
35
K-
Max. friction torque 20 Ncm.
Edition 09.98 S00.5114.56.20
------------ 35-13 ------------
Disassembling and assembling output shaft (pinion shaft)
35
Gears/Shafts
OCTAVIA
16 15 14 12 11 10 9 8 7 6 5 4 3 24 23 22 21 20 19 18 17
13 28 27 26 25 40 39 38 37 36
35 34 33 32 31 30 29
S350202
Hook Kukko 1-250 Countersupport Kukko 22/2 Separating device Kukko 17/2 Internal extractor Kukko 21/6 Thrust plunger MP 3-448 Thrust plunger MP 3-449
2 1
Special tools, testers and aids required Thrust plate MP 3-407 Thrust plunger MP 3-408 Thrust piece MP 3-411 Thrust plunger MP 3-423 Two-legged puller Kukko 20/10
------------ 35-14 ------------
Edition 11.00 S00.5114.59.20
OCTAVIA
Mounting rails MP 3-457 Thrust disc MP 3-460
Tube section MP 3-461
Insertion tool MP 3-466 V.A.G 1582
V.A.G 1582/5
Tube section MP 3-450 Thrust ring MP 3-452
Thrust disc MP 3-455 Notes:
Removing and installing output shaft page 34-34 Always replace both taper roller bearings together
Pay attention to the technical data page 00-2 when installing new gears or a new output shaft assignment Parts List.
Since 08.00 the gearboxes have been manufactured with a modified synchromesh for 1st gear 25 4 nuts for mounting bearing
Edition 08.02 S00.5114.60.20
1 ) # # # ' ' ( "0 ( )" ! 1 & )# & ! ! & ( ( ( 5$ " % 4 ( ' ) ) ! ! 3 $ # " % $ ' ( ) 2
Gears/Shafts
35
With large taper roller bearing outer race and bolts Replace outer only together with large taper roller bearing and bearing mount
Shoulder of thrust washer points toward taper roller bearing speed sliding gear
bearing For 1st gear Dimensions 38x43x25
gear snychroniser ring For gearbox 08.00 Inspect for wear Fig. 9 Marking Fig. 14
gear inner race For gearbox 08.00 Inspect for wear Fig. 16 Inspect lugs for wear Fitting location Fig. 29
gear race For gearbox 08.00 Place onto inner race (item 14), fitting location Fig. 29 Replace if scores or signs of wear present gear synchroniser ring For gearbox 08.00 Marking Fig. 30 Inspect for wear Fig. 17 Fitting location Fig. 29
Determining thickness page 35-26, Setting output shaft race
taper roller bearing Remove Fig. 1 Press on Fig. 2
taper roller bearing inner race Pull off Fig. 3 Press on Fig. 4
shaft Is matched to final drive gear, always replace together Setting page 35-26
and 2nd gear sliding sleeve with synchroniser body Pull off over bearing mount after removing circlip (item 18) Fig. 6 Disassemble Fig. 10 Assemble sliding sleeve with synchroniser body Fig. 10 and Fig. 11 Fitting location 08.00 Fig. 12 Fitting location 08.00 Fig. 31 Press on Fig. 13
7 Large taper roller bearing inner race Pull off Fig. 7 Press on Fig. 8
8 Seal Place seals (4 in total) onto the bolts of the bearing mount
2nd gear synchroniser ring Marking 08.00 Fig. 14 Marking 08.00 Fig. 30 Inspect for wear Fig. 17 Insert so that recesses engage in the locking pieces of the sliding sleeve (item 17)
------------
------------
35
Gears/Shafts
OCTAVIA
20 - 2nd gear outer race Insert into synchroniser ring (item 19) fitting location Fig. 18 Replace if scores or signs of wear are present 21 - 2nd gear inner race Inspect for wear Fig. 16 Inspect lugs for wear Fitting location Fig. 19 22 - 2nd speed sliding gear Fitting location Fig. 20
23 - Needle bearing For 2nd gear Dimensions 35 x 40 x 23.8 24 - Thrust washer Dimensions 30.8 x 52 x 3,5 25 - Sleeve for needle bearing of 3rd gear Press off together with 2nd speed sliding gear Fig. 5 Press on Fig. 21 Dimensions 30.6 x 35 x 25.85 26 - Needle bearing For 3rd gear Dimensions 35 x 39.6 x 25.5
Edition 08.02 S00.5114.60.20
------------ 35-14.2 ------------
OCTAVIA
2
28 3rd Inspect for wear Fig. 9 2 3rd and
30
32
Edition 08.02 S00.5114.60.20
0 6 7 ' " 0 0 %" 9 ! 6 ( 5 4 $ 3 8 # ! ' " # & 0 2 1" % ! % " & $ ( % ! $ 0 ( " ) ! % " #
Gears/Shafts 33
35
3rd s
th
Dimensions 29.2 x 49 x 2.5 For output shaft Removing and installing page 34-42
35
Press off together with 2nd speed sliding gear (item 22) and 3rd speed sliding gear (item 27) Fig. 5 Disassemble Fig. 23 Fitting location of sliding sleeve with synchroniser body Fig. 25 Assemble sliding sleeve with synchroniser body Fig. 23 and Fig. 24 Press on Fig. 26
