Gearbox 0aj
Gearbox 0aj
Gearbox 0aj
Workshop Manual
Octavia II 2004 ➤ , Octavia II 2010 ➤ ,
Octavia III 2013 ➤ , Octavia III 2014 ➤ ,
Superb II 2008 ➤ , Yeti 2010 ➤ ,
Yeti 2011 ➤
Manual gearbox 0AJ
Edition 05.2014
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Manual gearbox 0AJ - Edition 05.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification characters, aggregate assignment, ratios, capacities . . . . . . . . . . . . . . . . . . 2
2 Transmission System - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Designation of components and transmission ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 General repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Summary of components - Foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Summary of components - Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Removing and installing holder for knee airbag with crash strut for clutch pedal (Yeti) . . . . 23
1.5 Removing and installing bearing bush (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.6 Removing and installing the over-centre helper spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.7 Removing and installing tension spring and over-centre helper spring (Octavia III) . . . . . . 30
1.8 Removing and installing the clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.9 Removing and installing bearing block for clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.10 Removing and installing the master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.11 Removing and installing clutch position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.12 Check hydraulic clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.13 Removing and installing the slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.14 Removing and installing cables for clutch control (Octavia III) . . . . . . . . . . . . . . . . . . . . . . 74
1.15 Bleeding the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2 Clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.1 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.2 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1 Summary of components - repairing the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.3 Fault finding power transmission - problems with the clutch and clutch control . . . . . . . . . . 84
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1 Repairing shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1 Fitting location of shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.2 Summary of components for clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.3 Summary of components - Gearshift knob with shift lever collar . . . . . . . . . . . . . . . . . . . . 92
1.4 Summary of components - Gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.5 Summary of components - Control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.6 Removing and installing gearshift knob with shift lever collar . . . . . . . . . . . . . . . . . . . . . . 101
1.7 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.8 Disassembling and assembling shift mechanism housing . . . . . . . . . . . . . . . . . . . . . . . . 115
1.9 Removing and installing the cable lock from the relay lever . . . . . . . . . . . . . . . . . . . . . . . . 118
1.10 Removing and installing shift cable and selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.11 Setting the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.1 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.2 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.4 Transporting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Contents i
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Manual gearbox 0AJ - Edition 05.2014
ii Contents
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Manual gearbox 0AJ - Edition 05.2014
00 – Technical data
1 Identification of the gearbox
(SRL000697; Edition 05.2014)
⇒ “1.1 Location on the gearbox”, page 1 .
⇒ “1.2 Identification characters, aggregate assignment, ratios,
capacities”, page 2 .
Note
Note
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Drive shaft
5 - Output shaft
6 - Differential gear
I - 1. gear
II - 2. gear
III - 3. gear
IV - 4. gear
V - 5. gear
VI - 6. gear
R - Reverse gear
A - Final drive
Note
3.1 Components
Gearbox
♦ When installing the manual gearbox, ensure the dowel
sleeves are correctly located between the engine and gear‐
box.
♦ When assembling mounts as well as waxed components, the
contact surfaces must be cleaned. Contact surfaces must be
free of wax and grease.
♦ Bolts and other attachments should have a classification in the
⇒ Electronic Catalogue of Original Parts .
♦ When replacing the gearbox check the gear oil level
⇒ page 153 .
♦ Capacities and specifications ⇒ page 2 .
Sealant
♦ Thoroughly clean the contact surfaces of the housing before
applying the silicone sealant.
♦ Apply sealant AMV 188 200 03 evenly and not too thick.
O-rings, gasket rings, gaskets
♦ Always replace O-rings, gasket rings and gaskets ⇒ Elec‐
tronic Catalogue of Original Parts .
♦ After removing gaskets, check the contact surface in the hous‐
ing or shaft for burrs or damage which occured during the
assembly.
♦ Radial shaft seals - before mounting lightly oil at outside di‐
ameter and fill half the space between the sealing lips
-arrow- with sealing grease G 052 128 A1.
♦ The open side of the sealing rings is turned towards the fluid
to be sealed.
♦ Press in new gasket ring in such a way that the sealing lip is
not located on the same point as the sealing lip of the old gas‐
ket ring (use tolerance for insertion depth).
♦ Before inserting lightly oil the O-rings, in order to prevent the
rings being squashed during installation.
♦ Inspect the oil level after replacing the gaskets and gasket
rings ⇒ page 153 .
Locking elements
Synchronizer rings
♦ These are not interchangeable. If re-using, allocate synchron‐
izer rings to the same sliding gear.
♦ Inspect for wear, replace if necessary ⇒ Electronic Catalogue
of Original Parts .
♦ Check grooves -arrow 1- on synchronizer ring -A-, or check
the inside of the ring for flattened parts (grooves worn).
♦ When installing the intermediate ring -B-, check outer contact
surface -arrow 2- and inner contact surface -arrow 3- for
grooves, blue coloring (caused by overheating) and other
damages.
♦ Insert with some gearbox fluid.
Pinions
♦ Clean and heat on a heating plate or with the induction heater
unit - VAS 6414- to approx. 100°C before pressing on.
♦ Check fitting position.
Sliding gears
♦ Check 1st to 6th gear sliding gears after assembly for low axial
play or for smooth operation.
Clutch control
♦ When removing gearbox, remove slave cylinder without open‐
ing the line system.
♦ If the slave cylinder with connected hydraulic line is removed,
do not depress the clutch pedal. Otherwise the piston is press‐
ed out of the slave cylinder.
♦ Do not tilt the clutch pressure plate; release and tighten cross‐
wise in small stages.
♦ If the clutch pedal does not return to its initial position after the
coupling procedure - clutch pedal in home position - the clutch
control must be bled (further measures ⇒ page 63 ).
♦ In order to reduce unpleasant odours if the clutch is burnt,
thoroughly clean the clutch housing as well as the flywheel and
the engine on the side of the gearbox.
30 – Clutch
1 Repairing clutch control
⇒ “1.1 Overview”, page 11
⇒ “1.2 Summary of components - Foot controls”, page 13
⇒ “1.3 Summary of components - Hydraulics ”, page 16
⇒ “1.4 Removing and installing holder for knee airbag with crash
strut for clutch pedal (Yeti)”, page 23 .
⇒ “1.5 Removing and installing bearing bush (Octavia III)”,
page 23 .
⇒ “1.6 Removing and installing the over-centre helper spring”,
page 24
⇒ “1.7 Removing and installing tension spring and over-centre
helper spring (Octavia III)”, page 30 .
⇒ “1.8 Removing and installing the clutch pedal”, page 33
⇒ “1.9 Removing and installing bearing block for clutch pedal”,
page 40
⇒ “1.10 Removing and installing the master cylinder”, page 51
⇒ “1.11 Removing and installing clutch position sender”,
page 57
⇒ “1.12 Check hydraulic clutch control”, page 63 .
⇒ “1.13 Removing and installing the slave cylinder”, page 64
⇒ “1.14 Removing and installing cables for clutch control (Octavia
III)”, page 74 .
⇒ “1.15 Bleeding the clutch control ”, page 76
1.1 Overview
Note
♦ After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical
System; Rep. gr. 27 .
♦ Grease all bearing and contact surfaces with grease - G 000 450 02- .
