Professional Documents
Culture Documents
Workshop Manual
OCTAVIA
6-Speed Manual Gearbox 02M
The Workshop Manual is intended only for use within the koda Organisation;
it is not permitted to pass it on to third parties.
2000 KODA AUTO a. s.
Printed in CR
Service
List of Supplements for
OCTAVIA Workshop Manual
Edition: 04.04
Supplement
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Edition
09.00
04.02
08.02
04.04
Subject
Article Number
S00.5140.50.20
S00.5140.51.20
S00.5140.52.20
S00.5140.53.20
Printed in CR
S00.5140.53.20
OCTAVIA
00
01
Contents
Service
Technical Data
Page
00-1
00-1
00-2
00-3
00-4
00-5
00-6
Self-Diagnosis/Electrical Test
Page
00-7
00-8
5
5
5
5
5
30
Clutch
Page
34
Shift Mechanism/Housing
Edition 08.02
S00.5140.52.20
30-1
30-1
30-3
30-4
30-6
30-7
30-10
30-12
30-13
30-14
Page
34-1
34-1
34-3
34-5
34-8
34-10
34-14
34-17
34-28
34-33
34-34
34-34
34-35.1
34-35.1
34-36
34-36.1
34-37
34-39.1
34-40
------------1 ------------
!
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Service
35
39
OCTAVIA
34-50
34-55
34-60
34-63
Gear/Shafts
Page
35-11
35-24
35-28
35-38
Page
35-1
35-8
39-1
39-5
39-7.1
39-8
39-16
39-17
39-20
39-34
39-51
5
5
5
5
5
5
5
5
------------11 ------------
Edition 08.02
S00.5140.52.20
OCTAVIA
00
Technical Data
Identification of gearbox
Assignment page 00-2
K Location on gearbox
Code letters and date of manufacture of gearbox -arrow-
20
06
Code
letters
Day
Month
Year (1999)
of manufacture
19
07
Code
letters
Day
Month
Year (1999)
of manufacture
Edition 08.02
S00.5140.52.20
00
Technical Data
Manufactured
from
to
Assignment:
Transmission
ratio:
Engine
FBS
08.00
09.00
10.00
07.01
1.9-ltr./74 kW TDI
63 : 19 = 3.316
63 : 19 = 3.316
2nd gear
40 : 19 = 2.105
40 : 19 = 2.105
31 : 34 = 0.912
31 : 34 = 0.19
Speedo
Clutch plate
23 : 14 x 31 : 11 = 4.630
electronic
2.6 litres
Specification
hydraulic
240 mm
108 mm
from
to
Engine
EUM
02D
EUM
EUM
08.00
09.00
1.9-ltr./74 kW TDI
10.00
07.01
17 : 27 x 27 : 17 = 1.00
1.9-ltr./74 kW TDI
17 : 27 x 27 : 17 = 1.00
1.0 litre
23 : 14 x 31 : 11 = 4.630
EUM
28 : 37 = 0.757
108 mm
Specification
28 : 37 = 0.757
240 mm
34 : 37 = 0.919
Clutch mechanism
34 : 37 = 0.919
Assignment:
42 : 11 = 3.818
5th gear
Specification
Manufactured
42 : 11 = 3.818
38 : 29 = 1.310
Reverse gear
Code letters
63 : 15 = 4.200
38 : 29 = 1.310
6th gear
Capacity
63 : 15 = 4.200
3rd gear
4th gear
------------
------------
FEM
1.9-ltr./74 kW TDI
1st gear
0.42 litre
0.25 litre
100 mm
FEM
Edition 08.02
S00.5140.52.20
OCTAVIA
00
Technical Data
Code
Manufactured
from
to
Assignment
Ratio:
Engine
1.9-ltr./74 kW TDI
72 : 17 = 4.235
72 : 22 = 3.273
2nd gear
48 : 23 = 2.087
45 : 34 = 1.324
5th gear
37 : 41 = 0.902
Reverse
23 : 14 x 36 : 13 = 4.630
6th gear
Capacity
Speedometer
Specification
108 mm
FWU
2.6 litres
240 mm
electronic
hydraulic
Clutch plate
Assignment
34 : 45 = 0.756
Clutch mechanism
Manufactured
41 : 45 = 0.911
Code
42 : 17 = 3.769
3rd gear
4th gear
Edition 04.02
S00.5140.51.20
08.01
1st gear
ESW
02D
from
to
Engine
FWU
08.01
1.9-ltr./74 kW TDI
17 : 27 x 27 : 17 = 1.00
1.0 litre
0.25 litre
00
------------
Technical Data
------------
OCTAVIA
Edition 04.02
S00.5140.51.20
OCTAVIA
00
Technical Data
*anufactured
from
to
-ssignment
Transmission
ratio:
ESW
0+.01
0,.03
0+.03
.ngine
1./l0,4kWTD1
1./l0,4kWTD1
2inaldrivefor5thand4thgear
,2:2233.2,3
,2:2233.2,3
2inaldrivefor1stto4thgear
1stgear
4thgear
41:4530./11
4thgear
Reversegear
Speedo
Specification
45:3431.324
3,:4130./02
3,:4130./02
23:14534:1334.54/
23:14534:1334.54/
2.4litres
filledforlife
hydraulic
240mm
10+mm
-ssignmentofrearfinaldrivecodeletters
2*8
Capacityinfinaldrive
Specification
6earoilchangeinterval
from
to
.ngine
02D
FWU
0+.01
0,.03
Specification
-ssignmentofmanualgearbo5codeletters
Edition 04.04
S00.5140.53.20
FWU
0+.03
1./l0,4kWTD1
1./l0,4kWTD1
1,:2,52,:1,31.00
1.0litre
6earoil650S-.,5W/07syntheticoil)
filledforlife
Capacityin:alde5coupling
Change;uantityin:alde5coupling
34:4530.,54
electronic
Driveshaftflange
Ratio:92:91front0rearbeveldrive
41:4530./11
34:4530.,54
Clutchplate
-ssignment
4+:2332.0+,
45:3431.324
Clutchmechanism
*anufactured
4/:1333.,4/
6earoil651S-.,5W/07syntheticoil)
6earoilchangeinterval
Code letters
,2:1,34.235
42:1,33.,4/
4+:2332.0+,
5thgear
Capacity
,2:1,34.235
2ndgear
3rdgear
Driveshaftflange
FMU
0.42litre
0.25litre
:igh-performanceoilfor:alde5
coupling60521,5-1
100mm
.SW
100mm
2*8
00
Technical Data
OCTAVIA
*anufactured
-ssignment
Transmission
ratio:
.ngine
2inaldrivefor1stto4thgear
2inaldrivefor5thto4thgear
1stgear
Clutchmechanism
Clutchplate
Driveshaftflange
1)
Two-massflywheel
1./l0/4kWTD1
4+:2133.23+
4+:2432.415
4/:1333.,4/
4thgear
42:4330./,,
4thgear
35:4330.+14
Reversegear
6earoilchangeinterval
0+.03
4+:2332.0+,
5thgear
Specification
0/.02
0,.03
FMH
2ndgear
3rdgear
