Fabia Gearbox 0A8

Service
Workshop Manual
FABIA 2003
Gearbox 0A8
Edition 10.03
Gearbox code
FJW FSM HDS
Service Department. Technical Information
Printed in Czech Republic

S00.5329.00.20
The Workshop Manual is intended only for use within the Organisation koda.
It is not permitted to pass it on to other persons.
KODA AUTO a. s.
Service
Printed in Czech Republic

S00.5329.00.20
FABIA 2003 Gearbox 0A8
List of Supplements to Workshop Manual
FABIA 2003
Gearbox 0A8
Edition 10.03
Supplement
1
Edition 02.04
S00.5329.01.20
Edition
Subject
Article Number
10.03
Basic Edition
S00.5329.00.20
02.04
Supplement to manual gearbox with code HDS
S00.5329.01.20
List of Supplements
List of Supplements
Edition 02.04
S00.5329.01.20
Table of Contents
00 Technical Data
Identification of the gearbox ......................................................................... 00-1
page
- Location on the gearbox .............................................................................. 00-1
page
- Identification characters, aggregate assignment, ratios, capacities ........................... 00-1
page
Overview of Transmission System ................................................................. 00-2
page
General Repair Information .......................................................................... 00-3
page
Repairing the clutch control ......................................................................... 30-1
page
- Summary of components - Foot controls .......................................................... 30-1
page
- removing and installing, setting clutch pedal switch -F36- ...................................... 30-1
page
- Removing and installing the over-centre helper spring .......................................... 30-1
page
- Removing and installing the clutch pedal .......................................................... 30-1
page
- Summary of components - Hydraulics ............................................................. 30-1
page
- Removing and installing the master cylinder ...................................................... 30-1
page
- Bleeding the clutch system .......................................................................... 30-1
page
Repairing the clutch control ......................................................................... 30-2
page
Repairing the clutch ................................................................................... 30-3
page
- Clutch - Overview of components ................................................................... 30-3
page
- removing and installing clutch ....................................................................... 30-3
page
Repairing the gearshift mechanism ................................................................ 34-1
page
- Fitting location of shift mechanism .................................................................. 34-1
page
I - Summary of components - gearshift knob and cover ...................................... 34-2
page
- Separating collar from gearshift lever .............................................................. 34-2
page
II - Summary of components - shift lever and shift housing ................................. 34-3
page
III - Summary of components - Control cables .................................................. 34-4
page
Removing and Installing Shift Mechanism ....................................................... 34-5
page
- Removing ............................................................................................... 34-5
page
- Installing ................................................................................................ 34-5
page
Setting the shift mechanism ......................................................................... 34-6
page
- Operation ............................................................................................... 34-6
page
Removing and installing the gearbox ............................................................. 34-7
page
- Removing ............................................................................................... 34-7
page
- Installing ................................................................................................ 34-7
page
Inspecting gear oil ..................................................................................... 34-8
page
Disassembling and assembling the gearbox for gearbox as of gearbox manufacturing

date 07.03 ................................................................................................ 34-9
page
- Gearbox overview ..................................................................................... 34-9
page
- Summary of components ............................................................................. 34-9
page
- Gearbox housing and gearshift mechanism - Summary of components ..................... 34-9
page
- Drive shaft, output shafts (input shafts), differential and gearshift rods - Summary of
components ............................................................................................ 34-9
page
- Mounting sequence ................................................................................... 34-9
page
30 Clutch
34 Control/Housing
Edition 02.04
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Table of Contents

Repairing the gearbox housing ..................................................................... 34-10 page
- Repairing the gearbox housing for gearbox up to gearbox manufacturing date 06.03 ..... 34-10 page
1
1
- Repairing the gearbox housing for gearbox as of gearbox manufacturing date 07.03 ..... 34-10 page
Repairing the clutch housing ....................................................................... 34-11 page
- Repairing the clutch housing for gearbox up to gearbox manufacturing date 06.03 ........ 34-11 page
- Repairing the clutch housing for gearbox as of gearbox manufacturing date 07.03 ........ 34-11 page
Disassembling and assembling the gearshift mechanism on the gearbox side ........ 34-12 page
- Disassembling and assembling the gearshift mechanism on the gearbox side for gearbox
up to gearbox manufacturing date 06.03 .......................................................... 34-12 page
- Disassembling and assembling the gearshift mechanism on the gearbox side as of gearbox
manufacturing date 07.03 ............................................................................ 34-12 page
Disassembling and assembling the gearshift forks ........................................... 34-13 page
- Disassembling and assembling the gearshift forks for gearbox up to gearbox manufacturing
date 06.03 .............................................................................................. 34-13 page
- Disassembling and assembling the gearshift forks for gearbox as of gearbox manufacturing
date 07.03 .............................................................................................. 34-13 page
35 Wheels, shafts
Disassembling and assembling the drive shaft ................................................. 35-1
page
- Disassembling and assembling the drive shaft for gearbox up to gearbox manufacturing
date 06.03 .............................................................................................. 35-1
page
- Disassembling and assembling the drive shaft for gearbox as of gearbox manufacturing
date 07.03 .............................................................................................. 35-1
page
Setting drive shaft ..................................................................................... 35-2
page
- Setting drive shaft for gearbox up to gearbox manufacturing date 06.03 .................... 35-2
page
- Setting drive shaft for gearbox as of gearbox manufacturing date 07.03 ..................... 35-2
page
Disassembling and assembling output shaft gears 1 through 4 ............................ 35-3
page
Setting output shaft gears 1 through 4 ........................................................... 35-4
page
Disassembling and assembling output shaft 5th/6th and reverse gear ................... 35-5
page
Setting output shaft 5th/6th and reverse gear ................................................... 35-6
page
Replacing the flange shaft gasket rings (gearbox assembled) .............................. 39-1
page
- Replacing the left flange shaft seal ring ............................................................ 39-1
page
- Replacing the right flange shaft seal ring .......................................................... 39-1
page
Disassembling and assembling the differential ................................................. 39-2
page
- Disassembling and assembling the differential for gearbox up to gearbox manufacturing

date 06.03 .............................................................................................. 39-2
page
- Disassembling and assembling the differential for gearbox as of gearbox manufacturing

date 07.03 .............................................................................................. 39-2
page
Setting overview ........................................................................................ 39-3
page
- Setting overview for gearbox up to gearbox manufacturing date 06.03 ...................... 39-3
page
- Setting overview for gearbox as of gearbox manufacturing date 07.03 ...................... 39-3
page
Adjusting the differential gear ...................................................................... 39-4
page
39 Final drive/Differential
II
Table of Contents
Edition 02.04
S00.5329.01.20
00
00 Technical Data
00-1
Identification of the gearbox
Assignment 00-1 page 3
3
1
Location on the gearbox

Identification characters and manufacturing data of
the gearbox -arrow 1 Gearbox 0A8 -arrow 2- and -arrow 3-
2
S34-0692
Identification characters and manufacturing data of

the gearbox -arrow 1Example:
FJW
20
06
Identification
characters
Day
Month
Manufacturing
year 2003
Additional data depend on the manufacturing.

S34-0693
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00-1 page 1
00
Gearbox 0A8 -arrow 2- and -arrow 3Note

The identification 0A8 on the gearbox housing -arrow 3is only present on gearboxes as of 07.03.
3
1
S34-0694
Distinguishing features of the gearboxes 0A8
I - Gearbox up to 06.03: The gearbox housing is closed

in the area of the bearing for the drive shaft -arrow
AII - Gearbox as of 07.03: Gearbox housing in the area
of the bearing for the drive shaft is provided with a
cap -arrow B-.
II
S34-0697
00-1 page 2
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00
Identification characters, aggregate assignment, ratios, capacities

Gearbox
6 speed 0A8
Identification characters
FJW
FSM1)
HDS
Manufacturing
date
05.03
06.03
07.03
01.04
1.9 ltr./96 kW TDI
1.9 ltr./96 kW TDI
1.9 ltr./96 kW TDI
Final drive for

1st gear through
4th gear
65 : 22= 2,955
65 : 22= 2,955
68 : 21= 3,238
Final drive for

5th gear
through 6th
gear
65 : 27= 2,407
65 : 27= 2,407
68 : 26= 2,615
1th gear
49 : 13 = 3,769
49 : 13 = 3,769
49 : 13 = 3,769
2th gear
48 : 23 = 2,087
48 : 23 = 2,087
48 : 23 = 2,087
3th gear
45 : 34 = 1,324
45 : 34 = 1,324
45 : 34 = 1,324
4th gear
41 : 45 = 0,911
41 : 45 = 0,911
42 : 43 = 0,977
5th gear
37 : 41 = 0,902
37 : 41 = 0,902
39 : 40 = 0,975
6th gear
34 : 45 = 0,756
34 : 45 = 0,756
35 : 43 = 0,814
36 : 13 x 23: 14 = 4,549
36 : 13 x 23: 14 = 4,549
36 : 13 x 23: 14 =
4,549
from
through
Assignment:
Ratio:
Engine
Reverse gear
electronic
Speedometer2)
Capacity
Specification
2.3 liters
Gearbox oil G 005 100
SAE 75W90 (synthetic oil)
Gear oil change interval
Gearbox oil G 052 171

SAE 70W75 (synthetic oil)
Gearbox oil G 052

171 SAE 70W75
(synthetic oil)
Filled for life
Clutch control
hydraulic
Clutch plate
240 mm
240 mm
240 mm
Drive shaft flange
108 mm
108 mm
108 mm
1)
2)
Drive shaft must not be adjusted (firm/loose bearing).

Only on vehicles without ABS.
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00
00-1 page 4
Edition 02.04
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00
00-2
Overview of Transmission
System
Overview of Transmission system 6 speed Gearbox

02M, Rep. Gr. 00.
Edition 10.03
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Overview of Transmission System
00-2 page 1
00
00-2 page 2
Overview of Transmission System
Edition 10.03
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00
00-3
General Repair Information
To carry out gearbox repairs successfully and correctly,

scrupulous care and cleanliness, as well as the proper
tools, are essential requirements. Obviously, the generally valid basic safety rules apply to repair work.
Below is a summary of the general instructions to be applied to individual repair operations (also given elsewhere
at various parts of the workshop manual). They apply to
this workshop manual.
Contact corrosion!
The gearbox housing is made out of magnesium.
Bolts and other attachments that come into direct con-
tact with the gearbox can have varying finishes depending on whether the gearbox housing is of
magnesium.
The use of substitute components causes contact cor-
rosion (screws, nuts, washers ). This will result in

damage to the gearbox housing.
If you have any doubts about re-using parts, always
use new parts in accordance with Spare Parts catalogue.
Gearbox
When installing, ensure the dowel sleeves are correct-
ly located between the engine and gearbox.

If replacing the gearbox, pour in gear oil up to lower
edge of filler hole.

Capacity and specification Chap. 00-1.
Gaskets, seals
Clean contact surfaces thoroughly and apply sealant
-AMV 188 200 03-.

Apply sealant evenly, and not too thickly.
Replace O-rings.
Replace radial shaft seals.
Before installing:
Lightly oil the outer diameter and pack half the space between the sealing lips -arrow- with sealing grease
-G 052 128 A1-.
After installing:
Check gear oil level, if necessary pour in up to lower edge
of filler hole, specification Chap. 34-8.
Locking elements
Edition 10.03
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00-3 page 1
00
Replace circlips.
Do not over-tension the circlips.
Circlips must be positioned in the base of the groove.
Replace roll pins. Fitting position: slot longitudinally to
power flow -arrow-.