I - Summary of components -
Foot controls (Octavia II. Su‐
perb II and Yeti) ⇒ page 13
II - Summary of components -
Foot controls (Octavia III)
⇒ page 14
III - Summary of components -
Hydraulic (left-hand drive)
⇒ page 16
IV - Summary of components -
Hydraulic (right-hand drive)
⇒ page 16
1.2.1 Summary of components - Foot controls (Octavia II, Superb II and Yeti)
1 - Front wall
❑ with mount for bracket
2 - Gasket
❑ replace ⇒ Electronic
Catalogue of Original
Parts
❑ between bracket and
front wall
❑ self-adhesive
❑ glue to bracket
3 - Bearing bracket
❑ for support of clutch
pedal
❑ removing and installing
⇒ page 40
4 - Screw
5 - Over-centre helper spring
❑ removing and installing
⇒ page 24
6 - Bushing
7 - Bearing bolt
8 - Clutch pedal
❑ removing and installing
⇒ page 33
9 - Support
❑ removing and installing
⇒ page 33
10 - Gasket
❑ replace ⇒ Electronic
Catalogue of Original
Parts
❑ between master cylinder and bracket
11 - Master cylinder
❑ removing and installing ⇒ page 51
❑ test tightness ⇒ page 63
12 - Clutch position sender - G476-
❑ removing and installing ⇒ page 57
❑ check ⇒ Vehicle diagnostic tester
13 - Clip
❑ to remove and install the tube-hose line pull out retaining clip up to the stop
14 - Tubing
❑ Plastic return hose ⇒ page 16
1 - Master cylinder
❑ removing and installing
⇒ page 52
2 - Bushing
❑ removing and installing
⇒ page 23
❑ is not lubricated
3 - Clip
❑ to remove and install the
tube-hose line pull out
retaining clip up to the
stop
4 - Gasket
❑ Self-adhesive
❑ after removing the mas‐
ter cylinder, replace ⇒
Electronic Catalogue of
Original Parts
❑ stick onto the master
cylinder
5 - Clutch position sender -
G476-
❑ check ⇒ Vehicle diag‐
nostic tester in the oper‐
ating mode Targeted
fault finding
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ removing and installing
⇒ page 59
6 - Carrier bolt
❑ after removing, replace
⇒ Electronic Catalogue of Original Parts
❑ is not lubricated
7 - Spring stop
8 - Hexagon nut
❑ Pillar to front wall
❑ 3 pieces
❑ self-locking
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
❑ 25 Nm
9 - Bearing shell
❑ 2 pieces
❑ is fitted on both sides
❑ fitted only with over-centre helper spring
❑ is not lubricated
10 - Bearing bracket
❑ for the clutch pedal
❑ removing and installing ⇒ page 42
❑ Drive in bushings into the bores for mounting bolts console/front wall mandrel - VW 207-
11 - Over-centre helper spring
❑ installed according to the type
❑ removing and installing ⇒ page 26
❑ Do not lubricate bearing on console
12 - Carrier bolt
❑ for master cylinder
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
❑ is not lubricated
13 - Over-centre helper spring
❑ installed according to the type
❑ different versions, assignment ⇒ Electronic Catalogue of Original Parts
❑ removing and installing ⇒ page 30
❑ is not lubricated
14 - Bushing
15 - Sliding sleeve
❑ installed according to the type
❑ Bearing for over-centre helper spring
❑ is slid onto the clutch pedal
❑ Lubricate the bearing for over-centre helper spring with grease -G 052 567 A2- ⇒ Electronic Catalogue
of Original Parts
16 - Carrier bolt
❑ of the tappet for master cylinder
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
❑ is not lubricated
17 - Clutch pedal
❑ removing and installing ⇒ page 35
❑ is not lubricated
18 - Pedal rubber
19 - Bushing
❑ is not lubricated
20 - Tension spring
❑ for the clutch pedal
❑ installed according to the type
❑ removing and installing ⇒ page 30
❑ is not lubricated
21 - Damping element
❑ only fitted with tension spring
❑ is not lubricated
1 - Hexagon bolt
❑ 20 Nm
2 - Vent valve
❑ Bleed the clutch control
⇒ page 76
❑ 4.5 Nm
3 - Dust cap
4 - Supply hose
5 - Brake fluid reservoir
6 - Gasket
❑ must be located on the
return hose
7 - Master cylinder
❑ removing and installing
⇒ page 51
8 - Clip
❑ to remove and install the
tube-hose line pull out
retaining clip up to the
stop
9 - Seal / O-ring
❑ Renew if damaged
❑ fit onto the line connec‐
tion
❑ Insert with brake fluid
❑ Gasket rings/O-rings
are adapted to the ver‐
sion of the line connec‐
tion ⇒ page 22
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
10 - Support
❑ for tube-hose line
11 - Tube-hose line
❑ Assignment ⇒ Electronic Catalogue of Original Parts
❑ removing and installing ⇒ page 74
12 - Seal / O-ring
❑ Renew if damaged
❑ fit onto the line connection
❑ Insert with brake fluid
❑ Gasket rings/O-rings are adapted to the version of the line connection ⇒ page 22
❑ Assignment ⇒ Electronic Catalogue of Original Parts
13 - Clip
❑ to remove and install the tube-hose line pull out retaining clip up to the stop
14 - Slave cylinder
❑ removing and installing ⇒ page 64
Note
– Push in the tube-hose line -1- at the connection -4- until the
clip -3- locks audibly into place.
– For testing pull on the tube-hose line.
– Turn the master cylinder tappet so that the recesses -1- and
bolt -2- are visible.
The recesses -1- and bolts -2- are facing the same direction.
– Remove bearing bush -A- from recesses -1-.
Install
– Turn the master cylinder tappet so that the recesses -1- and
bolt -2- are visible.
The recesses -1- and bolts -2- are facing the same direction.
– Insert the bearing bush -A- into the recesses -1- and turn in
the tappet lug until flush.
– Connect the master cylinder tappet with the clutch pedal, to
do so use a new carrier bolt ⇒ Electronic catalogue of original
parts .
– Connect battery ⇒ Electrical System; Rep. gr. 27 .
– Unscrew clutch pedal -1- from bracket -3-, to this end release
nut -2- and pull out screw -5-.
Note
Note
Tightening torque
Component Nm
Clutch pedal to bearing bracket ⇒ page 13
Crash strut to bracket/steering column 9
– Press the catches -arrows- and detach the carrier bolt -1- of
the tappet for master cylinder to the right.
– Insert crash strut -1- and tighten screw -2- ⇒ Body Work; Rep.
gr. 70 .
– Install data bus diagnostic interface - J533- ⇒ Electrical Sys‐
tem; Rep. gr. 97 .
– Install footwell vent driver's side ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
– Install knee airbag driver's side, in case it was removed ⇒
Body Work; Rep. gr. 69 .
– Connect battery ⇒ Electrical System; Rep. gr. 27 .
– Unscrew clutch pedal -1- from bracket -3-, to this end release
nut -2- and pull out screw -5-.
Note
Note
– Insert over-centre helper spring -2- from above into the bracket
and while doing so hold the spring end in the fitting position
using the release tool - T10178- .
– Insert bearing bolt of clutch pedal into the step bearing of the
over-centre helper spring.
– Press on clutch pedal -1- slightly, slide through screw and
tighten self-locking nut.
– Install the footwell vent ⇒ Heating and Air Conditioning; Rep.
gr. 87 .
– If present, install the crash strut or the knee airbag ⇒ Body
work; Rep. gr. 69 .
– Install the bottom part of the dash panel and the bottom plastic
cover for the steering wheel ⇒ Body Work; Rep. gr. 70 .
– Install the storage area on the driver's side and the bottom
plastic covering for the steering wheel ⇒ Body Work; Rep. gr.
70 .
Tightening torques
Component Nm
Clutch pedal to bearing bracket ⇒ page 13
Note
Note
– Insert over-centre helper spring -2- from above into the bracket
and while doing so hold the spring end in the fitting position
using the release tool - T10178- .
– Insert bearing bolt of clutch pedal into the step bearing of the
over-centre helper spring.
– Press on clutch pedal -1- slightly, slide through screw and
tighten self-locking nut.
– Secure the steering column to the steering gear with a new
screw ⇒ Chassis; Rep. gr. 48 .
– Install holder for knee airbag with crash strut for clutch pedal
⇒ page 23 .