Capacity
ERF
Speedo
45:3431.324
3/:4030./,5
23:14534:1334.54/
electronic
2.3litres
6earoil651S-.,5W/07syntheticoil)
filledforlife
hydraulic
240mm1)
10+mm
Edition 04.04
S00.5140.53.20
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III
- 3rd gear
II
IV
- 4th gear
- 5th gear
- Reverse
VI
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S00.5140.52.20
- 2nd gear
- 6th gear
- Final drive
- Speedometer drive
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Technical Data
2-
th/6th and
6-
78-
9-
0-
-R
2-
T
I
- 1st gear
III
- 3rd gear
II
IV
- 5th gear
- Reverse
- 6th gear
- Final drive
W1
W2
------------
- 4th gear
VI
------------
- 2nd gear
- Speedometer drive
- Rear bevel gear
Edition 08.02
S00.5140.52.20
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S00.5140.52.20
------------
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00
!
Technical Data
A number of generally applicable items of information regarding individual repair procedures which are otherwise listed at various points in
the Workshop Manual - are summarised here.
They apply to this Workshop Manual.
When removing and installing bearing brackets as well as waxed components, clean the
contact surfaces. The contact surfaces must
be free of wax and grease.
If the manual gearbox, bevel gear or the rear
final drive is replaced, replenish the gear oil
up to the bottom edge of the filler hole.
Thoroughly clean contact surfaces and apply sealant AMV 188 200 03.
Apply an even film sealant - not too thick.
Always replace O-rings.
Radial shaft seals:
------------
------------
Edition 08.02
S00.5140.52.20
!
"
#
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Replace circlips
Slacken and tighten nuts and bolts for attaching covers and housings diagonally
across.
Do not twist particularly sensitive parts - such
as clutch pressure plates - and slacken and
tighten diagonally across in stages.
The tightening torques apply to non-oiled
nuts and bolts.
Always replace self-locking nuts and bolts.
It is important to ensure that the contact surfaces at all bolted connections as well as the
nuts and bolts are waxed, if necessary, only
after installation.
S00.5140.52.20
------------
------------
00
Technical Data
Install new tapered roller bearings as supplied, and do not additionally oil.
Always replace all the tapered roller bearings mounted on 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 identical size; bearings are
matched.
Position needle bearing with the inscribed
side (large metal thickness) facing the insertion drift.
Re-gauge shims at several points with a micrometer. Different tolerances make it possible to exactly gauge the required thickness
of shim.
Inspect for burns and damage.
------------
------------
Edition 08.02
S00.5140.52.20
OCTAVIA
S00.5140.50.20
OCTAVIA
For master cylinder and bearing
bracket
Always replace
For mounting clutch pedal
$ %
Always replace
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Always replace
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Removing and installing page 30-4
------------
------------
S00.5140.50.20
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OCTAVIA
Removing and installing page 30-5
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Note:
S00.5140.50.20
K-
OCTAVIA
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S00.5140.50.20
OCTAVIA
K-
The mount -A- must be fitted onto the operating rod -B- of the master cylinder.
K-
S00.5140.50.20
------------
------------
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OCTAVIA
Attached to body
Pull out only as far as the stop for removing and installing the bleeder
Pull out only as far as the stop for removing and installing the line
Removing and installing page 30-4
Always replace
------------
------------
S00.5140.50.20
OCTAVIA
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S00.5140.50.20
Detach bleeder hose -2- and connector -3of air mass meter.
Take off additional relay carrier in left of engine compartment and unclip cable holder.
------------
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S00.5140.50.20
OCTAVIA
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S00.5140.50.20
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S00.5140.50.20
OCTAVIA
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S00.5140.50.20
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OCTAVIA
Clutch
Installing
Note:
Carry out additional operations when disconnecting and reconnecting the battery earth strap
Electrical System; Repair Group 27.
------------
------------
K-
After completing the bleeding operation, depress the clutch pedal several times.
Edition 04.02
S00.5140.51.20
"
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OCTAVIA
S00.5140.50.20
3 in total
!