36
For needle bearing of output shaft Press off Fig. 5 Press on Fig. 28 Dimensions 29 x 34 x 18.15
For needle bearing Press off together with 3rd and 4th gear sliding sleeve and synchroniser body (item 29) Fig. 5 Press on Fig. 27 Dimensions 29 x 35 x 24.1
38 5th Remove and install Fig. 34-25 ished Fitting location page 34-30
For 4th gear Dimension 35 x 40 x 23.8 Inspect for wear Fig. 9
Holds dished washer
A - Internal extractor 37 46 mm, e.g. Kukko 21/6 B - Counter support, e.g. Kukko 22/2
------------
------------
35
Gears/Shafts
OCTAVIA
K Fig. 2
Pressing in small taper roller bearing outer race
K Fig. 3
Pulling off small taper roller bearing inner race
A - Vice/soft protector jaws Position grip behind the rollers of the bearing and pull off inner race.
K Fig. 4
Pressing on small taper roller bearing inner race
------------ 35-16 ------------
Edition 11.00 S00.5114.59.20
OCTAVIA
Gears/Shafts
35
K Fig. 5
Pressing off 2nd, 3rd and 4th speed synchroniser body, sliding sleeve, sliding gear together with sleeve for needle bearing
A - Separating device 22...115 mm, e.g. Kukko 17/2 B - M10 x 20 bolt Position separating device below 2nd speed sliding gear (item 22) and press off.
Note: Support the separating device in such a way that 1st and 2nd gear sliding sleeve is not pulled off at the same time.
K Fig. 6
Pulling off sliding sleeve with synchroniser body over bearing mount
A - M10 x 20 bolt Remove circlip (item 18 page 35-14.1). Pull off together with 1st speed sliding gear and 1st and 2nd gear sliding sleeve with synchroniser body.
K Fig. 7
Pulling off large taper roller bearing inner race
A - Soft protective jaws Insert M10 x 20 bolt into the hole of the output shaft before fitting on the pulling device.
Edition 11.00 S00.5114.59.20
------------ 35-17 ------------
# 0 " 4 d # # 0 ` Y W d # c c ) 1 b ' 1 a Y U U T S # 0 " # " 4 V ` 0 X " " U U U S V 5 R F8 D I B F 7 B D P I D 7 F D D D E G C B G A Q 8W 8 A " " " 2 ( " 1 ( g 0 ) (i h f e U U U # # #E # # c q ' ' p # # Y W % 9 # 7 T Y $ "W G 7 & ! 3@@9 ' H 6 " @ 7 4 d d
------------
35
------------
Gears/Shafts
K Fig. 10
K Fig. 9
K Fig. 8
A -
Inspecting synchroniser ring of 1st gear 08.00, of 3rd and 4th gear for wear
Pressing on large taper roller bearing inner race
Disassembling and assembling 1st and 2nd gear sliding sleeve and synchroniser body
Edition 11.00 S00.5114.59.20
OCTAVIA
OCTAVIA
Gears/Shafts
35
K Fig. 11
Assembling 1st and 2nd gear sliding sleeve and synchroniser body
l Sliding sleeve has been pushed over synchroniser body. Insert locking pieces and install springs offset 120. The angled end of the springs must engage in the recesses in the locking piece.
K Fig. 12
Fitting location of 1st and 2nd sliding sleeve and synchroniser body 08.00
The teeth on the sliding sleeve (arrow 1) point toward the splines for 3rd and 4th gear synchroniser body -A-. The wide shoulder of the synchroniser body (arrow 2) then points toward 1st gear -B-.
K Fig. 13 Note:
Pressing on 1st and 2nd gear sliding sleeve and synchroniser body
Place 1st gear synchroniser ring onto 1st speed sliding gear before pressing on.
Edition 11.00 S00.5114.59.20
------------ 35-19 ------------
35
Gears/Shafts
OCTAVIA
K Fig. 14
Marking of 1st and 2nd gear synchroniser rings 08.00
1st gear synchroniser ring - 3 halfway up the flattened tooth (arrow) 2nd gear synchroniser ring - 3 or 2 halfway up flattened tooth (arrow) Only the synchroniser ring with 2 half-flattened teeth is available as a replacement part for 2nd gear.
K Fig. 15
Distinguishing synchroniser rings for 1st gear and 2nd gear
Gearbox 08.00 Synchroniser ring for 1st gear - has no recess Synchroniser ring for 2nd gear - has three recesses (arrows) Gearbox 08.00 Synchroniser rings for 1st and 2nd gear are identical; marking page 35-25, Fig. 30
K Fig. 16 -
Inspecting inner race for 1st gear and 2nd gear for wear
Press inner race onto the taper of the sliding gear and measure size of gap a with a feeler gauge. Installed dimension Wear limit 0.3 mm
------------