Tightening torques
Component Nm
Clutch pedal to bearing bracket ⇒ page 13
Steering column to steering gear. ⇒ Chassis; Rep. gr. 48
Install holder for knee airbag with crash ⇒ page 23
strut for clutch pedal
– Press the catches -arrows- and detach the carrier bolt -1- of
the tappet for master cylinder to the right.
– Inser the bolt -1- into the mount -2- of the carrier.
– Insert the bearing -3- into the mount -4- for the clutch pedal.
– Press the clutch pedal in -direction of arrow B- (⇒ previous
figure), until the over-centre helper spring engages in direction
of carrier.
– Connect the tappet for master cylinder with the clutch pedal,
to do so use the new carrier bolt ⇒ Electronic catalogue of
original parts .
– Insert crash strut -1- and tighten screw -2- ⇒ Body Work; Rep.
gr. 70 .
– Install data bus diagnostic interface - J533- ⇒ Electrical Sys‐
tem; Rep. gr. 97 .
– Install footwell vent driver's side ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
– Install knee airbag driver's side, in case it was removed ⇒
Body Work; Rep. gr. 69 .
– Connect battery ⇒ Electrical System; Rep. gr. 27 .
– Unscrew clutch pedal -1- from bracket -3-, to this end release
nut -2- and pull out screw -5-.
– Swivel clutch pedal slightly forwards and remove over-centre
helper spring -4- from the bracket.
Note
– Attach support -2- to the actuator rod -1- of the master cylinder.
– Press support into the clutch pedal until it audibly clicks into
place.
Tightening torque
Component Nm
Clutch pedal to bearing bracket ⇒ page 13
Crash strut to bracket/steering column 9
Install
Installation is performed in the reverse order, while paying atten‐
tion to the following:
-1- - Socket wrench (SW 14)
• Replace bearing bolt after removal.
– Slightly press on the clutch pedal and insert a new bearing bolt
⇒ Electronic catalogue of original parts .
• It is important that the studs -A- are positioned horizontally.
– Turn the bearing bolt to the right in -direction of arrow-.
• The catches -B- must click audibly into place.
• Then the studs -A- are positioned vertically.
– Installing over-centre helper spring at carrier ⇒ page 24 or in‐
stalling over-centre helper spring at carrier ⇒ page 30 .
Right-hand drive with Climatronic system
– Installing right temperature flap control motor - V159- ⇒ Heat‐
ing, Air conditioning; Rep. gr. 87 .
Continued for all versions
– If present, install the mount -arrow- with the parking aid control
unit - J446- ⇒ Electrical System; Rep. gr. 94 .
– Connect battery ⇒ Electrical System; Rep. gr. 27 .
– Unscrew clutch pedal -1- from bracket -3-, to this end release
nut -2- and pull out screw -5-.
– Swivel clutch pedal slightly forwards and remove over-centre
helper spring -4- from the bracket.
– Attach support -2- to the actuator rod -1- of the master cylinder.
– Press support into the clutch pedal until it audibly clicks into
place.
Tightening torques
Component Nm
Clutch pedal to bearing bracket ⇒ page 13
– Unscrew clutch pedal -1- from bracket -3-, to this end release
nut -2- and pull out screw -5-.
Note
– Attach support -2- to the actuator rod -1- of the master cylinder.
– Press support into the clutch pedal until it audibly clicks into
place.
Tightening torques
Component Nm
Clutch pedal to bearing bracket ⇒ page 13
Steering column to steering gear. ⇒ Chassis; Rep. gr. 48
Install holder for knee airbag with crash ⇒ page 23
strut for clutch pedal
Note
Note
Note
When working in the footwell, protect the floor carpet with cloths
from escaping brake fluid.
– Remove lower part of the dash panel insert on the driver's side
⇒ Body Work; Rep. gr. 70 .
Note
– Press in tube-hose line -1- with new gasket ring -2- onto the
connection of the master cylinder -4-, until the locking clip -3-
is heard to click into position.
– For testing pull on the tube-hose line.
– Bleed clutch mechanism ⇒ page 76 .
– Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
– Install air filter ⇒ Engine; Rep. gr. 24 .
Note
Tightening torque
Component Nm
Bearing bracket ⇒ page 13
Crash strut to bracket/steering column 9
Right-hand drive
A heat-protection matting is installed in combination with certain
engines. The appearance may differ from the figure.
– Remove heat-protection matting. Pay attention to the positions
-1...4-.
Continued for all versions
Caution
Note
– Pull out the clip -3- at the tube-hose line up to the stop and
detach the tube-hose line.
– Close the openings.
– Detach the tube-hose line -2- from the master cylinder and
close with the closing tool - T10249/1- .
– Push the driver seat as far as possible towards the rear.
– Push steering wheel as far as possible towards the top, while
doing so use the entire adjustment range of the steering col‐
umn.
Note
Install
Installation is performed in the reverse order, while paying atten‐
tion to the following:
Note
– Insert crash strut -1- and tighten screw -2- ⇒ Body Work; Rep.
gr. 70 .
– Install data bus diagnostic interface - J533- ⇒ Electrical Sys‐
tem; Rep. gr. 97 .
– Install footwell vent driver's side ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
– Install knee airbag driver's side, in case it was removed ⇒
Body Work; Rep. gr. 69 .
Right-hand drive
– If present, coil the heat-protection matting in the sequence
-1, 2 and 3- around the cable.
– Secure the heat-protection matting with the circlip -4-.
Continued for all versions
– Bleed clutch mechanism ⇒ page 76 .
– Install battery ⇒ Electrical System; Rep. gr. 27 .
Tightening torques
♦ Bearing bracket for clutch pedal on front wall ⇒ page 13 .
Note
Note
Note
When working in the footwell, protect the floor carpet with cloths
from escaping brake fluid.
– Remove the storage area on the driver's side and the bottom
plastic covering for the steering wheel ⇒ Body Work; Rep. gr.
70 .
– Removing the footwell vent ⇒ Heating and Air Conditioning;
Rep. gr. 87 .
– If present, remove the crash strut or the knee airbag ⇒ Body
work; Rep. gr. 69 .
– Release release pin -B- and pull master cylinder out of bracket
-arrow 1- and -arrow 2-.
Note
– Fit tube-hose line -1- with gasket ring -2- onto the connection
of the master cylinder -4-, until the locking clip -3- is heard to
click into position.
– Check that it locks in place correctly by pulling on the line
-1-.
– Connect the plastic return hose -3- at the master cylinder and
connect the clutch position sender - G476- -4- at the master
cylinder.
– Bleed clutch mechanism ⇒ page 76 .
– Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
– Install air filter ⇒ Engine; Rep. gr. 24 .
Tightening torques
Component Nm
Bracket to body ⇒ page 13
Note
Note
Note
When working in the footwell, protect the floor carpet with cloths
from escaping brake fluid.
Note
– Install holder for knee airbag with crash strut for clutch pedal
⇒ page 23 .
– Fit the plastic line -1- with gasket ring -2- onto the connection
of the master cylinder -4-, until the locking clip -3- is heard to
click into position.
– Check that it locks in place correctly by pulling on the line
-1-.
– Bleed clutch mechanism ⇒ page 76 .
– Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
– Install air filter ⇒ Engine; Rep. gr. 24 .
Note
Tightening torques
Component Nm
Bracket to body ⇒ page 13
Component Nm
Install holder for knee airbag with crash ⇒ page 23
strut for clutch pedal
– Place a spacer -A- between clutch pedal and stop and press
clutch pedal forwards.
♦ Length of spacer = approx. 40 mm
– Release release pin -B- and pull master cylinder out of bracket
-arrow 1- and -arrow 2-.
Install
• Move clutch pedal up to the stop into home position.
– Attach support -2- to the actuator rod -1- of the master cylinder.
– Place a spacer -A- between clutch pedal and stop and press
clutch pedal forwards.
♦ Length of spacer = approx. 40 mm
– Lock master cylinder at bracket -arrow 1- and -arrow 2-.