OCTAVIA
Note:
(Gearbox removed)
Counterholder MP 1-223
Note:
Always replace
Slacken and tighten in stages diagonally across
S00.5140.50.20
OCTAVIA
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S00.5140.50.20
------------
------------
OCTAVIA
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Take off before removing shift mechanism.
Arrow -A-Shift movement
Arrow -B-Selector movement
# $
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Notes:
Before disconnecting the battery, determine
the code of radio sets fitted with anti-theft
coding.
Remove shift mechanism in order to replace
the shift mechanism cables page 34-10.
S00.5140.50.20
34
Shift Mechanism/Housing
OCTAVIA
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
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When removing, also take off cover
-item 2 Removing page 34-10
&
When removing, also take off gearshift knob -item 1 Removing page 34-10
Separating cover from gearshift knob
page 34-4
S00.5140.50.20
* +
34
Shift Mechanism/Housing
K
OCTAVIA
K
Edition 09.00
S00.5140.50.20
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S00.5140.50.20
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------------
------------
34
OCTAVIA
Shift Mechanism/Housing
0-
4-
Attached to body
3-
------------
------------
piece
7 - Shift housing
8-
bush
9-
pin
Edition 09.00
S00.5140.50.20
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OCTAVIA
Press onto shift lever guide
Fitting location page 34-1
Installing Fig. 2
Note:
S00.5140.50.20
------------
------------
34
Shift Mechanism/Housing
OCTAVIA
Note:
3------------
washer
------------
4 - Shift housing
-
washer
Do not damage cables when removing
8 - Grommet
Mounting of support bracket to gearbox
Edition 09.00
S00.5140.50.20
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OCTAVIA
K 0
2 - Relay lever
meshes by means of sliding shoe in sliding rail of gearbox shift lever -arrow-.
K-
Use open-end wrench to lever selector cable -A- and shift cable -B- off the gearbox.
S00.5140.50.20
------------
------------
34
Shift Mechanism/Housing
K-
OCTAVIA
Note:
K-
Switch off ignition (if not already off) and disconnect earth strap at the battery.
K-
Detach bleeder hose -2- and unplug connector -3- of air mass meter.
Edition 09.00
S00.5140.50.20
OCTAVIA
K
K
K
S00.5140.50.20
34
Shift Mechanism/Housing
OCTAVIA
K
K
K
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
34
Shift Mechanism/Housing
K-
- Remove propshaft.
5-Speed Manual Gearbox 02C 4x4; Repair
Group 39; Removing and installing propshaft
-
Swivel shift housing down and take out together with cables.
Installing
Installation is carried out in the reverse order;
pay attention to the following points:
- Assembly exhaust system free of stress.
Engine, Mechanical Components; Repair
Group 26; Removing and installing parts of
exhaust system
K-
Turn the locking mechanism at the shift cable and at the selector cable fully to the right
-arrows 1-.
Edition 04.02
S00.5140.51.20
Tightening
torque
25 Nm
25 Nm
34
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OCTAVIA
Shift Mechanism/Housing
l Gearbox in Neutral.
K-
After pressing down the shift shaft, then insert the locking pin -A- into the gearbox -direction of arrow- until the pin locks in place.
Edition 09.00
S00.5140.50.20
OCTAVIA
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S00.5140.50.20
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Shift Mechanism/Housing
OCTAVIA
K
K
l
K
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
Shift Mechanism/Housing
34
Switchoffignitionanddisconnectearthstrap
atthebattery.
Removeenginetrimpanel.
Removebattery.
Removebatterycarrier.
K-
Edition 04.04
S00.5140.53.20
Takeoffintakehose-1-.
Detachbleederhose-2-andunplugconnector-3-ofairmassmeter.
Removeairfilterhousingcomplete@remove
screws-4-and-5-forthisstep.
34
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Shift Mechanism/Housing
K
OCTAVIA
K
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------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
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Do not
K
S00.5140.50.20
------------
------------
34
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Shift Mechanism/Housing
OCTAVIA
K-
Note:
When installing the mounting hooks of the supporting device, pay attention to hose and cable
connections in the area of the lifting eyes of the
engine to ensure that they are not damaged.
-
K-
K-
------------
------------
Edition 04.02
S00.5140.51.20
OCTAVIA
34
Shift Mechanism/Housing
K-
Edition 08.02
S00.5140.52.20
K-
K-
34
Shift Mechanism/Housing
K
K
K
------------
------------
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S00.5140.52.20
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S00.5140.52.20
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Shift Mechanism/Housing
K
K
Note:
K
Note:
------------
------------
Edition 08.02
S00.5140.52.20
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Notes:
Installing starter/cables:
S00.5140.52.20
------------
------------
34
Shift Mechanism/Housing
ightening
for
with ront
K Gearbox to engine
Item
Nm
M 12 x 55
80
31)
M 12 x 165
80
M 10 x 105
2
4
1)
Qty.
M 12 x 70
M 10 x 55
80
40
40
for
with 4
Gearbox to engine
Item
Nm
M12 x 55
80
31)
M12 x 165
80
M10 x 105
60
2
4
1)
Qty.
M12 x 70
M10 x 50
80
40
K Pay attention to the following sequence of operations when installing the gearbox support:
-
------------
------------
50 Nm + 90
Edition 08.02
S00.5140.52.20
OCTAVIA
K Gearbox to body
Bolts -arrows-
100 Nm
20 Nm + 90
Bolts -arrows B-
40 Nm + 90
Note:
I - 10 Nm
II - 70 Nm
25 Nm
25 Nm
20 Nm
60 Nm
S00.5140.50.20
10 Nm
------------
------------
34
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OCTAVIA
Shift Mechanism/Housing
and
and aids
K-
K-
Note:
When the bolts -A- ( page 34-29, Fig. N340887) are slackened, the engine/gearbox unit
moves forward slightly. Ensure that the seal in
the flange of the propshaft is not damaged when
removing and installing.