Bolts, nuts
Slacken and tighten nuts and bolts for attaching cov-
ers and housings diagonally across.

Do not twist particularly sensitive parts - e.g. clutch
pressure plates - and slacken and tighten diagonally

across in stages.
Tightening torques apply for non-oiled nuts and bolts.
Always replace the self-locking nuts and bolts.
It is important to ensure at all bolted connections that
the contact surfaces as well as the nuts and bolts are

waxed only after being installed, should this be necessary.
Bearings
New taper roller bearings are fitted as supplied and do
not require any additional lubrication.

Fit needle bearings to the gearbox with some gearbox
fluid.
Replace all taper roller bearings belonging to one
shaft at the same time. As far as possible use bearings of the same make!
Heat inner races to about 100 C for installing.
Do not exchange the outer and inner rings of bearings
of the same size - bearings go in pairs.

Position needle bearing with the lettered side (thicker
end) towards the drift pin.

Shims
Gauge shims at several points with a micrometer. Dif-
ferent tolerances allow to measure the required thickness for each washer very precisely.
Inspect for burrs and damage.
Install only shims which are in perfect condition.
Synchronizer rings
These are not interchangeable. If re-using, allocate
synchronizer rings to the same gear.

Inspect for wear, and replace if necessary.
Insert with some gearbox fluid.
Gears
Clean and heat on a heating plate to about 100 C be-
fore pressing on.

Temperature can be checked with a temperature
measuring instrument.
00-3 page 2
Edition 10.03
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30
30 Clutch
30-1
Repairing the clutch control
Summary of components - Foot controls

Special tools, test and measuring equipment and
auxiliary items required
Pliers -T10005 Polycarbamide grease -G 052 142 A2-
Note
Summary of components - Hydraulics 30-1
page 5.
Disconnect earth strap from battery.

Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.

If the battery earth strap is disconnected and connect-
ed, carry out additional operations Electrical System; Rep. Gr. 27.
Grease all bearing and contact surfaces with Polycar-
bamide Grease -G 052 142 A2-.

Prior to working on the foot controls remove the stor-
age area on the driver's side Body Work;

Rep. Gr. 70.
Edition 10.03
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30-1 page 1
30
1 - Support/Front wall
T for master cylinder and
1
bracket
2
2 - Gasket
T always replace
3
3 - Bracket
4 - Screw
4
5
5 - Gas/brake foot controls
6 - 28 Nm
T always replace
7 - Clutch pedal switch
T before removing the clutch
pedal item 11 remove the
19
20
switch by rotating it 45 to the
right and drawing it through
18
the assembly opening.
T removing and installing, setting 30-1 page 3
17
8 - Over-centre helper spring
T removing and installing
16
30-1 page 3
9
9 - Spacer bush
10 - Bushing
11 - Clutch pedal
30-1 page 4
15
12 - Support
14
13
30-1 page 6
12
13 - 28 Nm
T always replace
14 - Master cylinder
T removing and installing 30-1 page 6
15 - Retaining clip
T to remove and install the tube-hose line pull out retaining clip up to the stop.
16 - Tubing
17 - Bearing
T insert in bracket
T always replace
T Fitting position: the peg -arrow- locks into the master cylinder recess
18 - Screw
T Pedal stop on bracket
19 - Pedal stop
T screw onto bracket with screw item 18 with the master cylinder installed
20 - 25 Nm
T always replace
30-1 page 2
7
8
9
10
11
S30-0087
Edition 10.03
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30
removing and installing, setting clutch

pedal switch -F36Removing
Removing bottom part of dash panel Body Work;

Rep. Gr. 70; dash panel.
Unplug connector -1- from the clutch pedal switch

-F36-.
Turn clutch pedal switch -F36- -2- at the bracket 45

to the left and remove it from the support.
Installing
The installation occurs in reverse order, while paying attention to the following.
Move the clutch pedal -4- up to the stop into home position (clutch pedal not actuated).
Pull out the tappet -3- of the clutch pedal switch -F36fully.
Now insert the clutch pedal switch -F36- in the assem-
S30-0086
bly opening.
For locking turn the clutch pedal switch -F36- at the

bracket 45 to the right.
Insert connector at the clutch pedal switch -F36-.

Install the bottom part of the dash panel Body
Work; Rep. Gr. 70; dash panel.
Removing and installing the over-centre

helper spring
Removing

Remove clutch pedal switch -F36- 30-1 page 3.
T10005
Unlock the actuating rod/master cylinder from the clutch

pedal as follows:
S30-0051
Insert pliers -T10005- in the clutch pedal recesses.

Compress the support and separate the clutch pedal
from the master cylinder.
Press over-centre helper spring towards the front wall

-in the direction of the arrow- and remove downwards
from the bracket.
S30-0064
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30
Installing
Insert bearing for over-centre helper spring -arrow 1in the bracket.
The peg of the bearing is located in the recess of the master cylinder -arrow 2-.
2
S30-0068
Insert over-centre helper spring in the bearing.

Press over-centre helper spring towards the bearing
and position on the support of the clutch pedal -arrow-.
Connect clutch pedal to master cylinder 30-1

page 4.
Installing the clutch pedal switch 30-1 page 3.

Install the bottom part of the dash panel Body
Work; Rep. Gr. 70; dash panel.
Removing and installing the clutch pedal

Removing
S30-0065
Remove the over-centre helper spring 30-1

page 3
Unscrew hexagon nut -A- and remove hexagon screw

from bracket.
Remove clutch pedal.
Installing
Installation is performed in the reverse order. Pay attention to the following points:
S30-0054
30-1 page 4
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30
The support -A- must be located on the actuating rod

-B- of the master cylinder.
To click in the support push the clutch pedal towards

the front wall -direction of the arrow- and make sure it
catches correctly.
B A
V30-0419
Summary of components - Hydraulics

1 - Brake fluid reservoir
2 - Tubing
1
3 - Master cylinder
30-1 page 6
4 - Retaining clip
T only replace if the master cylinder has been removed
T dismantling Fig. 1 in 30-1
page 6
T push on Fig. 2 in 30-1
page 6
5 - Clutch pedal
18
30-1 page 4
6 - 25 Nm
7
17
T always replace
7 - O-ring
T pull onto line connection
T insert with brake fluid
15
8 - Tube-hose line
9 - Bracket
14
16
T Mounted at the structure
13
10 - O-ring
11 - Breather
12 - O-ring
T pull onto connection
12
11
10
13 - Retaining clip
T to remove and install pull out the retaining clip only up to the stop.
14 - Bleed valve
T Bleed the clutch system 30-1 page 8
15 - Dust cap
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8
9
S30-0088
30-1 page 5
30
16 - Retaining clip
T to remove and install pull out the bleeder only up to the stop.
17 - Slave cylinder
T for removing and installing, remove gearbox 30-2 page 1
18 - Retaining clip
T to remove and install pull out the retaining clip only up to the stop.
Fig. 1:
Lift off the support -A- in -the direction of

the arrow-.
N30-0024
Fig. 2:
Push the actuator rod/master cylinder in the

support -A- -direction of the arrow-.
Removing and installing the master cylinder

Pliers -T10005-
30-1 page 6
N30-0025
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30
Removing
MP 7-602
Disconnect the earth strap from the battery with the ignition off.
Removing air filter 1.9/96 TDI Engine, Fuel Injection; Rep. Gr. 23
Release and cut off tubing -A- to the brake fluid reservoir.
Remove the retaining clip -B- on the master cylinder

up to the stop.
Release and cut off the tube-hose line -C- from the
master cylinder.

Remove clutch pedal switch -F36- 30-1 page 3.
Note
To remove the master cylinder completely remove the
clutch control. Before removing first separate the master
cylinder from the clutch pedal.
B
S30-0075
Unlock the actuating rod/master cylinder from the clutch

pedal as follows:
Insert pliers -T10005- in the clutch pedal recesses.

Compress the support and separate the clutch pedal
from the master cylinder.
T10005
S30-0051
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30
Unscrew the hexagon nuts -arrow 1- and remove the

clutch controls -arrow A- together with the master cylinder.
Removing the over-centre helper spring 30-1

page 3.
Unhook the bearing/over-centre helper spring from
the bearing.
Unscrew pedal stop.

Remove the master cylinder.
Installing
S30-0052
The support -A- must be located on the actuating rod

-B- of the master cylinder.
To click in the support push the clutch pedal towards

the front wall -direction of the arrow- and make sure it
catches correctly.
After installing the master cylinder bleed the clutch

system 30-1 page 8.
Bleeding the clutch system

Brake filling and bleeding device -ROMESS S15-
Brake fluid specification Running Gear; Rep. Gr. 47.
B A
V30-0419
Connect the brake filling and bleeding device

-ROMESS S15-.
Insert the bleeder hose -A- on the slave cylinder -arrow- and open the bleeder valve.
Activate system with a pressure of 2 bar.

Allow approx. 100 cm3 of brake fluid to flow out until
no more air bubbles are visible.
Shut the bleeder valve.

Activate pedal forcefully from stop to stop between 10
and 15 times.
Open the bleeder valve.

Again allow approx. 100 cm3 brake fluid to flow out.
Shut the bleeder valve.
30-1 page 8
N30-0248
Edition 10.03
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30
After completing the bleeding procedure activate the

clutch pedal repeatedly.
Disconnect brake filling and bleeding device.
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30
30-1 page 10
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30
30-2
Repairing the clutch control 6 speed Gearbox 02M,

Rep. Gr. 30.
Edition 10.03
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30-2 page 1
30
30-2 page 2
Edition 10.03
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30
30-3
Repairing the clutch
Note
Pressure plate and clutch disc are assigned to each other
and must be replaced together.
Clutch - Overview of components

1 - Flywheel
1.9/96 Engine, Mechanics; Rep. Gr. 13
T make sure the centering pins
are tight
T The locating face for the
clutch lining must be free
from grooves, oil and grease
2 - Clutch disc
30-3 page 2
T must be replaced together
with pressure plate
T Fitting position Fig. 1 in
30-3 page 2
T Diameter of clutch disc
Chap. 00-1
3 - Pressure plate
30-3 page 2
T Check the extremities of the
membrane spring Fig. 2 in
30-3 page 2
T Check feather joints and riveted joints Fig. 3 in 30-3
page 2
T must be replaced together
with clutch disc
4 - M7 screw - 22 Nm
T release or tighten in small
stages crosswise
Edition 10.03
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S30-0114
30-3 page 1
30
Fig. 1:
Fitting location of clutch disc
Legend side of gearbox -arrow- points to the gearbox.
S30-0115
Fig. 2:
Check the extremities of the membrane

spring
Wear is allowed up to half the membrane spring -arrows- thickness.
Fig. 3:
Check feather joints and riveted joints
Check the feather joints between pressure plate and

cover for cracks as well as the riveted joints for firm
seating.
A pressure plate with damaged feather joints or with

loose riveted joints -arrows- must be replaced.
Note
Replace pressure plate and clutch disc together. Assign
pressure plate and clutch disc via engine identification
characters Spare Part Catalogue.
removing and installing clutch

Pressure pad -MP 1-223 Centering mandrel -T10097 Grease for plug serration of clutch disc -G 000 100-
30-3 page 2
Edition 10.03
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30
Removing
Remove the gearbox Chapter 34-7.