Note
Note
Note
– Release release pin -B- and pull master cylinder out of bracket
-arrow 1- and -arrow 2-.
Install
• Move clutch pedal up to the stop into home position.
– Attach support -2- to the actuator rod -1- of the master cylinder.
– Fit tube-hose line -1- with gasket ring -2- onto the connection
of the master cylinder -4-, until the locking clip -3- is heard to
click into position.
– Check that it locks in place correctly by pulling on the line
-1-.
– Connect the plastic return hose -3- at the master cylinder and
connect the clutch position sender - G476- -4- at the master
cylinder.
– Bleed clutch mechanism ⇒ page 76 .
– Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
– Install air filter ⇒ Engine; Rep. gr. 24 .
– Place a spacer -A- between clutch pedal and stop and press
clutch pedal forwards.
♦ Length of spacer: 40 mm
– Release release pin -B- and pull master cylinder out of bracket
-arrow 1- and -arrow 2-.
Install
• Move clutch pedal up to the stop into home position.
– Attach support -2- to the actuator rod -1- of the master cylinder.
– Place a spacer -A- between clutch pedal and stop and press
clutch pedal into operating position.
♦ Length of spacer: approx. 40 mm
– Lock master cylinder at bracket -arrow 1- and -arrow 2-.
Note
Note
Note
Note
Note
Note
Note
– Fit tube-hose line -1- with gasket ring -2- onto the connection
of the master cylinder -4-, until the locking clip -3- is heard to
click into position.
– Check that it locks in place correctly by pulling on the line
-1-.
– Bleed clutch mechanism ⇒ page 76 .
All vehicles
– Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
– Install air filter ⇒ Engine; Rep. gr. 24 .
Note
Note
Note
– Remove the slave cylinder (do not open the line system) and
check if no brake fluid drips out of the bellows, to do so remove
the bellows from the rod -arrow-.
– If necessary. bleed the clutch control ⇒ page 76 .
– Then depress the clutch pedal carefully, at the same time hold
the pedal in five different positions for approx. 20s over the
entire distance the pedal has to travel and check that the pedal
does not fall through on its own while being held (in five posi‐
tions). While doing so, a second mechanic must check if fluid
is leaking from the other components of the hydraulic clutch
control ⇒ page 63 .
Note
Removing
Note
– Remove lock washer -1- for shift cable from gearbox shift lever
-2-.
– Pull off shift cable from the stud of the gearbox shift lever.
The relay lever -4- is secured with a clip -3- in the cover
– Unclip -3- out of the hole of the relay lever and pull out relay
lever -4- together with the cable lock out of the cover.
– Remove the gearbox shift lever -2- from the gearshift shaft.
Note
Make sure no brake fluid comes into contact with the gearbox. If
this is the case, this point must be cleaned thoroughly.
– Pinch off the tube-hose line to the master cylinder with the
hose clamp - MP7-602 (3094)- (if the tube-hose line to the
master cylinder is made out of plastic, do not use the hose
clamp - MP7-602- and after pulling out the slave cylinder, only
close this line in a suitable manner).
– Pull retaining clip -A- for tube-hose line out of the slave cylinder
up to the stop.
– Pull tube-hose line out of the support -C-.
– Pull tube-hose line -B- out of the slave cylinder and close
openings.
– Unscrew the screws -arrows- for the slave cylinder and re‐
move the slave cylinder.
Note
Install
Installation is performed in the reverse order, pay attention to the
following points:
– Grease tappet head with grease for plug serration of clutch
disc - G 000 100- .
Tightening torque
Component Nm
Slave cylinder to gearbox ⇒ page 78
Gearbox shift lever to gearshift shaft ⇒ page 98
Cable support to gearbox ⇒ page 98
Note
Caution
Install
Installation is performed in the reverse order, while paying atten‐
tion to the following:
Note
Note
Removing
Note
– Remove circlip -1- for shift cable from gearbox shift lever -2-.
– Pull off shift cable from the stud of the gearbox shift lever.
The relay lever -4- is secured with a clip -3- in the cover
– Unclip -3- out of the hole of the relay lever and pull out relay
lever -4- together with the cable lock out of the cover.
– Pull retaining clip -A- for tube-hose line out of the slave cylinder
up to the stop.
– Pull tube-hose line out of the support -C-.
– Pull tube-hose line -B- out of the slave cylinder and close
openings.
– Unscrew the screws -arrows- for the slave cylinder and re‐
move the slave cylinder.
Install
Installation is performed in the reverse order, pay attention to the
following points:
– Grease tappet head with grease for plug serration of clutch
disc - G 000 100- .
Tightening torques
Component Nm
Slave cylinder to gearbox ⇒ page 78
Gearbox shift lever to gearshift shaft ⇒ page 98
Cable support to gearbox ⇒ page 98
Note
Removing
Note
– Remove circlip -1- for shift cable from gearbox shift lever -2-.
– Pull off shift cable from the stud of the gearbox shift lever.
The relay lever -4- is secured with a clip -3- in the cover
– Unclip -3- out of the hole of the relay lever and pull out relay
lever -4- together with the cable lock out of the cover.
– Remove the gearbox shift lever -2- from the gearshift shaft.
Note
Make sure no brake fluid comes into contact with the gearbox. If
this is the case, this point must be cleaned thoroughly.
– Pinch off the tube-hose line to the master cylinder with the
hose clamp - MP7-602 (3094)- (if the tube-hose line to the
master cylinder is made out of plastic, do not use the hose
clamp - MP7-602- and after pulling out the slave cylinder, only
close this line in a suitable manner).
– Pull retaining clip -A- for tube-hose line out of the slave cylinder
up to the stop.
– Pull tube-hose line out of the support -C-.
– Pull tube-hose line -B- out of the slave cylinder and close
openings.
– Unscrew the screws -arrows- for the slave cylinder and re‐
move the slave cylinder.
Note
Install
Installation is performed in the reverse order, pay attention to the
following points:
– Grease tappet head with grease for plug serration of clutch
disc - G 000 100- .
Tightening torques
Component Nm
Slave cylinder to gearbox ⇒ page 78
Gearbox shift lever to gearshift shaft ⇒ page 98
Cable support to gearbox ⇒ page 98
Caution
Note
– Pull the clip at the tube-hose line out of the master cylinder up
to the stop and detach the tube-hose line.
– Close the openings.
– Pull out the clip -A- up to the stop and detach the tube-hose
line -B- to the master cylinder.
– Close the openings.
Note
Ignore -arrows-.
Install
Installation is performed in the reverse order, while paying atten‐
tion to the following:
– Connect the tube-hose line -1- with connectors at the master
cylinder and at the slave cylinder.
– Test line by tugging on it.
• After removing the hose clamp - MP7-602 (3094)- , it may be
necessary to bring the return hose -2- back into its initial po‐
sition.
Right-hand drive
– If present, coil the heat-protection matting in the sequence
-1, 2 and 3- around the cable.
– Secure the heat-protection matting with the circlip -4-.