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
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S00.5140.50.20
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Notes:
------------
------------
K-
Edition 09.00
S00.5140.50.20
OCTAVIA
-
If the teeth are correctly positioned and centred, the bevel gear slips fully against the
manual gearbox as far as the stop.
K Pay attention to the following sequence of operations when installing the gearbox support:
S00.5140.50.20
34
Shift Mechanism/Housing
OCTAVIA
ightening
ightening
60 Nm
20 Nm + 90
I - 10 Nm
II - 70 Nm
1)
------------
60 Nm
------------
40 Nm + 45
25 Nm
Edition 09.00
S00.5140.50.20
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Gear oil specification page 00-2.
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S00.5140.52.20
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Shift Mechanism/Housing
and
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1 Clutch housing
3 5th/6th and
4
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shaft
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shaft
8
9
Edition 08.02
S00.5140.52.20
S00.5140.52.20
------------
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S00.5140.52.20
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------------
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Shift Mechanism/Housing
OCTAVIA
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Shift Mechanism/Housing
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on
shafts
2 Shift
and shift
and 2nd
shaft
4 5th/6th and
5 Shift
3 Shift
and shift
------------
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and shift
and 4th
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Shift Mechanism/Housing
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shafts
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Shift Mechanism/Housing
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The bottom mounting of the shift shaft -arrowis bolted to the end cover at the gearbox housing.
and
shift
and
shafts
and
and aids
Sleeve MP 3-424
------------
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K-
Edition 09.00
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S00.5140.52.20
------------
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34
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Shift Mechanism/Housing
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Notes:
The hexagon bolt -arrow- is positioned outside of the bolted flange. It is installed with a
washer.
Illustration does not show gearbox holder
------------
------------
Edition 08.02
S00.5140.52.20
OCTAVIA
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S00.5140.50.20
------------
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34
Shift Mechanism/Housing
OCTAVIA
K-
Draw in end cover -A- by alternately tightening the bolts -arrows- by hand (1/2 turn).
K-
Install bleeder
K-
Edition 08.02
S00.5140.52.20
OCTAVIA
K-
Edition 08.02
S00.5140.52.20
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Shift Mechanism/Housing
OCTAVIA
housing
and aids
------------
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Edition 09.00
S00.5140.50.20
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Clamp in repair stand Fig. 1
If replaced: set input shaft, output
shafts and differential page 39-16
Always replace
For 5th/6th and reverse gear output
shaft
List of settings page 39-16
Always replace
For shift rods
Replace each time removed
Removing Fig. 6
Installing Fig. 7
For input shaft
List of settings page 39-16
Always replace
For 1st to 4th gear output shaft
List of settings page 39-16
For differential
Removing and installing from page
39-8
If replaced: set differential
page 39-17
For differential
List of settings page 39-16
Replacing page 39-1
S00.5140.50.20
------------
------------
34
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Shift Mechanism/Housing
Attaching
housing to
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------------
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Edition 09.00
S00.5140.50.20
OCTAVIA
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Note:
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------------
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housing
into
Edition 09.00
S00.5140.50.20
OCTAVIA
34
Shift Mechanism/Housing
Edition 08.02
S00.5140.52.20
------------
------------
34
Shift Mechanism/Housing
OCTAVIA
Shaft cannot be removed with workshop equipment
Pressing shaft into clutch housing
Fig. 7
s
2 in total
6 Input shaft
Removing Fig. 5
Installing Fig. 6
8 W
For differential
------------
------------
Edition 08.02
S00.5140.52.20
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For differential
Removing and installing from page
39-8
If replaced: set differential
page 39-17
Is held by contact surface of housing
S00.5140.50.20
------------
------------
34
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------------
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Edition 09.00
S00.5140.50.20
OCTAVIA
S00.5140.50.20
------------
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OCTAVIA
Shift Mechanism/Housing
and
shift mechanism at
side
and aids
------------
------------
shoe
Clip into relay lever -item 6-
Edition 09.00
S00.5140.50.20
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OCTAVIA
Shift Mechanism/Housing
K ig. 3
------------
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into shift
seal f
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S00.5140.50.20
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MP
MP
MP
S00.5140.50.20
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------------
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in
Edition 09.00
S00.5140.50.20
OCTAVIA
Thrust plate MP 3-406
Thrust plate MP 3-407
Thrust plunger MP 3-408
Thrust piece MP 3-411
Thrust ring MP 3-413
Thrust plunger MP 3-423
Insertion sleeve MP 3-427
Tube section MP 3-429
Thrust piece MP 3-453
Thrust disc MP 3-467
Tube section MP 3-4012
Gearbox holder MP 3-501
Disc MP 6-415
Retaining plate T30027
Insertion sleeve T30034
Taper roller bearing puller V.A.G 1582
Grip V.A.G 1582/7
Separating device 22...115 mm,
e.g. Kukko 17/2
Internal extractor 46...58 mm,
e.g. Kukko 21/7
Countersupport, e.g. Kukko 22/2
S00.5140.50.20
------------
------------
35
OCTAVIA
Gear/Shafts
Notes:
Pay attention to the technical data when installing new gears page 00-2.