------------
Dimension -a-
0.75...1.25 mm
Edition 11.00 S00.5114.59.20
OCTAVIA
Gears/Shafts
K Fig. -
Press synchroniser ring (outer race and inner race) onto the taper of the sliding gear and measure size of gap a with a feeler gauge. Installed dimension Wear limit 0.5 mm
Dimension -a-
K Fig.
The lugs (arrows) point toward 1st gear -A-.
K Fig.
The lugs (arrow 1) engage in the recesses (arrow 2) of the synchroniser ring -B-.
Edition 11.00 S00.5114.59.20
# % $ ' & ! ! "

35
gear for inner for 1st gear and 2nd 1.2...1.8 mm Fitting of inner
-----------------------
35
------------
& & $ % " # !

Gears/Shafts
OCTAVIA
K Fig. 0
Fitting ing gear
of
The higher shoulder -A- points toward 1st gear -B-. The recesses in the shoulder (arrows) engage in the lugs of the outer race (arrow Fig. 18).
K Fig. 1
Fitting on ing on
and for 3rd gear
Fit on needle bearing, 3rd speed sliding gear and synchroniser ring.
K Fig.
3rd gear
of
ring for
Marking: 3 x 1 teeth missing in each case -arrows-.
------------
Edition 11.00 S00.5114.59.20
I d Q 5 ) d R Q 2 ( 2 % 6 2 & Q 5 ) 5 & 5 9 E A b A A ! " ! ! a I 5 5 % ) ( 3 2 5 3 ( 5 5 6 5 6 5 6 3 ( 5 ) 9 4 9 RQ G9 )& 65 (& % 6 5 2 6 ( 5 5 ) ( Q 5 & H 9 A A Y 9 W #H 2Hc7 )e& (H' % 6 Q ( 6 ( Q 6 5 5 % 6 ) ( 3 & 2 A 7 7 #D 2` (( 5 3 2 8 6 5 D G % ( 5 6 5 &' Q 5 & 6 5 5 9 A 9 @ 9 $ !( "Q ) 5 T S 4 @ 2 R G 5 6 5 5 ) D ( 6 Q ( 6 55 (( 28 2'6 %H 5 6'H HA A A A5 @ 5V ('5 2% 6) (CC 3 Q 8 6 &0 &@ 5 5 % 6 ) 3 ( 2 2 3 5 9H '5 P 4 2 A @ 52 (( 2A 6Q (7' 5& 3'H 86 6C 5 2 5 &A 5 D 5 D ) &6 ( 6 6 & G 9HX 9 A '3 F 9 2I 8' 5 ( 2 6 ( 3 ACHH @' $ 9 E 5& 5'H 5'# ) D ( 6 A B $CU 28 85 5% (3 26 66 (I 2 3 8 5 6 5 % 6 ) &6 ( 3 2 & A3' @2 9& 1 4 '6 ) ( % $C''C ! " '5 6 HC'I 'C# 7&' &I & C'C'''# 8 CHC'C' 0 &&H # '# ''# 7 ' 6 2 8
1 Fitting ing gear and synchroniser 3rd and gear and synchroniser and of 3rd and gear and synchroniser
------------
OCTAVIA
Edition 11.00 S00.5114.59.20
Gears/Shafts
K Fig.
K Fig.
K Fig.
3rd and
------------
35
G H G IT E DQ R F S P @ 1E $!) % % 8 3 3 % ) B % # % C ) 3 A 3 0 &% & 6 7 !'1 6 6 ) % 1 1 $ % % 8 3 & & 6 $# )E 17 $0 % $ #9 3 $ 5 4 3 % 00 0 % % $ 0 1 $ ) % &$ 6 & ( !'9 F " 0 !" 5 3' "20" '"! ! ! ! 0
------------
35
------------
Gears/Shafts
K Fig.
K Fig.
K Fig.
roniser
on 3rd and and
on
on
for
for
gear synch-
gear
Edition 11.00 S00.5114.59.20
OCTAVIA
OCTAVIA
Gears/Shafts
35
K Fig. 29
Fitting location of outer race, inner race and synchroniser ring of 1st gear
Place inner race -A- onto 1st speed sliding gear.
The angled shoulders -arrow 1- point toward the outer race -B-. Fit on outer race -B-.
The shoulders -arrows 2- engage in the recesses -arrows 3- of the sliding gear. Fit on synchroniser ring -C-.
The recesses -arrows 4- engage in the shoulders -arrows 1- of the inner race -A-.
K Fig. 30
Marking of synchroniser rings of 1st and 2nd gear 08.00
Marking: 3 x 2 teeth missing in each case -arrows-
K Fig. 31
Fitting location of 1st and 2nd gear sliding sleeve and synchroniser body 08.00
Chamfered edge -arrow A- and outer teeth of sliding sleeve -arrows B- point toward 2nd speed sliding gear.
Edition 11.00 S00.5114.59.20
------------ 35-25 ------------
35
Gears/Shafts
OCTAVIA
Setting output shaft