Insert counterholder -MP 1-223- to slacken the bolts.
Release fixing screws (6 in total) in small stages
crosswise.
MP 1-223
Remove pressure plate and clutch disc.

Installing
Note
Replace the clutch discs and pressure plates if the riv-
eting is damaged or loose.
S30-0116
Always replace clutch disc and pressure plate togeth-
er.
Assign clutch disc and pressure plate via engine iden-
tification characters Spare Part Catalogue.
In order to reduce unpleasant odours if the clutch is
burnt, thoroughly clean the clutch bell as well as the

flywheel and the engine on the side of the gearbox.
Clean the drive shaft serration and hub serration on a
used clutch disc, remove corrosion and only apply a

very thin layer of grease for plug serration of clutch
disc -G 000 100- onto the 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.
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 shortened.
The thrust surface of the pressure plate and the clutch
disc lining must fully rest against the flywheel. Only

then may the fixing screws be inserted.
Pay attention to the fitting position of the clutch disc.
S30-0115
The legend side of gearbox -arrow- points to the

gearbox.
Insert counterholder -MP 1-223- to tighten the bolts.
Position the pressure plate on the dowel pins of the

flywheel
T10097
Screw in all the screws by hand uniformly, until the

bolt head rests against the pressure plate.
Tighten the screws in small stages crosswise so as

not to damage the centering holes on the pressure
plate and the centering pins of the flywheel.
Install the gearbox Chapter 34-7.
MP 1-223
S30-0113
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30
30-3 page 4
Edition 10.03
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34
34 Control/Housing
34-1
Repairing the gearshift mechanism
Fitting location of shift mechanism

A - Shift cable for shift movement
B - Selector cable for selector
movement
C - Heat shield
T take off before removing the
shift mechanism
Arrow -A- Shift movement
Arrow -B- Selector movement
1 - Gearshift lever
2 - Reversing lever
6
3
B
A
Note
Before disconnecting the
battery determine the code of

radio sets fitted with anti-theft
coding.
Remove shift mechanism for
replacing control cables
34-5 page 1.
Do not kink the control cables.
2
A
A
B
Edition 10.03
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S34-0674
34-1 page 1
34
I - Summary of components gearshift knob and cover

34-2 page 1
II - Summary of components Shift lever and shift housing
34-3 page 1
III - Summary of components Control cables 34-4 page 1
Removing and installing shift
mechanism 34-5 page 1
Setting the shift mechanism
34-6 page 1
III
II
S34-0675
34-1 page 2
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34
34-2
I - Summary of components - gearshift knob and cover
1 - Gearshift knob
T with collar
T the gearshift knob and collar
cannot be separated
T always replace together
34-2 page 2
2 - Warm-type clamp
T for securing the gearshift
knob to the gearshift lever
3 - Surround of centre console
4 - Sound insulation
I
1
2
3
S34-0676
Edition 10.03
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34-2 page 1
34
Separating collar from gearshift lever

Removing
Lever the collar upwards and out of centre console

surround -arrows-.
Pull the collar upwards over the gearshift knob.
Open clamp -arrow- and pull off gearshift knob together with the collar.
Installing
Turn collar inside out.

Insert gearshift knob and collar and compress collar
clamp -arrow-.
When inserting the gearshift knob on the selector lever
the gearshift knob must lock into the round slot of the
gearshift lever.
34-2 page 2
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34
34-3
II - Summary of components - shift lever and shift housing
Note
Grease bearing and friction surfaces with Polycarbamide Grease -G 052 242 A2-.
1 - Lock washer
Fig. 1 in 34-3 page 2
2 - Bush
3 - Pressure spring
4 - Bush
5 - 5 Nm
6 - Cover
7 - Damping
8 - Bearing shell
9 - Shift lever guide
10 - Insulating washer
11 - Gasket
T between shift housing and
body
T adhesive
T stick onto shift housing
12 - Shift lever
13 - Damping
14 - Shift housing
15 - Bushing
16 - Bearing bolt
17 - Guide bush
18 - Pressure spring
T installing Fig. 2 in 34-3
page 2
19 - Selector lever
20 - 5 Nm
21 - Floor plate
T bend up tabs for removing
T replace
22 - Selector cable
T at selector angle plate
T Fitting position Chapter Fitting location of shift mechanism in 34-1
23 - Shift cable
T press onto shift lever guide
T Fitting position Chapter Fitting location of shift mechanism in 34-1
24 - Lock washer
25 - 25 Nm
T 4 pieces
26 - Bushing
T fits in one position only
27 - Lock washer
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34-3 page 1
34
Fig. 1:
Removing and installing circlip
To remove and install the circlip -arrow A- press spacer bush -arrow B- with screwdriver up to the stop in the
direction of the arrow -arrow C- and remove circlip.
Note
Do not twist bush when pressing down.
Mounting slot in shift lever for circlip must be visible.
Release spring carefully.
B
N34-1363
Fig. 2:
Installation of pressure spring
Insert pressure spring so that leg -A- is positioned

above the stud -arrow-.
After this, pull the leg -B- down far enough so that it
moves underneath the stud -arrow-.
34-3 page 2
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34
34-4
III - Summary of components - Control cables
Note
Grease bearing and friction surfaces with Polycarbamide Grease -G 052 242 A2-.
1 - Shift cable
III
T press onto shift lever guide
T Fitting position Chapter
1
3
Fitting location of shift
mechanism in 34-1
2 - Selector cable
T at selector angle plate
T Fitting position Chapter
Fitting location of shift
mechanism in 34-1
2
3 - Lock washer
4 - Shift housing
5 - Lock washer
1
T do not damage cables when
removing
6 - 23 Nm
T 2 pieces
18
2
T for support
7 - Support
9
5 6 5
8 - Grommet
8
11
T mounting of support to gear14 13
box
9 - Spacer
10 - 23 Nm
17
11 - Cable lock
10
T for selector cable at relay le12
ver item 18
16
12 - Cable lock
15
T for shift cable at gearbox shift
9
lever item 16
13 - Lock washer
14 - Bushing
T insert in gearshift shaft cover
15 - 23 Nm
16 - Gearshift lever
T with balancing weight
T insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft
T after installing set shift mechanism 34-6 page 1
T Fitting position Fig. 1 in 34-4 page 2
17 - Sliding shoe
18 - Reversing lever
T Fitting position Fig. 1 in 34-4 page 2
4
5
7
8
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S34-0677
34-4 page 1
34
Fig. 1:

Fitting location of gearbox shift lever/relay
lever
1 - Gearbox shift lever with balancing weight

2 - Relay lever is inserted over the sliding shoe into the
sliding rail of the gearbox shift lever -arrow-
1
S34-0678
34-4 page 2
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34
34-5
Removing and Installing

Shift Mechanism
Removing
Disconnect the earth strap from the battery with the ignition off.

surround -arrows-.
Pull the collar upwards over the gearshift knob.
Open clamp -arrow- and pull off gearshift knob together with the collar.
Remove the centre console Body Work;

Rep. Gr. 68.
Remove noise insulation.
Unscrew nuts -arrows- attaching the shift housing.

Remove air filter Rep. Gr. 23; Removing and installing air filter.
Remove battery and battery tray Electrical System;

Rep. Gr. 27.
S34-0499
Edition 10.03
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Removing and Installing Shift Mechanism
34-5 page 1
34
Remove circlip -2- from gearbox shift lever -1- and circlip -4- from relay lever -3-.
Remove shift cable and selector cable from the studs
-arrows-.
S34-0683
Remove cable support -A- from the gearbox -arrows-.
S34-0680
Detach bracket -1- below the exhaust system.

Unhook front exhaust pipe from bracket -2-.
Unbolt bracket for front exhaust pipe -2-.
Separate exhaust system at the double clamp -3-.
Remove exhaust pipe.

Note
The front silencer remains hanging in the hanger -4-.
Remove heat shield -5-.

Swivel shift housing down and remove with control cables.
Installing
Assemble exhaust system free of stress 1.9/96 Engine, Mechanics; Rep. Gr. 26.
Pay attention to the fitting location of the strut -1-.
34-5 page 2
S34-0489
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34

The cable locks are bored through with holes continuously for attaching to the gearbox shift lever or to
the relay lever.
The holes in the cable locks have different diameters.
Fig. 1:
Assignment
Cable lock for:
Dimension
a
Shift cable at gearbox shift lever
10 mm
Selector cable at relay lever
8 mm
Apply a small quantity of grease onto the studs -arrows- of the gearbox shift lever -1- and of the relay lever -3-.
Replace the circlips -2- and -4- after each removal.

Secure the shift cable with the circlip -2- and the se-
lector cable with the circlip -4-.

Setting the shift mechanism 34-6 page 1.
S34-0683
Install the centre console Body Work; Rep. Gr. 68.

Replace clamp -arrow-.
Install Electrical System; Rep. Gr. 27.

Pay attention to the work steps after connecting the
battery Electrical System; Rep. Gr. 27; Battery; disconnect and connect battery.
Tightening torques
Components
Torque
Shift housing to body
25 Nm
Strut to body
25 Nm
Cable support to gearbox
23 Nm
Bracket to body
25 Nm
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34-5 page 3
34
34-5 page 4
Edition 10.03
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34
34-6

Rig pin -T10027-
Note
The following are required for correct setting of the
shift mechanism:
Operating and transmission elements of the shift
mechanism are in perfect condition.

Shift mechanism operates freely.
Gearbox, clutch and clutch control must be in perfect
condition.
Gearbox in Neutral.

Rep. Gr. 27.
S34-0681
Pull forward the locking mechanism at shift cable and

at selector cable as far as the stop -direction of arrow
1-, then lock by turning to the left -direction of arrow 2-.
Determine gearshift shaft for gearboxes up to 06.03:
Carefully press the gearshift shaft down in direction of

-arrow 1-.
When pressing down the gearshift shaft push the locking bolt -A- into the gearbox -direction of arrow-, until
it locks in place.
This locks the gearshift shaft, it can no longer be moved.
A
S34-0686
Determine gearshift shaft for gearboxes as of 07.03:
Carefully press the gearshift shaft down in -direction
of arrow 1-.
When pressing down the gearshift turn the locking bolt

-A- in -direction of arrow 3- upwards and while doing
so press it simultaneously in -direction of arrow 2-, until it locks into the gearshift shaft.
This locks the gearshift shaft, it can no longer be moved.
2
3
Continued for all gearboxes
S34-0728
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34-6 page 1
34

cover -arrows-.
If available remove the noise insulation.

Guide shift lever in Neutral to the left into the 1st/2nd
gear gate.
Insert rig pin -T10027- through hole -A- into hole -B-.
Now turn the locking mechanism at the shift cable and

at the selector cable to the right as far as the stop -direction of the arrow 1-.
The spring pushes the locking mechanism into the initial

position -direction of arrow 2-.
Gearbox up to 06.03:
2
1
S34-0682
34-6 page 2
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34
Now pull the locking bolt -A- back to the initial position
-in direction of arrow-.
Gearbox as of 07.03:
A
S34-0687
Now turn the locking bolt -A- back to the initial position
in -direction of arrow 2-.
The locking bolt -A- must be pressed in -direction of arrow
1-.
Continued for all gearboxes
1
2
S34-0729
Pull rig pin -T10027- out of hole -A- and -B-.