Continued for all versions
– Bleed the clutch control ⇒ page 76
– Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
Note
Note
1 - Release bearing
❑ Do not wash the bear‐
ing, just wipe clean
❑ replace noisy bearings
⇒ Electronic Catalogue
of Original Parts
❑ removing and installing
⇒ page 79
❑ remove and install to‐
gether with the clutch re‐
lease lever Pos. 3 and
guide bushing Pos. 5
⇒ page 79
2 - Screw
❑ after removing, replace
⇒ Electronic Catalogue
of Original Parts
❑ 5 Nm + 90°
3 - Clutch release lever
❑ remove and install to‐
gether with the release
bearing Pos. 1 and
guide bushing Pos. 5
⇒ page 79
❑ Original grease must be
removed from the con‐
tact surface of the clutch
release lever
❑ grease contact surface
on the ball stud with
grease - G 000 100-
4 - Retaining spring
❑ attach to clutch release
lever
5 - Guide bushing
❑ for release bearing
❑ removing and installing ⇒ page 79
❑ remove and install together with the clutch release lever Pos. 3 and release bearing Pos. 1
⇒ page 79
❑ grease guide bushing in the area of the release lever with grease - G 000 100-
6 - Gasket ring for drive shaft
❑ removing and installing ⇒ page 190
❑ replace ⇒ Electronic Catalogue of Original Parts
7 - Ball pin
❑ Original grease must be removed from the contact surface of the clutch release lever
❑ grease with grease for plug serration of clutch disc - G 000 100-
❑ 20 Nm
8 - Gearbox
9 - Screw
❑ 20 Nm
10 - Support
11 - Slave cylinder
❑ removing and installing ⇒ page 64
❑ Grease tappet head with grease for plug serration of clutch disc - G 000 100-
3 Repairing clutch
⇒ “3.1 Summary of components - repairing the clutch”,
page 80
⇒ “3.2 Removing and installing clutch”, page 80
⇒ “3.3 Fault finding power transmission - problems with the clutch
and clutch control”, page 84
1 - Flywheel
❑ make sure the centering
pins are correctly fitted
❑ The locating face for the
clutch lining must be
free from grooves, oil
and grease
❑ Removing and Installing
⇒ Engine; Rep. gr. 13
2 - Clutch disc
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ Fitting position: The
spring cage points to‐
wards the pressure
plate
❑ the logo “gearbox side”
always points towards
the pressure plate and
the gearbox
⇒ page 82
❑ center ⇒ page 80
❑ slightly grease the ser‐
ration
3 - Pressure plate
❑ removing and installing
⇒ page 80
❑ Check the extremities of
the membrane spring
⇒ page 82
❑ Check feather joints and
riveted joints
⇒ page 83
4 - Screw
❑ assign via ⇒ Electronic Catalogue of Original Parts
❑ release or tighten gradually and crosswise.
❑ Tightening torque:
♦ M6 = 13 Nm
♦ M7 = 20 Nm
Note
♦ Before replacing the clutch disc and pressure plate fault find‐
ing power transmission - observe complaints of the clutch and
clutch control ⇒ page 84 .
♦ Check whether the dowel sleeves for centering the gearbox
are present in the cylinder block, insert if necessary.
♦ If the dowel sleeves are not present, this can result in difficul‐
ties to shift, clutch problems and if necessary noises from
gearbox (gear rattling).
♦ Replace the clutch discs and pressure plates if the riveting is
damaged or loose.
♦ Assign the clutch disc and pressure plate via the ⇒ Electronic
catalogue of original parts and in accordance with the engine
identification characters.
♦ Clean the drive shaft serration and hub serration on used
clutch discs. Remove corrosion and only apply a very thin layer
of grease for plug serration of clutch disc - G 000 100- on the
drive shaft serration.
♦ Subsequently move the clutch disc up and down on the drive
shaft until the hub fits smoothly on the shaft.
♦ Remove all excess grease.
♦ The pressure plates are protected against corrosion and are
greased. Only clean the thrust surface as otherwise the life of
the clutch may be considerably reduced.
3. Repairing clutch 81
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Manual gearbox 0AJ - Edition 05.2014
Removing
– Removing the gearbox ⇒ page 128 .
Caution
Note
The thrust surface of the pressure plate and the clutch disc lining
must fully rest against the flywheel before the screws are inserted.
– Screw in all the screws by hand uniformly, until the bolt head
rests against the pressure plate.
– Tighten the screws in small stages crosswise (tightening tor‐
que ⇒ page 80 ), so as not to damage the centering holes on
the pressure plate and the centering pins of the flywheel.
– Installing the gearbox ⇒ page 128
3. Repairing clutch 83
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Manual gearbox 0AJ - Edition 05.2014
Note
3. Repairing clutch 85
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Manual gearbox 0AJ - Edition 05.2014
♦ Flywheel depth too large or ex‐ – Assign the sealing flange via the
cess removal at the base of the ⇒ electronic catalogue of origi‐
thrust surface. nal parts .
3. Repairing clutch 87
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Manual gearbox 0AJ - Edition 05.2014
34 – Controls, housing
1 Repairing shift mechanism
⇒ “1.1 Fitting location of shift mechanism”, page 89 .
⇒ “1.2 Summary of components for clutch”, page 91
⇒ “1.3 Summary of components - Gearshift knob with shift lever
collar ”, page 92
⇒ “1.4 Summary of components - Gearshift mechanism”,
page 96
⇒ “1.5 Summary of components - Control cables”, page 98
⇒ “1.6 Removing and installing gearshift knob with shift lever col‐
lar”, page 101
⇒ “1.7 Removing and installing selector mechanism”, page 104
⇒ “1.8 Disassembling and assembling shift mechanism housing
”, page 115 .
⇒ “1.9 Removing and installing the cable lock from the relay lev‐
er”, page 118
⇒ “1.10 Removing and installing shift cable and selector cable”,
page 121 .
⇒ “1.11 Setting the shift mechanism ”, page 122
A - Shift cable
B - Selector cable
C - Heat shield
❑ take off before removing
the shift mechanism
1 - Gearshift lever
2 - Reversing lever
Note
♦ After the battery earth strap is disconnected and connected. carry out additional operations ⇒ Electrical
System; Rep. gr. 27 .
♦ Remove shift mechanism for replacing control cables ⇒ page 115 .
♦ Do not kink the control cables.
I - Montageübersicht - Schalt‐
knopf mit Schalthebelmansch‐
ette - ⇒ page 92 .
II - Montageübersicht - Schalt‐
betätigung - ⇒ page 96
III - Montageübersicht - Betäti‐
gungsseilzüge - ⇒ page 98
1 - Gearshift knob
❑ with collar
❑ The gearshift knob and
collar can be separated
from each other (when
separating, the catch
ring is damaged)
❑ Plaque of gearshift lever
can only be separated
from the gearshift knob
e.g. with a screwdriver.
❑ removing and installing
⇒ page 101
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
2 - Collar
3 - Open warm-type clamp
❑ for securing the gear‐
shift knob to the gear‐
shift lever
❑ always replace ⇒ Elec‐
tronic Catalogue of
Original Parts
1.3.2 Summary of components - gearshift knob with shift lever collar (Octavia III)
1 - Gearshift knob
❑ with collar
❑ The gearshift knob and
collar cannot be separa‐
ted
❑ removing and installing
⇒ page 101
❑ Plaque of gearshift lever
can only be separated
from the gearshift knob
e.g. with a screwdriver.
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ always replace together
⇒ Electronic Catalogue
of Original Parts
2 - Collar
❑ with frame
3 - Open warm-type clamp
❑ For securing gear knob
to gear lever
❑ always replace ⇒ Elec‐
tronic Catalogue of
Original Parts
1 - Gearshift knob
❑ with collar
❑ the gearshift knob and
collar cannot be separa‐
ted
❑ Plaque of gearshift lever
can only be separated
from the gearshift knob
e.g. with a screwdriver.
❑ removing and installing
⇒ page 102
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ always replace together
⇒ Electronic Catalogue
of Original Parts
2 - Collar
3 - Open warm-type clamp
❑ for securing the gear‐
shift knob to the gear‐
shift lever
❑ always replace ⇒ Elec‐
tronic Catalogue of
Original Parts
1 - Gearshift knob
❑ with collar
❑ the gearshift knob and
collar cannot be separa‐
ted
❑ Plaque -arrow- of gear‐
shift lever can be sepa‐
rated from the gearshift
knob e.g. with a screw‐
driver
❑ always replace together
⇒ Electronic Catalogue
of Original Parts
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ removing and installing
⇒ page 103
2 - Cover
❑ for centre console
❑ lever off from the centre
console with the release
tool - T30098-
3 - Shift lever
4 - Centre console
Note
♦ Grease bearing and friction surfaces with grease - G 000 450 02- .