(Determining shim for output shaft) Special tools, testers and aids required End gauge MP 3-405/17 Universal dial gauge holder MP 3-447 Commercially available torque gauge Threaded piece MP 3-4004/2 Resetting output shaft is necessary if drive pinion and crown wheel clutch housing or taper roller bearing have been replaced. List of settings page 39-11 Notes: New taper roller bearings for output shaft are low-friction types. For this reason, the friction torque can only be used to a limited extent and a reference. It is only possible to correctly set the bearing preload by determining the thickness of the shim.
Do not additionally treat new taper roller bearings with gearbox oil for measuring friction torque. The bearings have already been factory-treated with a special oil for this purpose. -
Press small taper roller bearing outer race together with a 0.65 mm thick shim into the clutch housing as far as the stop page 35-16. Insert output shaft and tighten nuts for mounting bearing to 25 Nm and torque a further 90. Insert dial gauge (3 mm range) and set to O with a preload of 1 mm. Move output shaft up and down, read off play on dial gauge and note (example: 0.30 mm).
------------

K------------
Edition 09.98 S00.5114.56.20
OCTAVIA
Gears/Shafts
35
Note: Do not rotate the output shaft during the measurement otherwise the bearings will settle and falsify the result of the measurement.
Determining shim The specified bearing preload is achieved if a constant value for compression (0.20 mm) is added to the measurement obtained (0.30 mm) and to the thickness of shim inserted (0.65 mm). Example: Shim inserted + Measurement + Compression (constant value) Thickness of shim 0.65 mm 0.30 mm 0.20 mm 1.15 mm
Remove output shaft and take out outer race for small taper roller bearing page 35-16.
The following sizes of shims are available: Thickness (mm) 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 Part No. 020 311 391 P 020 311 391 Q 020 311 391 020 311 391 A 020 311 391 B 020 311 391 C 020 311 391 D 020 311 391 E 020 311 391 F 020 311 391 G 020 311 391 H 020 311 391 J 020 311 391 K 020 311 391 L
020 311 391 M 020 311 391 N
Different tolerances make it possible to exactly gauge the required thickness of shim.
Edition 10.96 S00.5114.51.20
------------