2 - Shim
Determining thickness page 35-8
------------
------------
4 - Circlip
If the taper roller bearing
-item 5- and the input shaft
-item 8- are replaced, re-determine
Fig. 11
5 - Taper roller bearing inner race
Pulling off Fig. 3
Fitting on Fig. 10
Edition 09.00
S00.5140.50.20
OCTAVIA
Pressing off Fig. 4
Pressing on Fig. 9
Pressing off Fig. 5
Pressing on Fig. 7
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Pressing on Fig. 8
Removing Fig. 12
Fitting location Fig. 13
Pressing in Fig. 14
"
S00.5140.50.20
&
"
------------
------------
35
OCTAVIA
Gear/Shafts
ner
off
------------
------------
off 5th
off
and
Edition 09.00
S00.5140.50.20
OCTAVIA
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S00.5140.50.20
------------
------------
35
Gear/Shafts
K Fig. 9
OCTAVIA
Note:
The slot at the 5th speed gear must point to the
taper roller bearing.
K Fig. 10
K Fig. 11
Determining circlip
Determinethethickestcirclipwhichcanstill
<ustbeinserted>andinsert.
Thefollowingcirclipsareavailable:
Thickness (mm)
Part No.
1.,/
02*3111+,6
1.+4
02*3111+,.
1.+3
1.+/
02*3111+,D
1./2
02*3111+,C
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OCTAVIA
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------------
------------
35
OCTAVIA
Gear/Shafts
shaft
------------
------------
K-
Press taper roller bearing fully into the gearbox housing without the shim.
Edition 09.00
S00.5140.50.20
OCTAVIA
K-
Note:
This procedure must be repeated for each further measurement otherwise the dial gauge
moves back into its initial position.
-
K-
S00.5140.50.20
------------
------------
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OCTAVIA
Gear/Shafts
of
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ness
K-
gauge
mm
bearings
dial
bearing
be
Note:
If no bearing play can be measured but the input shaft has a perceptible rock and can be easily rotated, the setting is also o.k.
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
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MP 3-461
plate
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puller V
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S00.5140.50.20
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------------
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OCTAVIA
Gear/Shafts
the
s
or t
roller
are
it is then necessary to set the
1-
------------
3-
4 - aper r
outer r
Pulling out Fig. 3
Pressing in Fig. 4
5 - aper
inner
Pressing off Fig. 8
Pressing on Fig. 9
-
------------
Removing Fig. 1
Inserting Fig. 2
shaft
For 1st to 4th gear
Setting page 35-24
Edition 09.00
S00.5140.50.20
#
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OCTAVIA
Inspect for wear Fig. 10
Inspect lugs for signs of wear
Fitting location Fig. 12
Fit onto synchroniser ring -item 9 Replace if scores or traces of wear
present
Fitting location Fig. 12
)
Holds thrust washers -item 19- in position on output shaft
For 4th gear
Dimensions 42 x 48 x 26.8
Inspect for wear Fig. 11
Insert so that the recesses engage in
the locking pieces of the sliding sleeve
-item 12-
Pull off together with 4th speed sliding gear after removing circlip -item
25- Fig. 6
Disassembling Fig. 13
Fitting location of sliding sleeve/
synchroniser body Fig. 20
Assembling sliding sleeve/synchroniser body Fig. 13 and Fig. 14
Pressing on Fig. 21
'
Inspect for wear Fig. 11
Insert into synchroniser ring -item 26-,
fitting location Fig. 17
Replace if scores or signs of wear present
Place into synchroniser ring -item 14-,
fitting location Fig. 17
Replace if scores or signs of wear
present
Inspect for wear Fig. 10
Inspect lugs for signs of wear
Fitting location Fig. 18
Fitting location Fig. 19
S00.5140.50.20
Press off together with 2nd speed sliding gear after removing circlip -item
13- Fig. 7
Disassembling Fig. 13
Assembling sliding sleeve/synchroniser body Fig. 13 and Fig. 14
Fitting location Fig. 15
Pressing on Fig. 16
Inspect for wear Fig. 10
Inspect lugs for signs of wear
Fitting location Fig. 18
Pulling off Fig. 5
Pressing on Fig. 23
------------
------------
35
Gear/Shafts
OCTAVIA
3 -
33 -
------------
r
Pulling out Fig. 25
Pressing in Fig. 26
------------
35 -
Edition 09.00
S00.5140.50.20
OCTAVIA
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Gear/Shafts
into
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------------
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Edition 09.00
S00.5140.50.20
OCTAVIA
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------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
!
1 - Spring
2 - Locking piece
3 - Sliding sleeve
4 - Synchroniser body
Insert locking pieces and install springs offset 120. The angled end of the spring must
engage in the hollow locking piece.
The identification groove -arrow 1- and the narrow shoulder -arrow 2- of the synchroniser body
point toward 1st gear.
S00.5140.50.20
------------
------------
35
!
OCTAVIA
Gear/Shafts
on
and
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K i .
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for
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------------
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Edition 09.00
S00.5140.50.20
OCTAVIA
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------------
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S00.5140.50.20
OCTAVIA
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Gear/Shafts
shaft
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l Sealing surfaces of clutch housing and gearbox housing must be cleaned free of sealant.
l When conducting the measurement, install
the shaft to be measured.
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
K-
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K-
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
1.40
1.45
1.50
1.70
1.75
1.80
2.05
2.10
2.15
2.20
1.55
1.60
1.65
1.85
1.90
1.95
2.00
K-
S00.5140.50.20
K-
Slacken bolts attaching clutch housing/gearbox housing diagonally across until the bolts
release the gearbox housing or the output
shaft, respectively.