♦ Disassembling and assembling the gearshift mechanism ⇒ page 115 .
1 - Floor plate
❑ bend up tabs for remov‐
ing
❑ after removing, replace
⇒ Electronic Catalogue
of Original Parts
2 - Gasket
❑ after removing, replace
⇒ Electronic Catalogue
of Original Parts
3 - Shift lever
❑ can be installed or re‐
moved with the shift lev‐
er guide pos. 15 moun‐
ted
4 - Insulating washer
❑ push up to the stop
-arrow- onto the shift
lever
❑ in case of damage re‐
place ⇒ Electronic
Catalogue of Original
Parts
5 - Lock washer
❑ do not damage cable
when removing
❑ after removing, replace
⇒ Electronic Catalogue
of Original Parts
6 - Selector cable
❑ removing and installing
⇒ page 121
❑ Fitting position
⇒ page 89
❑ adjust ⇒ page 122
7 - Bush for selector cable
8 - Shift cable
❑ removing and installing ⇒ page 121
❑ Fitting position ⇒ page 89
❑ adjust ⇒ page 122
9 - Damping
❑ removing and installing ⇒ page 97
10 - Bearing shell
❑ removing and installing ⇒ page 115
❑ when removing, the catches of the bearing shell are usually damaged
Note
Note
Grease bearing and friction surfaces with grease - G 000 450 02- .
1 - Shift cable
❑ slacken from the shift
lever guide within the
shift mechanism
❑ press onto the selector
angle guide within the
shift mechanism
❑ connect with cable lock
Pos. 11 connect 11
❑ Fitting position
⇒ page 89
❑ removing and installing
⇒ page 121
❑ attach with cable strap
to the selector cable
⇒ page 100
❑ after installing set shift
mechanism
⇒ page 122
2 - Selector cable
❑ slacken from selector
angle plate within the
shift mechanism
❑ press onto selector an‐
gle plate within the shift
mechanism
❑ connect with cable lock
Pos. 10 connect 10
❑ Fitting position
⇒ page 89
❑ removing and installing
⇒ page 121
❑ attach with cable strap
to the selector cable
⇒ page 100
❑ after installing set shift mechanism ⇒ page 122
3 - Bush for selector cable
4 - Shift housing
5 - Locking clips
❑ do not damage cable when removing
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
6 - Screw
❑ 3 pieces
❑ for cable support
❑ 20 Nm
7 - Cable support
❑ for control cables Volkswagen Technical Site: http://vwts.ru http://vwts.info
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
8 - Grommet
❑ Mounting of cable support to gearbox
9 - Bush
10 - Cable lock
❑ for selector cable at relay lever
❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are
different
❑ after installing set shift mechanism ⇒ page 122
❑ remove and install together with relay lever Pos. 13 ⇒ page 118
❑ remove and press onto relay lever ⇒ page 118
❑ Assignment ⇒ page 120
11 - Cable lock
❑ for shift cable at gearbox shift lever
❑ after installing set shift mechanism ⇒ page 122
❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are
different
❑ Assignment ⇒ page 120
12 - Circlip
❑ always replace ⇒ Electronic Catalogue of Original Parts
13 - Reversing lever
❑ Fitting position ⇒ page 100
❑ after installing set shift mechanism ⇒ page 122
❑ remove and install together with cable lock Pos. 10 ⇒ page 118
14 - Sliding shoe
15 - Nut
❑ always replace ⇒ Electronic Catalogue of Original Parts
❑ 23 Nm
16 - Gearshift lever
❑ with balancing weight
❑ insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft ⇒ page 100
❑ after installing set shift mechanism ⇒ page 122
❑ Fitting position ⇒ page 100
– Open clamp -arrow- and pull off gearshift knob together with
the collar.
Install
– Turn collar inside out.
– Open clamp -arrow- and pull off gear knob together with gaiter.
Install
Installation is performed in the reverse order, while paying atten‐
tion to the following:
– Press the gearshift knob together with the collar as far as the
stop onto the shift lever.
Note
When inserting the gearshift knob on the shift lever the gearshift
knob must lock into the round slot of the gearshift lever.
– Open clamp -arrow- and pull off gearshift knob together with
the collar.
Install
– Turn collar inside out.
Note
– Remove circlip -1- for shift cable from gearbox shift lever -2-.
– Pull off shift cable from the stud of the gearbox shift lever.
The relay lever -4- is secured with a clip -3- in the cover
– Unclip -3- out of the hole of the relay lever and pull out relay
lever -4- together with the cable lock out of the cover.
– Detach the tunnel bridge -1- below the exhaust system ⇒ En‐
gine; Rep. gr. 26 .
– Separate exhaust system at the clamping sleeve -arrows-.
– Support the front exhaust pipe.
Note
– Unhook the rear silencer -2- from the retaining straps and re‐
move.
– If necessary, remove pre-exhaust pipe ⇒ Engine; Rep. gr.
26 .
– Remove the heat shield below the shift housing.
– Swivel shift housing down and remove with control cables.
Install
Installation is performed in the reverse order, pay attention to the
following points:
The holes in the cable locks have different diameters.
Assign cable locks ⇒ page 120
– Apply a small quantity of grease - G 000 450 02- onto the stud
of the gearbox shift lever -2-.
– Replace circlip -1- after each removal.
– Secure the shift cable with the lock washer -1-.
The relay lever -4- is secured with a clip -3- in the cover
– Apply a small quantity of grease - G 000 450 02- onto the stud
of the relay lever.
– Insert the relay lever -4- together with the cable lock in the
cover and secure with the clip -3-.
Note
Note
Tightening torques
Component Nm
Shift housing to body ⇒ page 96
Cable support to gearbox ⇒ page 98
Underbody cover ⇒ Body Work; Rep. gr. 50
Removing
Note
– Remove circlip -1- for shift cable from gearbox shift lever -2-.
– Pull off shift cable from the stud of the gearbox shift lever.
The relay lever -4- is secured with a clip -3- in the cover
– Unclip -3- out of the hole of the relay lever and pull out relay
lever -4- together with the cable lock out of the cover.
– Detach the tunnel bridge -1- below the exhaust system ⇒ En‐
gine; Rep. gr. 26 .
– Separate the exhaust system at the double clamp -arrows-.
– Support the front exhaust pipe.
Note
– Unhook the rear silencer -2- from the retaining straps and re‐
move.
– If necessary, remove pre-exhaust pipe ⇒ Engine; Rep. gr.
26 .
– Remove the heat shield below the shift housing.
– Swivel shift housing down and remove with control cables.
Install
Installation is performed in the reverse order, pay attention to the
following points:
The holes in the cable locks have different diameters.
Assign cable locks ⇒ page 120
– Apply a small quantity of grease - G 000 450 02- onto the stud
of the gearbox shift lever -2-.
– Replace circlip -1- after each removal.
– Secure the shift cable with the lock washer -1-.
The relay lever -4- is secured with a clip -3- in the cover
– Apply a small quantity of grease - G 000 450 02- onto the stud
of the relay lever.
– Insert the relay lever -4- together with the cable lock in the
cover and secure with the clip -3-.
Note
Note
Tightening torques
Component Nm
Shift housing to body ⇒ page 96
Cable support to gearbox ⇒ page 118
Underbody cover ⇒ Body Work; Rep. gr. 50
Note
– Remove lock washer -1- for shift cable from gearbox shift lever
-2-.
– Pull off shift cable from the stud of the gearbox shift lever.
The relay lever -4- is secured with a clip -3- in the cover
– Unclip -3- out of the hole of the relay lever and pull out relay
lever -4- together with the cable lock out of the cover.
– Detach the tunnel bridge -1- below the exhaust system ⇒ En‐
gine; Rep. gr. 26 .
– Separate exhaust system at the clamping sleeve -arrows-.
– Support the front exhaust pipe.
Note
– Unhook the rear silencer -2- from the retaining straps and re‐
move.