------------
1 # v 2 # 1 # ! 2 1 x 2 y ) 2 ! w # " 2 " " t ! V ` f T I" P R Q R S S c H H V r P T" b h T I b T c" I I G s H q X) Y Q T I S c f T Y H V0 VP rI T q H i I I Y S S I h X Y T Q T h h H0 H p H V Y P bWQ T P I R I c h g H f I e S H P II Q d I I Q S c" Y P H V Y X I S S H)%% T QG% R Q% S P I G G G HP H% Uab Fv) E)) D 7v) 4 D A 4 8 6 4 8 C 2 b " 1u # % d "U P 0 " ) GG) G% G b " # %c aW` ` GG ' ! $ "BG #Ga " G( I3 WW &W 5 GWc W@`W S W9@G %WW%@ G aG Gaa 9 c ac 7 " aC c 9WG WG
------------
------------
35
Gears/Shafts
KA-
Do not treat new taper roller bearings gear oil for friction bearings are a special oil for
Notes:
New taper roller bearings for are a low-friction For reason, it is possible to friction as certain restrictions. a reference setting of bearing is possible of t
130 ... 180
M 10
25
35-16)
30
35-14,
90.
1.15
Edition 09.98 S00.5114.56.20
37,
OCTAVIA
OCTAVIA
Gears/Shafts
35
Disassembling and assembling reverse idler shaft
Special tools, testers and aids required Thrust plate MP 3-406 Thrust piece MP 3-411 Plunger MP 3-423 Locking device Kukko 22/1 Internal extractor Kukko 21/2 Plunger MP 3-448 Plunger MP 3-449 Thrust washer MP 3-455 Centering drift MP 3-463 1 - Clutch housing 2 - Needle sleeve Removing Fig. 1 Inserting Fig. 2 Always replace after removing 3 - Reverse idler gear 4 - Circlip Always replace after removing 5 - Reverse selector gear Take off circlip before replacing Shoulder faces toward reverse gear 6 - Reverse idler shaft Removing page 34-29 7 - Needle sleeve Removing Fig. 3 Inserting Fig. 4 Always replace after removing 8 - Reverse idler shaft support Removing and installing page 34-29
Edition 10.96 S00.5114.51.20
------------

------------
35
Gears/Shafts
OCTAVIA
K Fig. 1
Removing needle sleeve from clutch housing
A - Locking device, e.g. Kukko 22/1 B - Internal extractor 14.5 ... 18.5 mm, e.g. Kukko 21/2
Note: Needle sleeve is destroyed when it is removed and has to be replaced.
K Fig. 2
Inserting needle sleeve -A- into clutch housing
K Fig. 3
Pressing needle sleeve out of reverse idler shaft support
------------

------------
Edition 10.96 S00.5114.51.20
OCTAVIA
Gears/Shafts
35
K Fig. 4
Pressing needle sleeve into reverse idler shaft support
Edition 10.96 S00.5114.51.20
------------

------------
OCTAVIA
Replacing seals for flange shafts (gearbox installed in vehicle)