------------
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Gear/Shafts
and
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section MP 3-414
Thrust plunger MP
section MP
Thrust piece MP
MP
Mounting rail MP
T
section MP 3-461
Thrust piece MP
MP
plate
Taper roller
puller
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
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S00.5140.50.20
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------------
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OCTAVIA
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S00.5140.50.20
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Pulling off Fig. 3
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S00.5140.50.20
------------
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K i .
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th s
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
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------------
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S00.5140.50.20
OCTAVIA
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Gear/Shafts
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K i . 5
inner r
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No.
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
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35
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Gear/Shafts
and
shaft
l Sealing surfaces of clutch housing and gearbox housing must be cleaned free of sealant.
l When conducting the measurement, install
only the shaft to be measured.
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
"
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Ensure that the supporting bridge is not touching at any point in the area of the contact surface between gearbox housing and clutch housing -arrow A-.
-
S00.5140.50.20
------------
------------
35
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Gear/Shafts
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mm
383
K-
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
1.40
1.45
1.50
1.70
1.75
1.80
2.05
2.10
2.15
1.55
1.60
1.65
1.85
1.90
1.95
2.00
K-
S00.5140.50.20
K-
Slacken bolts attaching clutch housing/gearbox housing diagonally across until the bolts
release the gearbox housing or the output
shaft, respectively.
------------
------------
OCTAVIA
(Gearbox installed)
Universal tool MP 3-419
Extraction hook MP 3-419/37
Thrust piece T30028
Torque wrench (5...50 Nm), e.g. V.A.G 1331
Torque wrench (40...200 Nm),
e.g. V.A.G 1332
Commercially available 6 mm wrench socket
Drip tray
-
S00.5140.50.20
K-
39
Final Drive/Differential
K-
OCTAVIA
Pulloutseal
Installing
K-
Dnockinnewsealasfarasthestop@donot
twistseal.
Packspacebetweensealinglipanddustlip
halfwithgrease605212+-1.
1nsertflangeshaft.
-ttachflangeshaftwithsphericalbolt.
=oltsteering<ointandtrackcontrolarmonto
oldimpressionwithnew bolts.
=oltleftdriveshafttoflangeshaft.
2itonwheel.
1nspectgearoilinmanualgearbo5page
34-33.
- 1nstallnoiseinsulation
.ngine> *echanical Components@ Repair
6roup10@Removingandinstallingengine.
Tightening torques
Components
2langeshafttogearbo5
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Wheelboltstowheelhub
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1)
-lwaysreplacethesebolts.
Tightening
torque
25Am
1-10Am
11-,0Am
120Am
20AmB/0C
Edition 04.04
S00.5140.53.20
OCTAVIA
!
"
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Pulling Device T10037
Thrust piece T10049
6 mm wrench socket, at least 190 mm long,
e.g. V.A.G 1669
Dip tray
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------------
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S00.5140.52.20
OCTAVIA
!
K-
S00.5140.50.20
------------
------------
39
OCTAVIA
Final Drive/Differential
K
! "#$
K
K
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
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S00.5140.50.20
------------
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------------
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S00.5140.52.20
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Notes:
,
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Different diameter on left and right
Replacing with gearbox installed
39-1
Bolt to final drive gear
Always replace
)
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+
Bolt to threaded piece -item 26-
For differential
Determining thickness page 39-17
-
Pulling out Fig. 5
Pressing in Fig. 6
-.
+
With riveted final drive gear
If final drive gear is replaced, drill off
rivet heads Fig. 7
Attach final drive gear with bolts
Fig. 10
-.
+
S00.5140.52.20
*+
With grooves for meshing with thrust
washer
Fitting location: cone points toward differential housing
*+.
Holds conical ring, thrust washer and
compression spring in position when
flange shaft removed
Installing Fig, 12
Use drift for knocking out
Installing Fig. 12
0.
For locking shaft of differential bevel
gears
Removing and installing Fig. 11
,
Installing Fig. 12
-
.
+
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)
,
For left flange shaft
Different diameter on left and right
Replacing with gearbox installed
page 39-1
------------
------------
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OCTAVIA
Pipe MP 6-419
Tube T30019
------------
------------
S00.5140.52.20
"
!
OCTAVIA
With riveted final drive gear
If final drive gear is replaced, drill off
rivet heads Fig. 7
Attach final drive gear with bolts
Fig. 10
-.
*
Notes:
Bolt to final drive gear
Riveted in series production
Pressing off Fig. 8
Fitting location: the ground side points
toward the bolted surface of the differential housing
Heat to 100 C before installing
Place onto differential housing
Fig. 9
Bolted Fig. 10
"
Always replace
+ ,%
For differential
Determining thickness page 39-17
-
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Pressing in Fig. 6
,
For right flange shaft
Different diameter on left and right
Replacing with gearbox installed
page 39-1
Always replace
"
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1
Always replace
-.