– If necessary, remove pre-exhaust pipe ⇒ Engine; Rep. gr.
26 .
– Remove the heat shield below the shift housing.
– Swivel shift housing down and remove with control cables.
Install
Installation is performed in the reverse order, pay attention to the
following points:
The holes in the cable locks have different diameters.
Assign cable locks ⇒ page 120
– Apply a small quantity of grease - G 000 450 02- onto the stud
of the gearbox shift lever -2-.
– Replace circlip -1- after each removal.
– Secure the shift cable with the lock washer -1-.
The relay lever -4- is secured with a clip -3- in the cover
– Apply a small quantity of grease - G 000 450 02- onto the stud
of the relay lever.
– Insert the relay lever -4- together with the cable lock in the
cover and secure with the clip -3-.
Note
Note
Tightening torques
Component Nm
Shift housing to body ⇒ page 96
Cable support to gearbox ⇒ page 118
Underbody cover ⇒ Body Work; Rep. gr. 50
– Lift the upper leg -A- of the pressure spring over the tabs of
the selector angle.
– Use a screwdriver to press the catches -arrows- of the bearing
shell in direction of the bearing ball for the shift lever guide; if
necessary break off the catches -arrows-.
– Lever bearing shell -A- with shift lever guide and shift lever
-B- out of the shift housing.
– Then press the bearing shell off the bearing ball for the shift
lever guide and remove.
Caution
The lower leg of the pressure spring ( ⇒ page 116 ) can jump
off uncontrolled from the shoulder of the selector angle during
further handling.
– Thus carefully press down the lower leg from the shoulder of
the selector angle plate.
The legs of the pressure spring tighten “crosswise” with a loud
noise
– To slacken, turn around the legs of the pressure spring -A- and
-B- towards the right.
• The legs -A- and -B- must point in the opposite direction
(shown here for inserted shift lever guide).
– Insert shift lever guide with shift lever into the shift housing.
• The stud -arrow 1- is still located in the recess of the shift
housing.
– Turn shift lever guide in -direction of arrow 2-, until the ball stud
-A- is above the recess of the shift housing.
– Position shift housing with shift lever guide into the larger re‐
cess -arrow- of the Insert base - T10083- .
• The shift lever guide must protrude out of the shift housing as
far as the stop.
– Insert the leg -A- of the pressure spring from the top into the
guide.
– Pull leg -B- of pressure spring downwards and insert the leg
-B- next to the guide (in direction of the spherical head).
Note
– Carefully remove shift housing with shift lever guide from the
insert base - T10083- .
– Position shift housing with shift lever guide into the larger re‐
cess -arrow- of the Insert base - T10083- .
• The shift lever guide must protrude out of the shift housing as
far as the stop.
– Lift the upper leg -A- of the pressure spring over the stud of
the selector angle plate.
• Use a new bearing shell -B-.
– Grease the bearing shell and the bearing ball of the shift lever
guide with grease - G 000 450 02- .
– Press the bearing shell up to stop onto the bearing ball of the
shift lever guide.
– Remove shift housing from the insert base - T10083- .
– Press the bearing shell into the shift housing -arrows-.
• All catch pegs must click audibly.
– Insert the lower leg -C- of the pressure spring into the guide.
– Lift the upper leg -A- of the pressure spring over the stud of
the selector angle plate into the guide.
– Mount shift lever, shift cable, selector cable and floor plate.
– Installing shift mechanism ⇒ page 104 .
– Setting the shift mechanism ⇒ page 122 .
Note
Note
Lever off cable lock for selector cable from relay lever
• Relay lever removed.
– Insert cross-head screwdriver -A- between bushing -B- and
relay lever.
Bolt diameter for attaching the cable lock of the shift cable
Mounting pin for the cable lock of the shift cable Dimension “a”
∅ of the mounting pin 8.5 mm
Unlock catches -A- for shift cable and selector cable as follows:
– Slide sliding sleeve forwards up to the stop -arrow 1-.
– Turn sliding sleeve to the right up to the stop -arrow 2- until it
locks audibly.
– Remove the catches from the cables.
– Attach shift cable and selector cable to shift housing with cir‐
clips -2 and 3-.
– Press shift cable and selector cable onto shift lever and se‐
lector lever into shift housing (lock washers -1 and 4- are no
longer available).
Note
The following are required for correct setting of the shift mecha‐
nism:
– Lever the collar upwards and out of centre console cover with
release tool - T30098- -arrows-.
– Pull the collar upwards over the gearshift knob.
– If present, detach the noise insulation.
Now fix the gearshift lever as follows:
– Engage neutral position on gearshift lever.
– Lever the collar -A- together with the surround -B- off the cen‐
tre console -C- using the release tool - T30098-
-direction of arrow-.
– Pull the collar upwards over the gearshift knob.
Now fix the gearshift lever as follows:
– Ensure that the selector and shift cable -B- are pushed free of
tension into the catches -A-.
– Turn the locking mechanism at the shift cable and at the se‐
lector cable to the right as far as the stop
-direction of arrow°1-.
The spring pushes the locking mechanism into the initial position
-direction of arrow 2-.
Note
Note
The angle lever -A- must be pressed out of the shift housing up
to the stop and must point vertically upwards.
Note
– Undo frame -B- together with the collar -A- from the central
console -in the direction of arrow-.
– Pull gaiter upwards, inside out over gear knob.
– Guide shift lever in Neutral position to the left into the 1st/2nd
gear gate via the leg.
Note
Note
Note
♦ All cable straps which are detached or cut open when remov‐
ing, should be fitted on again in the same place when installing.
♦ After the battery earth strap is disconnected and connected,
carry out additional operations ⇒ Electrical System; Rep. gr.
27 .
– Remove lock washer -1- for shift cable from gearbox shift lever
-2-.
– Pull off shift cable from the stud of the gearbox shift lever.
The relay lever -4- is secured with a clip -3- in the cover
– Unclip -3- out of the hole of the relay lever and pull out relay
lever -4- together with the cable lock out of the cover.
Note
– Disconnect plug -1- for oil level and oil temperature sender -
G266- .
– Remove protection plate for drive shaft from the engine (if
present) -arrows-.
– Remove drive shafts from flange shafts and tie up as far as
possible; do not damage the surface protection.
Note
Note
– Align the
adjusting plate parallel to the gearbox.
– Press the gearbox in the area of the cover for the gearbox
housing to the front end -arrow 1- and turn it slightly towards
the bottom -arrow 2-.
– Pay attention to the intermediate plate on the engine.
– After this, carefully guide the gearbox with the right flange shaft
-A- past the flywheel -B- and the intermediate plate as shown.
– The left flange shaft -A- is carefully guided past the console
-B- of the assembly carrier as shown.
– Lower gearbox, to do so pay attention to the assembly carrier.
– Change the gearbox position at the spindles of the gearbox
mount - 3282- when lowering.
Note
Note
♦ All cable straps which are detached or cut open when remov‐
ing, should be fitted on again in the same place when installing.
♦ After the battery earth strap is disconnected and connected,
carry out additional operations ⇒ Electrical System; Rep. gr.
27 .
– Remove lock washer -1- for shift cable from gearbox shift lever
-2-.
– Pull off shift cable from the stud of the gearbox shift lever.
The relay lever -4- is secured with a clip -3- in the cover
– Unclip -3- out of the hole of the relay lever and pull out relay
lever -4- together with the cable lock out of the cover.
Note
– Disconnect plug -1- from oil level and oil temperature sender
- G266- .
– Remove drive shafts from flange shafts and tie up as far as
possible; do not damage the surface protection.
Note
Note
– Align the
adjusting plate parallel to the gearbox.
– Press the gearbox in the area of the cover for the gearbox
housing to the front end -arrow 1- and turn it slightly towards
the bottom -arrow 2-.
– Pay attention to the intermediate plate on the engine.