Perform the functional test 34-6 page 3.
Insert noise insulation.
Press collar into the cover.

Pay attention to the work steps after connecting the
battery Electrical System; Rep. Gr. 27; Battery; disconnect and connect battery.
Operation
Shift lever must be positioned in Neutral in the gate of
3rd/4th gear.
Depress clutch.
Shift through all gears several times. Pay particular attention to proper operation of the reverse gear lock.
If the gearshift lever catches when repeatedly engaging a
gear, check the play (stroke) of the shift shaft as follows:
Edition 10.03
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34-6 page 3
34
Carefully guide shift lever in Neutral to the left into the

1st/2nd gear gate.
The gearshift shaft must move downwards -arrow 1-.

If the gearshift mechanism is correctly set, now the
locking bolt -A- must be pushed into the gearbox -direction of arrow- and thus into the sliding-block of the
gearshift shaft (2nd mechanic).
If this is not the case set gearshift mechanism 34-6

page 1.
A
S34-0686
34-6 page 4
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34
34-7
Removing and installing

the gearbox
Removing
Gearbox attachment device -MP 3-478 Hose clamp -MP 7-602 Supporting device -MP 9-200 Lifting device -MP 9-201 Gearbox mount -3282 Adjusting plate -3282/27 Engine and gearbox jack (e.g. -V.A.G 1383 A-)
Grease -G 000 100-

Disconnect the earth strap from the battery with the ig-
1
1
nition off.
Remove the engine trim panel.

Remove air filter with air guide hose Rep. Gr. 23;
Removing and installing air filter.

Rep. Gr. 27.
Pull forward the locking mechanism at shift cable and
S34-0681
at selector cable as far as the stop -direction of arrow

1-, then lock by turning to the left -direction of arrow 2-.
Remove cable support -2- from the gearbox -arrowsand tie up.
S34-0680
Edition 10.03
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Removing and installing the gearbox
34-7 page 1
34
Detach circlip -arrow A- from the relay lever -1- and remove relay lever.
Remove the gearshift lever -2-, for this step unscrew

nut -arrow B-. To this end use if necessary a puller,
e.g. Kukko -20-10-.
Unscrew earth strap -3- from the top starter.

Disconnect plug -4- from the reversing light switch
-F4-.
Detach line -5- from the starter.

Unplug the connector from the speedometer sender
-G22-.
Remove engine/gearbox connecting screws at the

top.
Remove fixing screw for starter at the top.

Raise vehicle and remove front left wheel.
2
4
5
S34-0679
Remove noise insulation -arrows-.
S10-0114
Unscrew bracket from starter -arrow- and lay aside together with lines.
Remove the starter Electrical System; Rep. Gr.

27.
Remove the front left wheelhouse liner Body Work;

Rep. Gr. 66; Wheelhouse liner.
Remove drive shafts from the flange shafts.

Separate exhaust system at the double clamp and tie
up front exhaust pipe 1.9/96 TDI Engine, Mechanics; Rep. Gr. 26.
S34-0492
34-7 page 2
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34
Mark installation position of bolts -1- for left and right

steering joint, otherwise the steering geometry must
be checked.
Release screws -1-.

Unbolt left and right coupling rod -2- from the anti-roll
bar -arrow-.
Turn left coupling rod upwards.

Swivel out the left wheel-bearing housing.
For this step guide the left drive shaft into the wheelhouse and secure to the suspension strut with e.g.
wire.
Tie up the right drive shaft as far as possible. Avoid

damaging the paintwork on the drive shaft during this
operation.
Remove pendulum support -A- -arrows 1 and 2-.

Remove assembly carrier -B-, to do so use fixing de-
vice -T10096- Chassis; Rep. Gr. 40; Repairing

front axle.
1
B
2
S34-0690
Remove small cover plate -A- for flywheel behind the

right flange shaft -arrows-.
V34 - 3005
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34-7 page 3
34
Unclamp the hose to the slave cylinder with hose

clamp -MP 7-602-.
Lever out clamp -arrow- for tube-hose line up to the
MP 7-602
stop using a screwdriver.
Pull out tube-hose line in -direction of arrow-.

Note
Do not depress the clutch pedal.
S34-0535
Remove the support for the engine cover in the left lifting eye of the engine -arrow-.
S34-0493
Install supporting device -MP 9-200-.
MP 9-200
Note
When installing the lifting hooks of the supporting device,
pay attention to hose and cable connections in the area
of the lifting eyes of the engine to avoid damaging them.
MP 9-200/3
MP 3-4013
MP 9-201
S34-0685
34-7 page 4
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34
Remove the lug from the central bore hole of the lifting
device -MP 9-201-.
Place the bolt -arrow 1- back in the central bore hole
MP 9-200
of the lifting device.
Then insert the bolt -arrow 1- in the spindle of the supporting device -MP 9-200-.
Hang the lifting device -MP 9-201- in the lifting eyes at

the front -arrow 2- and rear -arrow 3- on the engine, as
shown in the illustration.
3
1
Note
MP 9-201
Use securing pins on the hooks and rig pins.
Take up the weight of the engine/gearbox unit at the
S34-0684
spindles.
Loosen screws -arrows- for engine mount to engine

support by about 5 turns.
ax
m
in
m
S10-0149
Unscrew screws -arrows- of unit mounting for gearbox

-2- from the console -1-.
Move engine/gearbox unit carefully into oblique position. To do so screw down the left spindle about 50
mm on the supporting device -MP 9-200-.
S34-0688
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34-7 page 5
34
Remove console -1- from the gearbox -arrows A

C-.
Remove the engine/gearbox rear connecting screw
below the right flange shaft.
Remove engine/gearbox connecting screws below.

Insert engine mount -3282- into engine and gearbox
jack, e.g.-V.A.G 1383 A-.
The gearbox mount -3282- is aligned for removal of the
gearbox 0A8 by using the adjusting plate - 3282/27-.
S34-0689
Align arms of the gearbox mount with the holes in the

adjusting plate.
Screw in mounting elements -A-, as shown on the ad-
justing plate.
B
A
A
02M
N34-1052
Position engine and gearbox jack below vehicle, arrow symbol -B- ( 34-7 page 6) on adjusting plate
points in the direction of travel/vehicle.
Align the adjusting plate -3282/27- parallel to the gearbox.
Secure the gearbox on the gearbox support -3282using screw -A-.
3282/27
Note
For gearboxes with cover in gearbox housing (for firm/
loose bearing of the drive shaft) place a nut M10 as a
spacer between gearbox and mount onto the screw -A-.
3282
Remove engine/gearbox connecting screw -arrow-.

Press gearbox from engine.
Position the gearbox via the spindles of the gearbox
N34-1053
mount -3282- inclined to the left.
After this lower gearbox carefully.
34-7 page 6
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34
Transporting the gearbox
Screw down gearbox suspension device -MP 3-478onto clutch housing.
Adjust supporting arm at slide with locking pin -arrow-.

Number of visible holes = 6
Raise gearbox with workshop crane and gearbox suspension device -MP 3-478-.
Place down gearbox, e.g. in a transport container.
Installing
The installation of the gearbox occurs in reverse order.
Install engine/gearbox mounting free of stress 1.9/96
Engine, Mechanics; Rep. Gr. 10.
MP 3-478
S34-0695
Note
Clean splines of drive shaft and apply a thin film of
grease -G 000 100-.

The clutch plate must slide freely up and down the
drive shaft.
If the gearbox is installed, ensure the intermediate
plate between the engine and gearbox is correctly installed.

Check whether the dowel sleeves for centering the
engine/gearbox are present in the cylinder block; insert if necessary.

Installing engine mounting on engine support 1.9/
96 Engine, Mechanics; Rep. Gr. 10.

Assemble exhaust system free of stress 1.9/96 En-
gine, Mechanics; Rep. Gr. 26.

Installing starter/cable Electrical System;
Rep. Gr. 27.

Check gear oil Chap. 34-8.
Bleed the clutch system Chap. 30-1.
Install assembly carrier Chassis; Rep. Gr. 40; Re-
pairing front axle

Remove air filter Rep. Gr. 23; Removing and in-
stalling air filter.

Fit the drive shaft to the flange shaft Chassis;
Rep. Gr. 40; Repairing front axle

Setting shift mechanism Chap. 34-6.

If the battery earth strap is disconnected and connect-
ed, carry out additional operations Electrical System; Rep. Gr. 27.
Tightening torques
Gearbox at engine
A
2
5
4
Edition 10.03
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N34-1057
34-7 page 7
34
1)
2)
Pos.
Screw
Pieces
Nm
11)
M 12 x 55
80
21)
M 12 x 70
80
32)
M 12 x 165
80
41)
M 10 x 55
40
51)
M 10 x 105
40
Replace bolts
additional starter to gearbox
Pos. A + B - dowel sleeves

Pendulum support to gearbox -screws 1- and assembly carrier -screw 2-
2
S34-0691
Note
Position the screws -1- in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier.
1 - 30 Nm + 90 (1/4 turn)
2 - 40 Nm + 90 (1/4 turn)
Replace bolts
Gearbox console -1- to gearbox
When installing the gearbox console, observe the following mounting sequence:
Screw in all screws -arrows A, B and C- by hand.

Tighten bolt -A- to 40 Nm + 90 (1/4 turn).
Tighten bolts -B and C- to 40 Nm + 90 (1/4 turn).
S34-0689
Replace bolts
Gearbox to body
Screws -arrows-
2
40 Nm + 90
Replace bolts
Components
Torque
Cable support to gearbox
23 Nm
Gearbox shift lever to gearbox
23 Nm
Steering joint to track control arm1)

M8
Coupling rod to anti-roll bar
Wheel bolts to wheel hub
Nut for attaching double clamp of exhaust system
1)
20 Nm + 90
40 Nm
S34-0688
120 Nm
40 Nm
Always replace these bolts.
34-7 page 8
Edition 10.03
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34
34-8
Inspecting gear oil

Socket wrench insert -T30023-
Gear oil specification Chapter Identification characters, aggregate assignment, ratios, capacities in 00-1
S10-0114
Unscrew plug for inspecting gear oil -arrow-.

The oil is at the correct level if the gear is filled up to the
lower edge of the oil filler hole.
Screw in screw -arrow- using a new sealing ring and

tighten to 45 Nm.
If re-filling, do the following:
Unscrew plug -arrow-.