Special tools, testers and aids required 6 mm wrench Universal tool MP 9-501 Additional part MP 3-420 Insertion drift MP 3-415 Pay attention to general repair information page 00-4
39
Removing Turn steering to full right lock (for seal on right), or to full left lock (for seal on left). Remove protective cap for right drive shaft at engine. Unbolt drive shaft from flange shaft. Tie up drive shaft sufficiently. Avoid damaging paintwork of drive shaft during this step. Place drip tray below. Remove spherical bolt for flange shaft; secure shaft with drift to prevent it from also rotating. Pull out flange shaft together with compression spring. Remove seal.
K-
Notes: Do not damage seal otherwise risk of leaks. If damaged, replace seal page 34-43.
Edition 11.00 S00.5114.59.20
------------ 39-1 ------------
39
Final Drive/Differential Installing
OCTAVIA
Installation is carried out in the reverse order; pay attention to the following points: KKnock new seal fully into sleeve; do not twist seal. Pack space between sealing lip and dust lip with universal grease. Pour in gear oil page 34-23.
Tightening torques Drive shaft to flange shaft: Running Gear; Repair Group 40; Assembly overview of wheel location, suspension strut, drive shaft, brake Flange shaft to gearbox 25 Nm
Protective cap to engine
35 Nm
------------ 39-2 ------------
Edition 11.00 S00.5114.59.20
OCTAVIA
Disassembling and assembling differential
39
Special tools, testers and aids required Sealant AMV 188 200 03 Pressure plate MP 3-406 Pressure plate MP 3-407 Thrust piece MP 3-459 Drift MP 3-510
Plunger MP 3-448 Pressure plate MP 3-464 Pressure plate MP 3-467 Plunger MP 3-408 Insertion sleeve MP 3-427 Countersupport Kukko 22/2
Edition 03.98 S00.5114.55.20
---------- 39-3 ----------
39
OCTAVIA
Internal extractor Kukko 21/7 Sleeve MP 3-474 Thrust piece MP 3-468 Notes: Heat taper roller bearing inner race to 100 C before installing.
Items 26 apply only to service selector 1 - Gearbox housing 2 - Bolt 3 - Differential housing Bolt to final drive gear In gearboxes with compression springs behind flange shafts for mounting conical rings (item 21), ground chamfer on both sides Fig. 7 Pay attention to different versions
Always replace both taper roller bearing together .
If the taper bearings, the differential housing, the gearbox housing and the clutch housing are replaced, set the differential page 39-12
------------ 39-4 ------------
Edition 08.02 S00.5114.60.20
OCTAVIA
Final Drive/Differential 18 - Flange shaft With hole for conical bolt Remove and install page 39-2 19 - Compression spring for flange shaft Installed behind flange shafts 20 - Thrust washer Installed behind flange shafts in combination with compression springs Installed position: flange pointing to compression spring, webs toward conical ring 21 - Conical ring Installed behind flange shafts in combination with compression springs With slots for meshing with thrust washer Installation position: cone points toward differential housing 22 - Circlip Installed behind flange shafts in combination with compression springs Holds conical ring, thrust washer and compression springs in position when flange shaft removed 23 - Thrust washer assembly Insert with gear oil Pay attention to different versions 24 - Large differential bevel gear Install Fig. 14 Pay attention to different versions 25 - Threaded piece Installed behind flange shafts in combination with compression springs Fig. 14 Pay attention to different versions 26 - Differential bevel gear shaft Use MP 3-510 for pressing off Install Fig. 14 Pay attention to different versions 27 - Roll pin For locking shaft for differential bevel gears Remove and install Fig. 13 28 - Small differential bevel gear Install Fig. 14 Pay attention to different versions 29 - Large differential bevel gear Install Fig. 14 Pay attention to different versions
39
4 - Final Drive gear Riveted in production Bolted Fig. 12 Heat to 100 C before installing Press off Fig 9 Mount on differential housing Fig. 11 Is matched to output shaft; always replace both parts together 5 - Base plate 6 - Nut, 70 Nm 7 - Shim For differential Determine thickness page 39-13 8 - Taper roller bearing outer race Knock out Fig. 5 Press in Fig. 6 9 - Taper roller bearing inner race Pull off Fig. 3 Press on Fig. 4 10 - Differential housing With riveted final drive gear If final drive gear is replaced, drill off rivet heads Fig. 8 Attach final drive gear with bolts Fig. 12 In gearboxes with compression springs behind flange shafts for mounting conical rings (item 21), ground chamfer on both sides Fig. 7 11 - Speedometer drive gear Place onto differential housing as far as stop before pressing on inner race 12 - Taper roller bearing inner race Pull off Fig. 3 Press on Fig. 4 13 - Taper roller bearing outer race Knock out Fig. 1 Press in Fig. 2 14 - Clutch housing 15 - Sleeve For mounting seal (item 16) Remove and install page 34-44 16 - Seal Replace page 39-1 17 - 25 Nm Screw in with threaded piece (item 25) for attaching flange shafts
Edition 08.02 S00.5114.60.20
------------

------------
39
OCTAVIA
K Fig. 1 -
Knocking outer race of taper roller bearing out of clutch housing
Remove flange shaft seal and mounting sleeve for seal first of all.
K Fig. 2
Pressing outer race of taper roller bearing into clutch housing
No shim is installed on the clutch housing side.
K Fig. 3 -
Pulling off inner races of taper roller bearing
Place thrust plate MP 3-467 onto differential housing before fitting on the pulling device.
Note: The procedure for pulling off both inner races of the taper roller bearing of the differential housing is identical.
------------ 39-6 ------------
Edition 10.96 S00.5114.51.20
OCTAVIA
39
K Fig. 4
Pressing on inner races of taper roller bearing
Note: Inner races of taper roller bearings for gearbox housing and clutch housing are pressed on with the same tools.
K Fig. 5
Removing outer race of taper roller bearing from gearbox housing
A - Locking device, e.g. Kukko 22/2 B - Internal extractor 46 ... 58 mm, e.g. Kukko 21/7
K Fig. 6 -
Fit on shim below outer race. Use sleeve MP 3-474 to support gearbox housing directly below bearing mount.
Edition 10.96 S00.5114.51.20
------------