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S00.5140.50.20
39
23 - O-ring
Always replace
24 - O-ring
Always replace
25 - Large differential bevel gear
Installing Fig. 12
26 - Differential bevel gear shaft
Use drift for knocking out
Installing Fig. 12
Final Drive/Differential
OCTAVIA
27 - Roll pin
For locking shaft of differential bevel
gears
Removing and installing Fig. 11
28 - Small differential bevel gear
Installing Fig. 12
29 - Threaded piece
Installing Fig. 12
30 - Thrust washer assembly
Insert with gear oil
Edition 09.00
S00.5140.50.20
OCTAVIA
&
For left flange shaft
Different diameter on left and right
Replacing with gearbox installed
page 39-1
Note:
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S00.5140.50.20
39
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Final Drive/Differential
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Note:
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K Fi .
inner
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roller
Note:
The
K Fi .
of
roller
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
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Final Drive/Differential
K Fi .
final drive
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------------
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Edition 09.00
S00.5140.50.20
OCTAVIA
8
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------------
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39
OCTAVIA
Final Drive/Differential
of
Note:
When carrying out removal and installation operations on the gearbox, it is only necessary to re-set the input shaft, 1st
to 4th gear output shaft, 5th/6th and reverse gear output shaft or the 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:
Gearbox housing
Clutch housing
Input shaft
Input shaft
Differential
page 35-8
page 35-24
page 35-38
page 39-17
------------
------------
Edition 09.00
S00.5140.50.20
OCTAVIA
differential housing
or the
S00.5140.50.20
------------
------------
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OCTAVIA
Final Drive/Differential
Note:
Inner race and outer race of the taper roller bearings are matched. Do not mix up.
K
K
------------
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Edition 09.00
S00.5140.50.20
OCTAVIA
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Use track control arm for levering out
Knock in thrust piece T10049 as far
as the stop page 39-32
Replace with gearbox installed
page 39-3
------------
2 in total
Replacing page 39-51
------------
Always replace
M10/M8
,
- .
For double screw -item 6-
S00.5140.52.20
OCTAVIA
39
Final Drive/Differential
8 - Bolt, 25 Nm
M8
9 - Bolt, 45 Nm
M10
10 - Oil drain plug, 60 Nm
With magnet and seal
11 - Large cover1)
Removing page 39-27
Do not twist when installing; tighten securing bolts in stages diagonally across
12 - O-ring
Always replace, if existing
23 - Small cover1)
Removing page 39-28
Do not twist when installing, tighten securing bolts in stages diagonally across
14 - Shim S1
Note thickness
Installed onto gearboxes between oil
deflector plate -item 13- and large
cover -item 11 Overview of setting page 39-35
25 - Shim S2
Note thickness
Overview of setting page 39-35
Edition 08.02
S00.5140.52.20
24 - O-ring
Always replace
26 - O-ring
Always replace
28 - Roller sleeve
Pulling out 39-28
Pressing in 39-28
29 - Shaft bevel gear1)
Is matched with head bevel gear
Clean thread
Grease serration for output flange with
multi-purpose grease
Insert page 39-38
30 - Large taper roller bearing for shaft
bevel gear1)
Inner race:
Place onto shaft bevel gear (item. 29)
Outer race:
Pressing out page 39-26
Pressing in page 39-31
31 - Output flange
Pulling out page 39-25
Pulling in page 39-32
Grease serration with multi-purpose
grease
------------
------------
39
Final Drive/Differential
OCTAVIA
36 - Bolt, 25 Nm
Insert with sealant AMV 188 200
37 - Drive pinion housing1)
Removing page 39-25
Installing page 39-31
Do not twist when installing; tighten securing bolts in stages diagonally across
38 - Shim S3
Note thickness
Overview of setting page 39-35
Before installing coat both sides with
sealant AMV 188 200
------------
------------
Edition 08.02
S00.5140.52.20
OCTAVIA
and
39
Final Drive/Differential
and
Extractor 3138
Pipe MP 6-419
Extractor T10037
Edition 08.02
S00.5140.52.20
------------
------------
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OCTAVIA
K-
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------------
------------
Edition 08.02
S00.5140.52.20
OCTAVIA
K-
K-
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Edition 08.02
S00.5140.52.20
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Final Drive/Differential
------------
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39
Final Drive/Differential
OCTAVIA
Notes:
Removing and installing drive pinion housing with installed output flange.
Clean the sealing surfaces of the drive pinion housing at the final drive housing and
shim S3 free of sealant.
K
K
Edition 08.02
S00.5140.52.20
OCTAVIA
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39
Final Drive/Differential
K
Note:
Inner race can be pulled off by hand, if necessary after removing the large cover on the head
bevel gear/input shaft carefully lift and pull off
inner race.
K
K
Edition 08.02
S00.5140.52.20
------------
------------
39
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Final Drive/Differential
K
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------------
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Edition 08.02
S00.5140.52.20
OCTAVIA
39
Final Drive/Differential
K
K
K
Note:
On certain gearboxes shim S1 is located between the oil deflector plate and the large cover
and must be re-installed In the same location
as previously installed.
Edition 08.02
S00.5140.52.20
39
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Final Drive/Differential
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K
Note:
K
1
------------
------------
Edition 08.02
S00.5140.52.20
OCTAVIA
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Final Drive/Differential
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Edition 08.02
S00.5140.52.20
------------
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Final Drive/Differential
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Edition 08.02
S00.5140.52.20
OCTAVIA
K
Edition 08.02
S00.5140.52.20
Final Drive/Differential
39
39
OCTAVIA
Final Drive/Differential
bevel gear
S Stage dimension
Is the dimension between the ground
face end/serration and contact surfaces of inner race/taper roller bearing and shim S4 on the shaft bevel
gear.
This dimension is recorded on the rear
side -arrow- of the shaft bevel gear
(in this example 3.95)
------------
------------
Edition 08.02
S00.5140.52.20
OCTAVIA
39
Final Drive/Differential
Position of shims
S1 - Shim for friction torque of taper roller
bearing/head bevel gear
S2 - Shim for friction torque and positioning of head bevel gear
S3 - Shim for shaft bevel gear
S4 - Shim for friction torque of taper roller
bearing of shaft bevel gear
When carrying out removal and installation work on the gearbox, it is only necessary to re-set the shaft bevel gear, head
bevel gear or the complete drive pinion set if parts are replaced which have a direct effect on the setting of the final
drive. Pay attention to the table below in order to avoid carrying out unnecessary setting operations:
Setting of the following:
Parts to be replaced:
Large cover
Small cover
x
x
Output flange
2)
x1)
1)
x2)
Only S3 page 39-41. The shaft bevel gear is removed together with the drive pinion housing. Shim S4 remains
unchanged in this case.