Pour in gear oil up to lower edge of filler hole.
Screw in screw -arrow- using a new sealing ring and
tighten to 45 Nm.
Install the noise insulation.
Edition 10.03
S00.5329.00.20
S34-0696
Inspecting gear oil
34-8 page 1
34
34-8 page 2
Inspecting gear oil
Edition 10.03
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34
34-9
Disassembling and assembling the gearbox for

gearbox as of gearbox
manufacturing date 07.03
Disassembling and assembling the gearbox for gearbox up to gearbox manufacturing date 06.03 (gearbox identification characters FJW) 6 speed
Gearbox 02M; Rep. Gr. 34; Disassembling and assembling gearbox for vehicles with front-wheel drive
Gearbox overview
1 - Clutch housing
2 - Reverse shaft
3 - Output shaft 5th/6th gear and
reverse gear
4 - Slave cylinder with release
bearing
5 - Drive shaft
6 - Output shaft gears 1 through
4
7 - Differential
8 - Right flange shaft
9 - Flange shaft left
10 - 2nd gear sliding gear
11 - 1st gear sliding gear
12 - 4th gear sliding gear
13 - 3rd gear sliding gear
16 - Reverse gear sliding gear
17 - Gearbox housing
14
15
16
17
1
2
3
4
5
6
7
8
13
12
11
10
9
S34-0738
Edition 10.03
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Disassembling and assembling the gearbox for gearbox as of

gearbox manufacturing date 07.03
34-9 page 1
34
Summary of components
l - Gearbox housing and gearshift mechanism - Summary
of components
ll - Drive shaft, output shafts (input shafts), differential and
gearshift rods - Summary of
components
II
S34-0698
34-9 page 2

Edition 10.03
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34
Gearbox housing and gearshift mechanism - Summary of components

1 - Conical screw, 33 Nm
2 - Flange shaft with pressure
spring
34-9 page 5
T complete Chap. 39-2
3 - Cap
4 - Circlip
5 - Switch for reversing lights, 20
Nm
6 - Gasket ring
T always replace
7 - Oil drain plug, 45 Nm
8 - Gasket ring
T always replace
9 - Locking screw, 45 Nm
T for gearshift shaft
10 - 15 Nm + torque a further 90
(1/4 turn)
T with captive washer
T always replace
11 - 15 Nm + torque a further 90
(1/4 turn)
T without washer
T always replace
12 - Shift mechanism
T disassembling and assembling Chapter 34-12
T remove with the gearbox installed: to do so remove air
filter, battery with battery tray
and locking screw item 9
13 - 20 Nm
T always replace
14 - O-ring
T always replace
15 - Clutch housing
T repair Chapter 34-11
16 - Gearbox housing
T repair Chapter 34-10
Edition 10.03
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4
5
6
7
8
10
16
15
14
13
12

11
10
S34-0739
34-9 page 3
34
Drive shaft, output shafts (input shafts), differential and gearshift rods - Summary of
components
1 - Output shaft gears 1 through
1
4
34-9 page 5
2 - Gear shift rod with shift fork
for 1st and 2nd gear
34-9 page 5
for 3rd and 4th gear
34-9 page 5
4 - Output shaft 5th/6th and reverse gear
34-9 page 5
for 5th and 6th gear
34-9 page 5
6 - Gearshift fork reverse gear
34-9 page 5
7 - Drive shaft
8 - Reverse shaft
T with thrust washer
34-9 page 5
9 - Thrust washer
10 - Breather
T Connect to slave cylinder item 14
11 - Clutch housing
12 - Gasket ring for drive shaft
13 - O-ring
T always replace
T moisten with brake fluid before installing
14 - Slave cylinder with release bearing
15 - 12 Nm
T 3 pieces
T always replace
17 - Flange shaft with pressure spring
T removing and installing 34-9 page 5
T complete Chap. 39-2
34-9 page 4
18
9
10
11
12
13
17
16
15

14
S34-0699
Edition 10.03
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34

18 - Differential
Fig. 1:
1234ABCD-
Fitting position of shafts and gear shift rods

in the geabox
3
C
Drive shaft
Output shaft gears 1 through 4
Output shaft 5th/6th and reverse gear
Reverse shaft
Selector rod 3rd and 4th gear
Selector rod 1st and 2nd gear
Selector rod 5th and 6th gear
Gearshift fork reverse gear
Mounting sequence
S34-0700
Removing and installing the gearbox housing, shift

mechanism, drive shaft, output shafts (input shafts),
differential and gear shift rods
Press-on sleeve -MP 3-412 Multi-purpose tool -MP 3-419 Adapter -MP 3-419/40 Supporting bridge -MP 3-425 Gearbox mount -MP 3-501 Assembly stand -MP 9-101 Drift pin -3382 Drift -T10168 Pressure plate -T40008 Hot-air blower
Separating device e.g. -Kukko 17/0 Sealant -AMV 188 200 03 Catch pan
Removing
Secure gearbox to the assembly support with screws

-arrows-.
Remove breather -A- from slave cylinder, to do so pull

out retaining clip up to the stop.
Turn the gearbox in the assembly support with the oil

drain plug downwards.
Position catch pan underneath.

Drain out gear oil.
A
MP 3-501
Edition 10.03
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MP 9-101
S34-0731
34-9 page 5
34
Remove slave cylinder with release bearing -arrows-.
MP 3-501
S34-0547
Put the gearshift shaft in neutral position, while doing

so the locating bolt -arrow- must be laid out.
Unscrew the locking screw -1-.

Then unscrew screws -3-.
Remove reversing light switch -2-.

Pull the gearshift shaft -4- out of the gearbox housing.
Remove both flange shafts.
3
4
S34-0701
Unscrew screws -B-, that serve to secure the gearbox

housing from the clutch housing.
Note
The hexagon bolt -arrow- is located outside the screw-
on flange. It is fitted with a washer.

The illustration shows no gearbox mount.
34-9 page 6

Edition 10.03
S00.5329.00.20
34
Interlock the drive shaft, to do so fit the press-on

sleeve -MP 3-412- via the drive shaft onto the clutch
housing.
Tighten the separating device -A-, e. g. -Kukko 17/0-
behind the splines of the drive shaft.
The reverse side of the separating device must rest on

the press-on sleeve with no play.
MP 3-412
S34-0732
Push the rubber through the middle of the cap -1- using a screwdriver -2-
Lever out the cap carefully out of the gearbox housing.
Remove the circlip -C- from the grooved ball bearing of

the drive shaft as follows:
B
S34-0734
Edition 10.03
S00.5329.00.20

34-9 page 7
34
Hold one end of the circlip with the screwdriver -A-.

With the 2nd screwdriver -B- lever the other end of the
circlip out of the slot of the grooved ball bearing -arrow-.
Then move screwdriver -B- around, levering out the

circlip step by step.
Remove the fixing screws -A- for the gearbox housing

on the clutch housing.
S34-0548
Screw the Adapter -MP 3-419/40- into the threaded

bore of the gearbox housing.
Heat the gearbox housing with the hot-air blower at

the bearing assembly for grooved ball bearing/drive
shaft to about 100 C for around 10 minutes.
MP 3-419
MP 3-419/40
Remove the gearbox housing from the clutch housing

-direction of arrow- using the multi-purpose tool
-MP 3-419-.
Note
If necessary carefully release with tyre lever from the projecting housing lands and make sure the sealing surfaces
are not damaged in the process.
S34-0737
Remove the separating device -A- and the press-on

sleeve -MP 3-412- from the drive shaft.
For the removal of the shafts from the clutch housing a
second mechanic is required.
MP 3-412
S34-0732
34-9 page 8

Edition 10.03
S00.5329.00.20
34
Lift the differential -1- with the left hand.

With the right hand lift the output shaft gears 1 through
4 together with the gear shift rods -2- -arrow A-.
At the same time the 2nd mechanic lifts the drive
shaft, the reverse shaft and the output shaft 5th/6th

gear -3- together with the gear shift rods out of the
clutch housing -arrow B-.
Note
If necessary the differential can be placed again in the
clutch housing after lifting the shafts.
If necessary remove the gasket ring for the drive shaft.
Installing
S34-0703
First insert the drive shaft -1-, the output shaft 5th/6th
gear -2- together with gear shift rod -3-, shift fork -4and reverse shaft -5-.
5
4
Then insert the differential -1-.
Note
S34-0704
For further installation of the shafts in the clutch housing

a second mechanic is required.
As shown in the figure take the output shaft gears 1
through 4 -3- with the gear shift rods -4- in the right
hand.
At the same time the 2nd mechanic must slightly lift

the drive shaft, the output shaft 5th/6th gear and reverse gear -2- together with the reverse shaft.
Now insert the output shaft gears 1 to 4 in -the direction of the arrow-.
S34-0705
The serrations of the drive shaft, output shafts and final drive/differential must be in mesh.
Edition 10.03
S00.5329.00.20

34-9 page 9
34
Place the shafts and the differential together with a

2nd mechanic in their bearing assembly.
Secure the supporting bridge -MP 3-425- for the drive
shaft to the clutch housing.
MP 3-425
Note
To provide a clearer illustration, the clutch housing is
shown at an angle of 180.
Screw in screw -A- until the drive shaft is lifted slightly.

Heat the gearbox housing with the -Heiluftgeblseat the bearing assembly for grooved ball bearing/drive
shaft to 100 C for around 10 minutes.
Apply sealant -AMV 188 200 03- uniformly on the
MP 3-501
MP 3-466
S34-0730
sealing surface.
Fit gearbox housing and tighten the connecting

screws of the clutch housing/gearbox housing.
Install circlip -1- for grooved ball bearing/drive shaft.

Remove supporting bridge -MP 3-425- for drive shaft.
S34-0736
In case the serrated sleeve for the gearshift shaft has

been removed, now drive it in with the drift -T10169up to the stop of the tool.
Turn the gearbox with the opening for the gearshift

shaft in the assembly support upwards.
T10169
MP 3-501
S34-0733
34-9 page 10

Edition 10.03
S00.5329.00.20
34
Insert the gearshift shaft -1- into the bottom bearing

-2- and into the gearshift forks -3-. The cap in the illustration is removed for purposes of clear presentation.
2
S34-0706
Now press the gearshift shaft -1- against the serrated

sleeve -2- -direction of arrow- and guide with the shift
finger -3- through the gearshift forks up to the stop
downwards.
The gearshift cover -4- must be positioned at the
same time parallel to the screw-on surface at the

gearbox housing.
The gearshift shaft must slide easily into the selector

movement (upwards and downwards).
1
Note
If the gearshift cover is positioned obliquely to the screwon surface, the gearshift shaft is not inserted into the bottom bearing.
S34-0707
Tighten screws -3- for the cover/gearshift shaft -4-.

Screw in locking screw -1-, at the same time the lock-
ing angle -arrow- must be laid out.
Install reversing light switch -2-.

Install both flange shafts with pressure springs, stop
discs and conical rings.
3
4
Edition 10.03
S00.5329.00.20

S34-0701
34-9 page 11
34
Drive in the gasket ring for the drive shaft.