------------
Pressing outer race of taper roller bearing into gearbox housing
39
OCTAVIA
KFig. 7
Differential housing with chamfer on both sides (arrow) for mounting conical rings/compression springs
K Fig. 8 -
Drilling off rivet heads
Use a 12 mm drill to drill off rivet heads on the recessed side and knock out rivets with a drift.
Note: Clean differential before and after drilling; protect taper roller bearings from drilling swarf.
K Fig. 9 -
Pressing off final drive gear
Fit pressure plate MP 3-467 onto differential housing.
Note: The pressure plate MP 3-467 can be used for all differential housings.
---------- 39-8 ----------
Edition 03.98 S00.5114.55.20
OCTAVIA
39
K Fig. 10 -
Fitting location of final drive gear
The groove all round -A- points toward the bolted face of the differential housing.
K Fig. 11 -
Heating final drive gear to about 100 C and fitting on
Guide final drive gear with bolts -A- from repair kit when fitting on.
K Fig. 12
Bolting final drive gear and differential housing together
Use special bolts from the repair kit for gearbox 02J.
Edition 03.98 S00.5114.55.20
---------- 39-9 ----------
% # % # # 8 D !B C 2 7 # E A # 1 0 9 % # # # # # # % # ! % $ $ & ) '4 1 0 3 5 # # #! !@ % % ! # # # # " & 3 # % $ $ # 2 & ! ! ! ! # ! 23(6!!4 !
----------
39
----------
K Fig. 14
K Fig. 13
Removing
Installing:
Installing differential bevel gears
Removing and installing roll pin for differential bevel gear shaft
Edition 03.98 S00.5114.55.20
OCTAVIA
OCTAVIA
39
List of settings
Note: When carrying out removal and installation work on the gearbox, it is only necessary to re-set input shaft, output shaft or differential if parts which directly affect the setting of the gearbox, are replaced. Pay attention to the table below in order to avoid carrying out unnecessary setting operations:
Carry out setting of: Input shaft page 35-9 Part replaced: Gearbox housing Clutch housing Input shaft Output shaft (crown wheel + drive pinion) Differential housing Taper roller bearings for input shaft Taper roller bearings for output shaft Taper roller bearings for differential 4th speed gear x x x x x x x x x x Output shaft Differential x x page 35-36 page 39-12
Edition 10.96 S00.5114.51.20
------------

------------
39
OCTAVIA
Setting differential
Special tools, testers and aids required Block gauge MP 3-405/17 Universal dial gauge holder MP 3-447 Thrust plate MP 3-464 Thrust piece MP 3-459 Setting device MP 3-462/4 Sleeve MP 3-462/7 Commercially available torque gauge It is only necessary to re-set the differential if gearbox housing clutch housing differential housing or the taper roller bearings of the differential are replaced. List of settings page 39-11.
Notes:
New taper roller bearings for the output shaft are a low-friction design. For this reason, the friction torque can only be used as a check with reservations. It is only possible to correctly set the bearing preload by determining the thickness of the shim. Do not treat new taper roller bearings additionally with gear oil for measuring the friction torque. The bearings have already been factory-treated with a special oil for this purpose. Inner and outer races of taper roller bearings are matched. Do not mix up.
------------

------------
Edition 10.96 S00.5114.51.20
OCTAVIA
39
Use thrust plate MP 3-464 to insert outer race of taper roller bearing into clutch housing without the shim page 39-6. Use thrust plate MP 3-464 to insert outer race of taper roller bearing into the gearbox housing without the shim page 39-7. Insert differential into the bearing housing. Fit on gearbox housing and tighten the 5 bolts to 25 Nm. Install dial gauge and zero with a preload of 1 mm. Move differential up and down, read off play on dial gauge and note. (Example: 0.70 mm)
K-
Note: Do not rotate the differential during the measurement otherwise the bearings will settle and falsify the result of the measurement.
Determining size of shim The specified bearing preload is achieved if a constant value for compression (0.40 mm) is added to the measurement obtained. Example: Measurement + Compression (constant value) Thickness of shim 0.70 mm 0.40 mm 1.10 mm
Take off gearbox housing and pull outer race of taper roller bearing out of gearbox housing page 39-7 or knock out with thrust piece MP 3-459. Insert a shim of the calculated thickness; the thickest shim first of all. Re-insert outer race and bolt gearbox housing tight.
Edition 10.96 S00.5114.51.20
------------

------------
39
OCTAVIA
The following sizes of shims are available:
Thickness (mm) 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25
Part No. 02A 409 210 02A 409 210 A 02A 409 210 B 02A 409 210 C 02A 409 210 D 02A 409 210 E 02A 409 210 F 02A 409 210 G 02A 409 210 H 02A 409 210 J 02A 409 210 K 02A 409 210 L 02A 409 210 M
If the thickness of shim measured is greater than the shims listed in the table, it is possible to install 2 shims which together make up the measurement obtained. Different tolerances make it possible to exactly gauge the required thickness of shim. K Inspecting friction torque A - Commercially available torque gauge 0 ... 600 Ncm
Notes:
New taper roller bearings for the output shaft are a low-friction design. For this reason, the friction torque can only be used as a check with reservations. It is only possible to correctly set the bearing preload by determining the thickness of the shim. Do not treat new taper roller bearings additionally with gear oil for measuring the friction torque. The bearings have already been factory-treated with a special oil for this purpose.
------------