Only S4 using differential measurement page 39-36.
Edition 08.02
S00.5140.52.20
------------
------------
39
Final Drive/Differential
OCTAVIA
Edition 08.02
S00.5140.52.20
OCTAVIA
39
Final Drive/Differential
Example:
Old output flange
43.50 mm
43.30 mm
Difference
0.20 mm
If the new output flange is longer - install a thinner shim S4 equal to the difference.
If the old output flange is longer - install a thicker
shim S4 equal to the difference.
-
Edition 08.02
S00.5140.52.20
------------
------------
39
OCTAVIA
Final Drive/Differential
Edition 08.02
S00.5140.52.20
OCTAVIA
39
Final Drive/Differential
Press outer race of small taper roller bearing for shaft bevel gear with thrust piece MP
3-458/1 into the drive pinion housing page
39-31.
K-
K-
Edition 08.02
S00.5140.52.20
K-
Read off play on the dial gauge and determine shim S4.
39
OCTAVIA
Final Drive/Differential
Example:
Shim
2.50 mm
0.20 mm
0.35 mm
Shim S4 =
1.95 mm
Note:
Assign shims following spare parts catalogue
The following sizes for shim S4 are available:
1.30
1.35
1.40
1.45
1.50
1.55
1.60
Thickness (mm)
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.35
2.40
2.45
2.50
2.20
2.25
2.30
Note:
When attaching drive pinion housing, a shim S3
(e.g. 1.2 mm) must be attached so that the shaft
bevel gear is not positioned at the final drive
housing.
K-
Edition 08.02
S00.5140.52.20
OCTAVIA
39
Final Drive/Differential
l Input shaft with shaft bevel gear is removed.
K-
100...240 Ncm
1)
used bearings1)
30...50 Ncm
Set correct friction torque, if necessary, by inserting a thinner shim S4 (to increase friction torque)
or a thicker one (to reduce friction torque).
Determining thickness of shim S3
l Input shaft with shaft bevel gear removed
l Outer race/taper roller bearing for bearing
of head bevel gear/input shaft) is installed.
K-
K-
Edition 08.02
S00.5140.52.20
------------
------------
39
Final Drive/Differential
OCTAVIA
K-
K-
72.50 mm
+ 16.00 mm
= 88.50 mm
------------
------------
Edition 08.02
S00.5140.52.20
OCTAVIA
39
Final Drive/Differential
Note:
+ 0.93 mm
+ 20.12 mm
+ 65.60 mm
Dimension -B-
Edition 08.02
S00.5140.52.20
3,95 mm
= 90.60 mm
39
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Final Drive/Differential
Note:
for
3 are available
Edition 08.02
S00.5140.52.20
OCTAVIA
!
39
Final Drive/Differential
ear
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Dial gauge
roller
for
Edition 08.02
S00.5140.52.20
K-
Insert head bevel gear/input shaft -5- into final drive housing.
Position inner race/taper roller bearing -3on head bevel gear/input shaft as far as the
stop.
------------
------------
39
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OCTAVIA
Final Drive/Differential
part of
2*.
fter
2*i
be referred to
2.
Note:
K-
------------
------------
Edition 08.02
S00.5140.52.20
OCTAVIA
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39
Final Drive/Differential
of
Notes:
Note:
clearance
Edition 08.02
S00.5140.52.20
------------
------------
39
OCTAVIA
Final Drive/Differential
1st measurement
0.30 mm
+ 2nd measurement
0.31 mm
+ 3rd measurement
0.30 mm
+ 4th meassurement
0.29 mm
Total
1.20 mm
Lift = 0.20 mm
S2*
Shim inserted
1.75 mm
0.30 mm
0.20 mm
S2
1.45 mm
1.65 mm
Note:
------------
------------
Edition 08.02
S00.5140.52.20
OCTAVIA
!"#
39
Final Drive/Differential
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
2.05
2.10
2.15
1.90
1.95
2.00
2.35
2.40
2.45
2.20
2.25
2.30
2.50
Different tolerances make it possible to exactly gauge the required thickness of shim.
S1
= Stot. - S2
S1
= 2.70 mm - 1.65 mm
S1
= 1.05 mm
Note:
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
Edition 08.02
S00.5140.52.20
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Final Drive/Differential
OCTAVIA
Note:
------------
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------------
Edition 08.02
S00.5140.52.20
OCTAVIA
$%
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Final Drive/Differential
needle
for
and
Take off middle and right part of noise insulation below engine and gearbox
Engine, Mechanical Components; Repair
Group 10, Removing and installing engine
- Remove drive shaft
Running Gear; Repair Group 40; Servicing
drive shafts; Removing and installing
Edition 08.02
S00.5140.52.20
K-
------------
------------
39
Final Drive/Differential
OCTAVIA
K-
------------
------------
The shaft must be rotated during the pressing operation (arrow) in order to avoid damaging the contact surface of the bearing on
the shaft.
K-
The shaft must be rotated during the pressing operation (arrow) in order to avoid damaging the contact surface of the bearing on
the shaft.
Edition 08.02
S00.5140.52.20
OCTAVIA
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Final Drive/Differential
Edition 08.02
S00.5140.52.20
------------
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