Install slave cylinder with release bearing and breather.
Shift through all gears.
Drive new cap with drift pin -3382- into the gearbox
housing.
3382
S34-0735
34-9 page 12

Edition 10.03
S00.5329.00.20
34
34-10 Repairing the gearbox

housing
Repairing the gearbox housing for gearbox up to gearbox manufacturing date
06.03
Repairing the gearbox housing for gearbox as of gearbox
manufacturing date 06.03 (identification characters
FJW 6 speed Gearbox 02M; Rep. Gr. 34; Repairing
the gearbox housing
Repairing the gearbox housing for gearbox as of gearbox manufacturing date

07.03
Drive bushing -MP 3-402 Multi-purpose tool -MP 3-419 Pressure plate -MP 3-420 Thrust piece -MP 3-423 Guide piece -MP 3-454 Gearbox mount -MP 3-501 Pipe section -MP 3-4012 Assembly stand -MP 9-101 Drift -T10168 Drift -T10169 Pressure plate -T10203 Retaining plate -T30027 Guide bolts -T30074 Spindle -T30100 Interior extractor 14.5...18.5 mm e.g. -Kukko 21/2 Interior extractor 23.5...30 mm e.g. -Kukko 21/4 Countersupport e.g. -Kukko 22/2-
Edition 10.03
S00.5329.00.20
Repairing the gearbox housing
34-10 page 1
34
1 - Gearbox housing
T if replaced: Setting the out18
1
put shafts and differential
gear Chapter 39-3
2 - Cap
T removing Fig. 1 in 34-10
page 3
T inserting Fig. 2 in 34-10
page 3
3 - Oil drain plug, 45 Nm
4 - Gasket ring
T always replace
5 - Oil filler plug, 45 Nm
17
6 - Locking bolt
T is pushed into the slidingblock of the gearshift shaft
16
15
for setting the gearshift
mechanism Chap. 34-6
T can be replaced without dis14
assembling gearbox
page 4
34-10 page 4
13
page 4
7 - Bushing
12
T for selector rods
11
page 5
10
page 5
8 - Serrated sleeve
T press out with gearbox disassembled Fig. 8 in 34-10 page 5
T drive out without disassembling gearbox Fig. 9 in 34-10 page 6
T inserting Fig. 10 in 34-10 page 6
9 - Needle bushing
T for reverse shaft
T replace after each removal
T removing Fig. 11 in 34-10 page 6
T installing Fig. 12 in 34-10 page 7
10 - Outer ring/tapered-roller bearing
T for output shaft 5th/6th and reverse gear
T removing and installing Chap. 35-5
T if replaced: Setting output shaft 5th/6th and reverse gear Chap. 35-6
11 - Adjusting washer
T Setting overview Chapter 39-3
T for output shaft gears 1 through 4
T removing and installing Chapter 35-3
T if replaced: Setting output shaft gears 1 through 4 Chap. 35-4
34-10 page 2
4
5
6
7
8
7
9
S34-0708
Edition 10.03
S00.5329.00.20
34

T for differential
T if replaced: Setting the differential gear Chap. 39-4.
T for differential
16 - Bushing
T removing Fig. 13 in 34-10 page 7
17 - Plug
T drive out with drift
18 - Gasket ring
T for left flange shaft
T replacing Chapter 39-1
Fig. 1:
Removing cap -A-
Push the rubber through the middle of the cap using a

screwdriver -B- and lever out the cap -direction of arrow-.
A
B
S34-0709
Fig. 2:
Drive in cap up to the stop
MP 3-402
S34-0710
Edition 10.03
S00.5329.00.20
34-10 page 3
34
Fig. 3:

Removing locating bolt for gearshift shaft
Break off the angle of the bolt in the released position

Insert a screwdriver -A- in the hole of the locating bolt
-B-.
Lever out the locating bolt in the -direction of the arrow-.
S34-0711
Fig. 4:
Fitting position of locating bolt
The marking on the locating bolt -arrow- must point to

the connection of the slave cylinder -1-.
The angle -a- must be approx. 45.
S34-0712
Fig. 5:
Driving in locating bolt for gearshift shaft
The locating bolt -arrow- must be released during

drive-in procedure.
Driving in locating bolt up to the stop of the tool.
T10203
S34-0713
34-10 page 4
Edition 10.03
S00.5329.00.20
34

Fig. 6:
Remove bushing for gear shift rod
A - Interior extractor 14.518.5 mm, e.g. -Kukko 21/2B - Countersupport, e.g. -Kukko 22/2-
B
T30027
S34-0714
Fig. 7:
Drive in the bushing for the shiftrod up to

the stop of the tool.
T10168
S34-0715
Fig. 8:
Press serrated sleeve -A- out of gearbox

housing
Position the gearbox housing on the pressure plates

-MP 3-406- and -MP 3-407- in such a way that the
dowel sleeves in the gearbox housing are not damaged.
MP 3-454
MP 3-407
MP 3-406
A
S34-0716
Edition 10.03
S00.5329.00.20
34-10 page 5
34
Fig. 9:
Drive out serrated sleeve without disassembling gearbox
Locking screw and gearshift shaft removed.
T30074
Turn the gearbox in such a way that the serrated

sleeve does not fall into the gearbox.
Drive out serrated sleeve with the guide bolt -T30074-.
S34-0717
Fig. 10: Drive in serrated sleeve
Gearbox housing screwed to clutch housing.

Drive in serrated sleeve with the drift -T10169- up to
T10169
MP 3-501
S34-0733
Fig. 11: Pull needle bushing for reverse shaft out of

the gearbox housing
A - Interior extractor 23.530 mm, e.g. -Kukko 21/4B - Countersupport, e.g. -Kukko 22/2-
Note
The needle bushing is damaged when removed and must
be replaced.
T30027
S34-0718
34-10 page 6
Edition 10.03
S00.5329.00.20
34

Fig. 12: Press needle bushing into the gearbox
housing
MP 3-423
Position the thrust washer -B- of the reverse shaft

onto the needle bushing -A- during press-in procedure.
Support the gearbox housing with a pipe section

-MP 3-4012 - directly below the bearing support.
S34-0719
Fig. 13: Remove bushing for gearshift shaft
MP 3-419/15
Hold the spindle -T30100- and turn the nut -B-.
MP 3-420
A - Interior extractor 14.518.5 mm, e.g. -Kukko 21/2-
T30100
B
S34-0720
Fig. 14: Driving in bushing for gearshift shaft
Drive in flush the bushing -A- for the gearshift shaft.
T10168
S34-0721
Edition 10.03
S00.5329.00.20
34-10 page 7
34
Fig. 15: Driving in plug
Drive in plug -1- with the mandrel -T30083- to the dimension -a- = approx. 3 mm below the upper edge of
the housing.
T30083
S34-0722
34-10 page 8
Edition 10.03
S00.5329.00.20
34
34-11 Repairing the clutch housing

Repairing the clutch housing for gearbox up to gearbox manufacturing date
06.03
Repairing the clutch housing for gearbox as of gearbox
manufacturing date 06.03 (identification characters
FJW 6 speed Gearbox 02M; Rep. Gr. 34; Repairing
the clutch housing
Repairing the clutch housing for gearbox as of gearbox manufacturing date

07.03
Thrust piece -MP 3-408 Thrust piece -MP 3-423 Drift -T10168 Pressure plate -T40008 Interior extractor 14.5...18.5 mm e.g. -Kukko 21/2 Interior extractor 23.5...30 mm e.g. -Kukko 21/4 Countersupport e.g. -Kukko 22/2-
Edition 10.03
S00.5329.00.20
Repairing the clutch housing
34-11 page 1
34
1 - Bushing
12
13
14
T for selector rods
page 3
11
page 3
10
2 - Shaft for reverse gear shift
fork
9
T Shaft cannot be removed
with workshop tools
T Press shaft into the clutch
8
15
housing Fig. 7 in 34-11
page 5
4
3 - Needle bushing
T for reverse shaft
T replace after each removal
page 3
page 4
4 - Fitting sleeve
T 2 pieces
5 - Clutch housing
T if replaced: Setting the output shafts and differential
gear Chapter 39-3
6 - Gasket ring for drive shaft
page 4
page 4
7
6
16
7 - Gasket ring
T for right flange shaft
T replacing Chapter 39-1
8 - Washer
T for differential
T Fitting position: the shoulder on the inside diameter points towards the gasket ring item 7
T for differential
T if replaced: Setting the differential gear Chap. 39-4.
10 - Oil deflecting washer
T Fitting position: Shoulder on the hole points to the output shaft
T if replaced: Setting output shaft gears 1 through 4 Chap. 35-4
T if replaced: Setting output shaft 5th/6th and reverse gear Chap. 35-6
13 - Washer
T always 0.65 mm thick
34-11 page 2
1
2
3
4
1
5
S34-0723
Edition 10.03
S00.5329.00.20
34

14 - Cylindrical-roller bearing
T for drive shaft
15 - Magnet
T is held in position by the separator surface of the housing
16 - Cap
Fig. 1:
Remove bushing for gear shift rod
A - Countersupport, e.g. -Kukko 22/1B - Interior extractor 14.518.5 mm, e.g. -Kukko 21/2-
Fig. 2:
Drive in the bushing for the shiftrod up to

T10168
S34-0724
Fig. 3:
Pull out the needle bushing from the clutch

housing
A - Countersupport, e.g. -Kukko 22/2B - Interior extractor 23.530 mm, e.g. -Kukko 21/4Note
The needle bushing is damaged when removed and must
be replaced.
Edition 10.03
S00.5329.00.20
34-11 page 3
34
Fig. 4:

Pressing in needle bushing -A- in the clutch
housing
Position the thrust washer -B- of the reverse shaft

onto the needle bushing during press-in procedure.
MP 3-423
A
S34-0559
Fig. 5:
Removing gasket ring for drive shaft
Carefully lever out gasket ring with screwdriver in the

-direction of the arrow-.
Fig. 6:
Insert the gasket ring for the drive shaft until

flush
34-11 page 4
Edition 10.03
S00.5329.00.20
34

Fig. 7:
Press shaft for reverse gear shift fork into

the clutch housing
MP 3-408
S34-0560
Edition 10.03
S00.5329.00.20
34-11 page 5
34
34-11 page 6
Edition 10.03
S00.5329.00.20
34
34-12 Disassembling and assembling the gearshift

mechanism on the gearbox side
Disassembling and assembling the gearshift mechanism on the gearbox side for
gearbox up to gearbox manufacturing
date 06.03
Disassembling and assembling the gearshift mechanism
on the gearbox side up to gearbox manufacturing date
06.03 (identification characters FJW 6 speed Gearbox 02M; Rep. Gr. 34; Disassembling and assembling
the gearshift mechanism on the gearbox side
Disassembling and assembling the gearshift mechanism on the gearbox side as

of gearbox manufacturing date 07.03
Pipe section -MP 3-479-
Edition 10.03
S00.5329.00.20
Disassembling and assembling the gearshift mechanism on the

gearbox side
34-12 page 1
34
1 - 23 Nm
2 - Gearshift lever
T insert in such a way that the
interrupted spacing of the
teeth matches the gearshift
shaft
T may be replaced with the
gearshift mechanism mounted
T Fitting location Chapter
34-3
3 - Gasket ring
T release with a screwdriver
page 3
4 - Bushing
5 - Lock washer
T for bell crank lever
page 2
6 - Gearshift shaft
T with cover
T can be installed or removed
with the gearbox mounted.
7 - Bushing
Chapter 34-10
8 - O-ring
T insert into the round slot of
the gearshift cover
T insert with gear oil
T always replace
9 - Cap
T for gearbox bleeder
10 - Reversing lever
T Fitting location Chapter 34-4
Fig. 1:
6
5
8
4
3
2
1
10
S34-0725
Remove lock washer for bell crank lever
Lift retaining clip in the -direction of the arrow-.
34-12 page 2

gearbox side
Edition 10.03
S00.5329.00.20
34

Fig. 2:
Insert gasket ring up to the stop
MP 3-479
S34-0726
Edition 10.03
S00.5329.00.20

gearbox side
34-12 page 3
34
34-12 page 4

gearbox side
Edition 10.03
S00.5329.00.20
34
34-13 Disassembling and assembling the gearshift

forks
Disassembling and assembling the gearshift forks for gearbox up to gearbox
Disassembling and assembling the gearshift forks for
gearbox up to gearbox manufacturing date 06.03 (identification characters FJW 6 speed Gearbox 02M; Rep.
Gr. 34; Disassembling and assembling the gearshift forks
Disassembling and assembling the gearshift forks for gearbox as of gearbox