------------
Friction torque for: new taper roller bearings 120 ... 320 Ncm. used taper roller bearings, at least 30 Ncm.
Edition 10.96 S00.5114.51.20

Manual Skoda Octavia - Gearbox m5 02J

Uploaded by

Copyright:

Available Formats

Manual Skoda Octavia - Gearbox m5 02J

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Skoda Octavia - Gearbox m5 02J

Uploaded by

Copyright:

Available Formats

What is the document about?

What is the document about?

What information is provided about taper roller bearings?

What information is provided about taper roller bearings?

Service

Workshop Manual OCTAVIA

Service Department. Technical Information

Printed in Czech Republic

Contents next page.

General repair information .........................................................................................................

Survey of power transmission ...................................................................................................

Servicing clutch release mechanism ........................................................................................ Servicing clutch ...........................................................................................................................

30-1 30-1 30-3 30-4 30-4 30-5 30-6 30-8 30-9

Removing and installing gearbox .............................................................................................. - Inspecting gearbox oil ..............................................................................................................

34-14.1 34-14.1 34-14.2 34-14.4 34-14.6 34-14.10 34-14.12 34-15 34-23

34-1 34-1 34-2 34-5 34-10 34-12

34-24 34-25 34-31 34-32 34-34 34-46 34-48 34-41

Disassembling and assembling shift forks ..............................................................................

Edition 08.02 S00.5114.60.20

Disassembling and assembling reverse idler shaft .................................................................

Setting output shaft ....................................................................................................................

Disassembling and assembling input shaft (drive pinion) .....................................................

Replacing seals for flange (gearbox installed ..........................................................................

Setting differential .......................................................................................................................

Disassembling and assembling differential ............................................................................. -

Edition 08.02 S00.5114.60.20

K Manual gearbox 02J (arrow 2)

Additional data are production-related.

Edition 07.97 S00.5114.53.20

Code letters, component assignment, ratios, capacities

ECW 1.8-ltr./110 kW 70 : 19 = 3.684 33 : 10 = 3.300 35 : 18 = 1.944 34 : 26 = 1.308 35 : 34 = 1.029 36 : 43 = 0.837

EBN 1.8-ltr./110 kW 70 : 19 = 3.684 33 : 10 = 3.300 35 : 18 = 1.944 34 : 26 = 1.308 35 : 34 = 1.029 36 : 43 = 0.837

Gear oil G51 SAE 75W90 (synthetic oil)

Gear oil G51 SAE 75W90 (synthetic oil)

08.97 TMF = two-mass flywheel

------------ 00-2 ------------

Edition 02.00 S00.5114.58.20

Code letters Assignment: Ratio: Z2:Z1

33 : 10 = 3.300 34 : 26 = 1.308 30 : 29 = 1.034 31 : 37 = 0.838

Speedo Gear oil G51 SAE 75W90 (synthetic oil)

17 : 10 x 36 : 20 = 3.060 13 : 22 = 0.591 1.9 + 0.1 litres

Specification Gear oil change interval Clutch mechanism Clutch plate

Drive shaft flange

225 mm (TMF)1) 108 mm

Code letters Assignment: Ratio: Z2:Z1

1.9-ltr./66 kW TDI 33 : 10 = 3.300 34 : 26 = 1.308 33 : 36 = 0.917 33 : 46 = 0.717 62 : 17 = 3.647

Gear oil change interval Clutch mechanism Clutch plate

Gear oil G50 SAE 75W90 (synthetic oil)

Drive shaft flange

TMF = two-mass flywheel

Gearbox with modified synchromesh for 1st gear

Edition 11.00 S00.5114.59.20

------------ 00-2.1 ------------

Final drive 2nd gear 1st gear

DQY 61 : 18 = 3.389 36 : 17 = 2.118

1.9-ltr./66 kW TDI 34 : 09 = 3.778 34 : 25 = 1.360 36 : 17 = 2.118 61 : 18 = 3.389

EGR2) 61 : 18 = 3.389 36 : 17 = 2.118

34 : 09 = 3.778 34 : 25 = 1.360 34 : 35 = 0.971 34 : 45 = 0.756

4th gear 5th gear