Pressure plate -MP 3-407 Pressure plate -MP 3-453 Distance sleeve -MP 3-458 Thrust piece -MP 6-405 Interior extractor 18 ... 23 mm, e.g. -Kukko 21/3 Countersupport, e.g. -Kukko 22/1-
Edition 10.03
S00.5329.00.20
Disassembling and assembling the gearshift forks
34-13 page 1
34
1 - Rubber insulation
T can be pulled out of the gear
shift rod and inserted by
hand
for 1st and 2nd gear
for 3rd and 4th gear
for 5th and 6th gear
5 - Gearshift fork reverse gear
6 - Ball sleeve
page 2
page 3
1
6
6
1
Fig. 1:
S34-0727
Remove ball sleeve for gearshift fork reverse gear
A - Interior extractor 1823 mm, e.g. -Kukko 21/3B - Countersupport, e.g. -Kukko 22/1-
34-13 page 2
Edition 10.03
S00.5329.00.20
34

Fig. 2:
Install ball sleeve for gearshift fork reverse

gear
Edition 10.03
S00.5329.00.20
34-13 page 3
34
34-13 page 4
Edition 10.03
S00.5329.00.20
35
35 Wheels, shafts
35-1
Disassembling and assembling the drive shaft
Disassembling and assembling the drive

shaft for gearbox up to gearbox manufacturing date 06.03
Disassembling and assembling the drive shaft for gearbox up to gearbox manufacturing date 06.03 (identification characters FJW 6 speed Gearbox 02M; Rep. Gr.
35; Disassembling and assembling the drive shaft
Disassembling and assembling the drive

shaft for gearbox as of gearbox manufacturing date 07.03
The drive shaft has a firm/loose bearing and can therefore not be adjusted.
Pressure plate -MP 3-406 Pressure plate -MP 3-407 Thrust piece -MP 3-408 Pressure plate -MP 3-411 Thrust piece -MP 3-423 Drift pin -MP 3-426 Pressure plate -MP 3-453 Thrust plate -MP 3-467 Pressure plate -MP 3-4014 Pipe section -T30041 Interior extractor 3037 mm, e.g. - Kukko 21/5 Separating device 1275 mm, e.g. - Kukko 17/1 Separating device 22115 mm, e.g. -Kukko 17/2 Extractor, e.g. -Kukko 18/1 Countersupport, e.g. -Kukko 22/2-
Edition 10.03
S00.5329.00.20
35-1 page 1
35
Note
When installing new pinions observe the technical data Chap. 00-1
Insert all bearings on the drive shaft with gear oil.
1 - Circlip
Chapter 34-9
2 - Gearbox housing
3 - Circlip
T determine Fig. 5 in 35-1
page 4 when replacing the
grooved ball bearing
item 4 and the drive shaft
item 6
4 - Grooved ball bearing
T remove Fig. 1 in 35-1
page 2
T pressing on Fig. 4 in 35-1
page 3
5 - 5th gear pinion
T pressing off Fig. 2 in 35-1
page 3
T Fitting position: the round
groove -arrow- points to the
grooved ball bearing
item 4
page 3
6 - Drive shaft
T with 3rd/4th gear pinon and
6th gear
7 - Cylindrical-roller bearing
T with circlip
page 4
page 4
T Fitting position: the circlip in the bearing points towards the drive shaft
8 - Clutch housing
Fig. 1:
3
4
5
6
S35-0254
Remove grooved ball bearing
First remove the circlip from the drive shaft.

Before fitting the extractor position thrust piece
MP 3-467
-MP 3-453- and pressure plate -MP 3-467- on the

drive shaft.
Position the separating device -B- in the round slot for

the circlip in the bearing.
A - Extractor, e.g. -Kukko 18/1B - Separating device 1275 mm, e.g. -Kukko 17/1-
MP 3-453
35-1 page 2
S35-0255
Edition 10.03
S00.5329.00.20
35

Fig. 2:
Pressing out 5th gear pinion
A - Separating device 22115 mm, e.g. -Kukko 17/2-
MP 3-423
MP 3-426
MP 3-406
Fig. 3:
MP 3-407
S35-0256
Pressing on 5th gear pinion
The groove -arrow- on the gearwheel must point up-
MP 3-408
wards.
MP 3-411
MP 3-406
T30041
S35-0257
Fig. 4:
Press on grooved ball bearing
Fitting position of grooved ball bearing: The slot for the

circlip points upwards -arrow A- and the shoulder -arrow B- must point towards the 5th gear pinion.
MP 3-408
Then determine the circlip Fig. 5 in 35-1 page 4
and install.
T30041
MP 3-411
B
MP 3-406
S35-0258
Edition 10.03
S00.5329.00.20
35-1 page 3
35
Fig. 5:
Determining the circlip
Insert circlip -A- with a thickness of 1.86 mm in the slot

of the drive shaft and push upwards.
Measure dimension between grooved ball bearing -Band positioned circlip -A- using a feeler gauge -C-.
Remove the circlip used to take the measurement.

Determine the first circlip required according to the table.
Note
assign circlips following spare parts catalogue.
The following circlips are available:
S35-0259
measured value (mm)
Circlip thickness (mm)
Axial play (mm)
0,01 0,05
1,86
0,01 0,05
0,05 0,07
1,89
0,01 0,05
0,07 0,10
1,92
0,01 0,05
0,10 0,13
1,95
0,01 0,05
0,13 0,16
1,98
0,01 0,05
Fig. 6:
B
C
Removing the cylindrical-roller bearing out

of the clutch housing
When removing compress circlip -arrow- of the cylindrical-roller bearing with pliers -C-.
A - Countersupport, e.g. -Kukko 22/2B - Interior extractor 3037 mm, e.g. -Kukko 21/5Fig. 7:
Press the cylindrical-roller bearing into the

clutch housing
When inserting compress circlip -arrow- of the cylin-
S35-0260
MP 3-408
MP 3-4014
drical-roller bearing with pliers -A-.
Remove pliers before the cylindrical-roller bearing is

in fitting position.
The circlip must lock into the clutch housing slot.
S35-0261
35-1 page 4
Edition 10.03
S00.5329.00.20
35
35-2
Setting drive shaft
Setting drive shaft for gearbox up to

Setting drive shaft for gearbox up to gearbox manufacturing date 06.03 (identification characters FJW 6
speed Gearbox 02M; Rep. Gr. 35; Setting drive shaft
Setting drive shaft for gearbox as of

The drive shaft for these gearboxes has a firm/loose
bearing and can therefore not be adjusted.
Edition 10.03
S00.5329.00.20
Setting drive shaft
35-2 page 1
35
35-2 page 2
Setting drive shaft
Edition 10.03
S00.5329.00.20
35-3
35
Disassembling and assembling output shaft

gears 1 through 4
The work procedure for this repair group is identical with

6 speed Gearbox 02M; Rep. Gr. 35.
Edition 10.03
S00.5329.00.20
Disassembling and assembling output shaft gears 1 through 4
35-3 page 1
35
35-3 page 2
Disassembling and assembling output shaft gears 1 through 4
Edition 10.03
S00.5329.00.20
35
35-4
Setting output shaft gears

1 through 4

Edition 10.03
S00.5329.00.20
Setting output shaft gears 1 through 4
35-4 page 1
35
35-4 page 2
Setting output shaft gears 1 through 4
Edition 10.03
S00.5329.00.20
35-5
35
Disassembling and assembling output shaft 5th/

6th and reverse gear

Edition 10.03
S00.5329.00.20
Disassembling and assembling output shaft 5th/6th and reverse

gear
35-5 page 1
35
35-5 page 2
Disassembling and assembling output shaft 5th/6th and reverse

gear
Edition 10.03
S00.5329.00.20
35
35-6
Setting output shaft 5th/

6th and reverse gear

Edition 10.03
S00.5329.00.20
Setting output shaft 5th/6th and reverse gear
35-6 page 1
35
35-6 page 2
Setting output shaft 5th/6th and reverse gear
Edition 10.03
S00.5329.00.20
39
39 Final drive/Differential
39-1
Replacing the flange shaft

gasket rings (gearbox assembled)
Replacing the left flange shaft seal ring

Multi-purpose tool -MP 3-419 Extraction hook -MP 3-419/37 Pressure plate -T30028 6 mm socket wrench insert, commercially available
Catch pan
Sealing grease -G 052 128 A1-
Removing
Raise vehicle and remove front left wheel.

Remove the front left wheelhouse liner Body Work;
Rep. Gr. 66; Wheelhouse liner.
Turn steering to full left.

Unscrew the left drive shaft from the flange shaft.
Mark installation position of bolts -1- for left steering
S10-0114
joint, otherwise the steering geometry must be

checked.
Release screws -1-.

Unbolt left coupling rod -2- from the anti-roll bar -arrow-.
Turn left coupling rod upwards.

Swivel out the left wheel-bearing housing.
For this step guide the left drive shaft into the wheelhouse and secure to the suspension strut with e.g.
wire.
Remove conical screw for flange shaft with 6 mm

socket wrench insert (commercially available), secure
with a drift to prevent it from turning.
Position the catch pan under the gearbox.

Remove the flange shaft with pressure spring.
Edition 10.03
S00.5329.00.20
Replacing the flange shaft gasket rings (gearbox assembled)
39-1 page 1
39
Remove the seal ring.
Installing
Drive the new seal ring in up to the stop, do not twist

the seal ring.
Fill half the space between the sealing lips and dust
lips with sealing grease -G 052 128 A1-.
Insert the flange shaft.

Secure the flange shaft with the conical screw.
Screw the steering joint and track control arm with the
new screws in the former positions Chassis;
Rep. Gr. 40; Repairing front axle.
Screw the left drive shaft onto the flange shaft

Chassis; Rep. Gr. 40; Repairing front axle
Attach the wheel.

Check gear oil level, if necessary top up Chap. 348.
Install the noise insulation. Engine, Mechanics;

Rep. Gr. 10; Removing and installing engine
Tightening torques
Components
Torque
Flange shaft on gearbox

(conical screw)
33 Nm
40 Nm

1)
120 Nm
20 Nm + 90
Always replace these bolts
Replacing the right flange shaft seal ring

Drive bushing -MP 3-489 6 mm socket wrench insert, commercially available
39-1 page 2
Edition 10.03
S00.5329.00.20
39

Catch pan
Sealing grease -G 052 128 A1-
Removing
Raise vehicle.
Turn steering to full right lock.
Unscrew the right drive shaft from the flange shaft.
S10-0114
Mark installation position of bolts -1- for right steering

joint, otherwise the steering geometry must be
checked.
Release screws -1-.

Unbolt right coupling rod -2- from the anti-roll bar -arrow-.
Tie up the drive shaft as far as possible, avoid damaging the paintwork on the drive shaft.
Remove conical screw for flange shaft with 6 mm

socket wrench insert (commercially available), secure
with a drift to prevent it from turning.
Position the catch pan under the gearbox.

Remove the flange shaft with pressure spring.
Lever out gasket ring with assembly lever.
Installing
Drive the new seal ring in up to the stop, do not twist

the seal ring.
Fill half the space between the sealing lips and dust
lips with sealing grease -G 052 128 A1-.
Insert the flange shaft.

Secure the flange shaft with the conical screw.
Screw the steering joint and track control arm with the
MP 3-489
new screws in the former positions Chassis;

Rep. Gr. 40; Repairing front axle.
Screw the right drive shaft onto the flange shaft

Chassis; Rep. Gr. 40; Repairing front axle
Check gear oil level, if necessary top up Chap. 348.
S39-0266
Install the noise insulation. Engine, Mechanics;

Rep. Gr. 10; Removing and installing engine
Edition 10.03
S00.5329.00.20
39-1 page 3
39
Tightening torques
Components
Torque
Flange shaft on gearbox

(conical screw)
33 Nm
40 Nm

1)
120 Nm
20 Nm + 90
Always replace these bolts
39-1 page 4
Edition 10.03
S00.5329.00.20
39
39-2
Disassembling and assembling the differential
Disassembling and assembling the differential for gearbox up to gearbox manufacturing date 06.03
Disassembling and assembling the differential for gearbox up to gearbox manufacturing date 06.03 (identification characters FJW 6 speed Gearbox 02M; Rep. Gr.
39; Disassembling and assembling the differential for vehicles with front-wheel drive
Disassembling and assembling the differential for gearbox as of gearbox manufacturing date 07.03
Pressure plate -MP 3-406 Pressure plate -MP 3-407 Thrust piece -MP 3-408 Pressure plate -MP 3-458/1 Thrust plate -MP 3-467 Pipe -MP 6-419 Inserting device -MP 9-400 Pipe -T30019 Tapered-roller bearing extractor -V.A.G 1582 Gripper -V.A.G 1582/6 Interior extractor 46 ... 58 mm, e.g. -Kukko 21/7 Countersupport, e.g. -Kukko 22/2-
Edition 10.03
S00.5329.00.20
39-2 page 1
39
Note
Before installing heat the inner ring of the tapered-roller bearing to 100C.
Replace both tapered-roller bearings together.
When replacing the tapered-roller bearing of the differential housing, gearbox housing or clutch housing adjust the
differential Chap. 39-4.
1 - Gearbox housing
24
11
T for differential
23
T Determine thickness
Chapter 39-4
13
3 - Outer ring/tapered-roller bear14
ing
15
page 4
2
16
page 5
21 17 20 22
3
4 - Inner ring/tapered-roller bear20
ing
4
19
5
page 4
18
page 4
6
5 - Differential housing
7
17
T with riveted pinion for final
drive
8
16
6 - Inner ring/tapered-roller bearing
15
14
page 4
13
page 4
12
11
page 3
10
page 3
8 - Washer
T always 0.65 mm thick
T Fitting position: the shoulder on the inside diameter points towards the gasket ring item 10
9 - Clutch housing
10 - Gasket ring
T for right flange shaft
T diameter of left and right differ
T replacing with gearbox installed Chap. 39-1
T screw into threaded piece item 21
12 - Right flange shaft
13 - Pressure spring for flange shaft
T fitted behind flange shaft
14 - Thrust washer
T Fitting position: Collar to pressure spring, leg to conical ring
15 - Conical ring
T with slots for thrust washer catch
39-2 page 2
S39-0271
Edition 10.03
S00.5329.00.20
39
16 17 18 -
19 -
20 21 22 23 24 -
T Fitting position: Cone towards differential housing

Circlip
T holds the conical ring, stop disc and pressure spring in position when the flange shaft is removed
Differential bevel gear large
Differential bevel gear shaft
T drive out with drift
Tensioning sleeve
T to secure the axle for differential bevel gears
T removing and installing Fig. 7 in 39-2 page 5
Differential bevel gear small
T removing and installing Fig. 8 in 39-2 page 5
Threaded part
Stop disc compound
T insert with gear oil
Flange shaft left
Gasket ring
T for left flange shaft
T diameter of left and right differ
T replacing with gearbox installed Chap. 39-1
Fig. 1:
Remove outer ring/tapered-roller bearing

from clutch housing
A - Countersupport, e.g. -Kukko 22/2B - Interior extractor 4658 mm, e.g. -Kukko 21/7Note
After pulling out the washer check for damage, if necessary replace.
Fig. 2:
Press outer ring/tapered-roller bearing into

the clutch housing
Insert the washer.
MP 3-408
Note
MP 3-458/1
Pay attention to the fitting position of the washer, the

shoulder on the inside diameter points towards the gasket ring.
Press outer ring/tapered-roller bearing into the clutch

housing.
MP 3-407
S39-0186
Edition 10.03
S00.5329.00.20
39-2 page 3
39
Fig. 3:
Remove inner rings/tapered-roller bearing
Before fitting the extractor position pressure plate

-MP 3-467- on the differential housing.
V.A.G 1582
Note
Both inner rings/tapered-roller bearings of the differential
housing are removed in the same way.
V.A.G 1582/6
N39-0728
Fig. 4:
Press on inner rings/tapered-roller bearing
MP 3-408
Note
The inner ring/tapered-roller bearing for the gearbox
housing and clutch housing are pressed on with the same
pressure tools.
MP 9-400
MP 3-407
MP 3-406
S39-0187
Fig. 5:
Remove outer ring/tapered-roller bearing

from gearbox housing
A - Countersupport, e.g. -Kukko 22/2B - Interior extractor 4658 mm, e.g. -Kukko 21/7-
A
B
S39-0188
39-2 page 4
Edition 10.03
S00.5329.00.20
39

Fig. 6:
Press in outer ring/tapered-roller bearing in

the gearbox housing
Support the gearbox housing with a pipe -T30019- di-
MP 3-408
MP 3-458/1
rectly below the bearing support.
T30019
MP 6-419
MP 3-407
S39-0189
Fig. 7:
Removing and installing the tensioning

sleeve for differential bevel gear shaft
Removing
Cover inner ring/tapered-roller bearing to avoid any

possible damage and swarf.
Drive out tensioning sleeve with a chisel, position the

chisel in the circular slot.
Installing
Drive into the differential housing up to the stop.
Fig. 8:
Install the differential bevel gears
Install stop disc compound with gearbox oil.

Insert both large differential bevel gears and secure
(e.g. with flange shaft).
Insert and swivel the small differential bevel gears into

position with a 180 offset.
Push in the differential bevel gear shaft -arrow A- up

to the first small bevel gear.
Insert the threaded parts -arrow B- in the large differential bevel gears.
Fitting position: Heel of the differential bevel gear
Insert the differential bevel gear shaft up to end position and secure with tensioning sleeve.
Edition 10.03
S00.5329.00.20
39-2 page 5
39
39-2 page 6
Edition 10.03
S00.5329.00.20
39
39-3
Setting overview
Setting overview for gearbox up to gearbox manufacturing date 06.03

Setting overview for gearbox as of gearbox manufacturing date 06.03 (identification characters FJW 6
speed Gearbox 02M; Rep. Gr. 39; Setting overview
Setting overview for gearbox as of gearbox manufacturing date 07.03

Note
When working on the gearbox it is only necessary to re-set the output shaft gears 1 through 4, output shaft 5th/6th
gear and reverse gear or differential gear if parts were replaced that directly affect the settting of the gearbox. To avoid
unnecessary settings, refer to the following table:
Set:
Replaced part:
Output shaft gears 1

through 4
Output shaft 5th/6th

and reverse gear
Differential
Gearbox housing
Clutch housing
Output shaft gears 1

through 4
Output shaft 5th/6th

and reverse gear
Differential gear housing

Tapered-roller bearing for output shaft
gears 1 through 4
x
x
Tapered-roller bearing for output shaft

5th/6th and reverse
gear
Tapered-roller bearing for differential gear
Edition 10.03
S00.5329.00.20
Setting overview
39-3 page 1
39
39-3 page 2
Setting overview
Edition 10.03
S00.5329.00.20
39
39-4
Adjusting the differential

gear

6 speed Gearbox 02M; Rep. Gr. 39; Adjusting the differential gear.
Edition 10.03
S00.5329.00.20
Adjusting the differential gear
39-4 page 1
39
39-4 page 2
Adjusting the differential gear
Edition 10.03
S00.5329.00.20

Fabia Gearbox 0A8

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Service

FJW FSM HDS

Service Department. Technical Information

Printed in Czech Republic

Printed in Czech Republic

FABIA 2003 Gearbox 0A8

List of Supplements to Workshop Manual

Supplement to manual gearbox with code HDS

FABIA 2003 Gearbox 0A8

FABIA 2003 Gearbox 0A8

- Location on the gearbox .............................................................................. 00-1

- Identification characters, aggregate assignment, ratios, capacities ........................... 00-1

Overview of Transmission System ................................................................. 00-2

General Repair Information .......................................................................... 00-3

Repairing the clutch control ......................................................................... 30-1

- Summary of components - Foot controls .......................................................... 30-1

- Removing and installing the over-centre helper spring .......................................... 30-1

- Removing and installing the clutch pedal .......................................................... 30-1

- Summary of components - Hydraulics ............................................................. 30-1

- Removing and installing the master cylinder ...................................................... 30-1

- Bleeding the clutch system .......................................................................... 30-1

Repairing the clutch control ......................................................................... 30-2

Repairing the clutch ................................................................................... 30-3

- Clutch - Overview of components ................................................................... 30-3

- removing and installing clutch ....................................................................... 30-3

Repairing the gearshift mechanism ................................................................ 34-1

- Fitting location of shift mechanism .................................................................. 34-1

I - Summary of components - gearshift knob and cover ...................................... 34-2

- Separating collar from gearshift lever .............................................................. 34-2

II - Summary of components - shift lever and shift housing ................................. 34-3

III - Summary of components - Control cables .................................................. 34-4

Removing and Installing Shift Mechanism ....................................................... 34-5

- Removing ............................................................................................... 34-5

- Installing ................................................................................................ 34-5

Setting the shift mechanism ......................................................................... 34-6

- Operation ............................................................................................... 34-6

Removing and installing the gearbox ............................................................. 34-7

- Removing ............................................................................................... 34-7

- Installing ................................................................................................ 34-7

Inspecting gear oil ..................................................................................... 34-8

Disassembling and assembling the gearbox for gearbox as of gearbox manufacturing

- Gearbox overview ..................................................................................... 34-9

- Summary of components ............................................................................. 34-9

- Gearbox housing and gearshift mechanism - Summary of components ..................... 34-9

- Mounting sequence ................................................................................... 34-9

FABIA 2003 Gearbox 0A8

Repairing the clutch housing ....................................................................... 34-11 page

Disassembling and assembling the gearshift forks ........................................... 34-13 page

Setting drive shaft ..................................................................................... 35-2

Disassembling and assembling output shaft gears 1 through 4 ............................ 35-3

Setting output shaft gears 1 through 4 ........................................................... 35-4

Setting output shaft 5th/6th and reverse gear ................................................... 35-6

- Replacing the left flange shaft seal ring ............................................................ 39-1

- Replacing the right flange shaft seal ring .......................................................... 39-1

Disassembling and assembling the differential ................................................. 39-2

- Disassembling and assembling the differential for gearbox up to gearbox manufacturing

- Disassembling and assembling the differential for gearbox as of gearbox manufacturing

Setting overview ........................................................................................ 39-3

Adjusting the differential gear ...................................................................... 39-4

FABIA 2003 Gearbox 0A8

Identification of the gearbox

Assignment 00-1 page 3

Location on the gearbox

the gearbox -arrow 1 Gearbox 0A8 -arrow 2- and -arrow 3-