– After this, carefully guide the gearbox with the right flange shaft
-A- past the flywheel -B- and the intermediate plate as shown.
– The left flange shaft -A- is carefully guided past the console
-B- of the assembly carrier as shown.
– Lower gearbox, to do so pay attention to the assembly carrier.
– Change the gearbox position at the spindles of the gearbox
mount - 3282- when lowering.
Note
Note
♦ All cable straps which are detached or cut open when remov‐
ing, should be fitted on again in the same place when installing.
♦ After the battery earth strap is disconnected and connected,
carry out additional operations ⇒ Electrical System; Rep. gr.
27 .
– Remove lock washer -1- for shift cable from gearbox shift lever
-2-.
– Pull off shift cable from the stud of the gearbox shift lever.
The relay lever -4- is secured with a clip -3- in the cover
– Unclip -3- out of the hole of the relay lever and pull out relay
lever -4- together with the cable lock out of the cover.
Note
– Disconnect plug -1- from oil level and oil temperature sender
- G266- .
– Remove protection plate for drive shaft from the engine (if
present) -arrows-.
– Remove drive shafts from flange shafts ⇒ Chassis; Rep. gr.
40 .
– Secure the drive shaft e.g. with the tensioning strap - T10038-
(while doing so do not damage the surface protection).
Note
Note
– Align the
adjusting plate parallel to the gearbox.
– Press the gearbox in the area of the cover for the gearbox
housing to the front end -arrow 1- and turn it slightly towards
the bottom -arrow 2-.
– Pay attention to the intermediate plate on the engine.
– After this, carefully guide the gearbox with the right flange shaft
-A- past the flywheel -B- and the intermediate plate as shown.
– The left flange shaft -A- is carefully guided past the console
-B- of the assembly carrier as shown.
– Lower gearbox, to do so pay attention to the assembly carrier.
– Change the gearbox position at the spindles of the gearbox
mount - 3282- when lowering.
Note
Note
♦ The clutch plate must slide freely up and down the drive shaft.
♦ If the gearbox is inserted. ensure the intermediate plate be‐
tween the engine and gearbox is correctly installed.
♦ Check whether the dowel sleeves for centering the gearbox
are present in the cylinder block. insert missing sleeves. If the
sleeves are not provided. complications while shifting as well
as problems with the clutch might occur and gearbox noises
could arise.
Note
Tightening torques
Component Tightening torque
Cable support to gearbox ⇒ page 98
Gearbox shift lever to gearshift shaft ⇒ page 98
Slave cylinder to gearbox ⇒ page 78
Pendulum support1) ⇒ Engine; Rep. gr. 10
Protective cap for drive shaft on engine ⇒ Chassis; Rep. gr. 40
Drive shaft to flange shaft ⇒ Chassis; Rep. gr. 40
Wheel bolts to wheel hub ⇒ Chassis; Rep. gr. 44
1)Always replace these screws ⇒ Electronic Catalogue of Orig‐
inal Parts .
Gearbox to body
– Replace bolts.
Screws -arrows°1- 60 Nm + torque a further 90°
(1/4 turn)
Tightening torques
Component Tightening torque
Cable support to gearbox ⇒ page 98
Gearbox shift lever to gearshift shaft ⇒ page 98
Slave cylinder to gearbox ⇒ page 78
Pendulum support1) ⇒ Engine; Rep. gr. 10
Drive shaft to flange shaft ⇒ Chassis; Rep. gr. 40
Wheel bolts to wheel hub ⇒ Chassis; Rep. gr. 44
1)Always replace these screws ⇒ Electronic Catalogue of Orig‐
inal Parts .
Gearbox to body
– Replace bolts.
Screws -arrows°1- 60 Nm + torque a further 90°
(1/4 turn)
Tightening torques
Component Tightening torque
Cable support to gearbox ⇒ page 98
Gearbox shift lever to gearshift shaft ⇒ page 98
Slave cylinder to gearbox ⇒ page 78
Pendulum support1) ⇒ Engine; Rep. gr. 10
Protective cap for drive shaft on engine ⇒ Chassis; Rep. gr. 40
Drive shaft to flange shaft ⇒ Chassis; Rep. gr. 40
Wheel bolts to wheel hub ⇒ Chassis; Rep. gr. 44
1)Always replace these screws ⇒ Electronic Catalogue of Orig‐
inal Parts .
3 Gear oil
⇒ “3.1 Check gear oil level”, page 153
Note
♦ Loosen or tighten oil filler plug or oil drain plug with hexagon
socket head with socket wrench insert - T30023 (3357)- .
♦ Assign oil filler plug or oil drain plug via the ⇒ Electronic Cata‐
logue of Original Parts .
1 - 1. gear
2 - 2. gear
3 - 3. gear
4 - 4. gear
5 - 5. gear
6 - 6. gear
7 - Cover for gearbox housing
8 - Gearbox housing
9 - Reverse gear
10 - Shift mechanism
❑ (Gearshift forks)
11 - Clutch housing
12 - Drive shaft
13 - Output shaft
14 - Differential gear
1 - Gearbox housing
❑ repairing ⇒ page 178
2 - 5th gear pinion
❑ removing and installing
⇒ page 166
❑ Fitting position and
press on ⇒ page 174
3 - Bushing
4 - 6th gear pinion
❑ Fitting position
⇒ page 176
5 - Inner ring/cylindrical-roller
bearing
❑ for output shaft
❑ identify before removing
❑ do not interchange with
inner ring/cylindrical-
roller bearing of input
shaft
❑ can be replaced sepa‐
rately
6 - Self-locking screw
❑ for output shaft
❑ after removing, replace
⇒ Electronic Catalogue
of Original Parts
❑ M8: 30 Nm + torque a
further 90° (1/4 turn)
❑ M10 x 1: 75 Nm + torque
a further 45° (1/8 turn)
7 - Cover for gearbox housing
❑ with cylindrical-roller bearing for drive shaft and for output shaft
❑ repairing ⇒ page 180
8 - Screw
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
❑ 5 Nm + 90°
9 - Self-locking screw
❑ for drive shaft
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
❑ M8: 30 Nm + torque a further 90° (1/4 turn)
❑ M10: 75 Nm + torque a further 45° (1/8 turn)
11 - Thrust washer
12 - Inner ring/cylindrical-roller bearing with thrust washer
❑ for drive shaft
❑ present on certain gearboxes
❑ assign according to the ⇒ Electronic catalogue of original parts .
13 - 6th gear sliding gear
14 - 6th gear synchronizer ring
15 - Needle bearing
❑ one-piece
❑ for 6th gear
❑ assign according to the ⇒ Electronic catalogue of original parts .
❑ replace together with bushing Pos. 17
16 - Needle bearing
❑ two-piece
❑ for 6th gear
❑ present on certain gearboxes
❑ assign according to the ⇒ Electronic catalogue of original parts .
❑ replace together with bushing Pos. 17
17 - Bushing
❑ for 6th gear needle bearing
❑ replace together with needle bearing Pos. 15 or 16
18 - Sliding sleeve with 5th and 6th gear synchronizer body
❑ disassembling and assembling ⇒ page 185
19 - 5th/6th gear shift fork
20 - Bearing bolt
❑ for 5th/6th gear shift fork
21 - 5th gear synchronizer ring
❑ is damaged by the drive shaft when removing
❑ always replace ⇒ Electronic Catalogue of Original Parts
22 - 5th gear sliding gear
23 - Needle bearing
❑ for 5th gear
1 - Conical screw
❑ 25 Nm
2 - Flange shaft with pressure
spring
❑ removing and installing
⇒ page 166
❑ complete ⇒ page 202
3 - Screw
❑ after removing, replace
⇒ Electronic Catalogue
of Original Parts
❑ 5 Nm + 90°
4 - Clutch housing
❑ repairing ⇒ page 178
5 - Gearbox housing
❑ repairing ⇒ page 178
6 - Clutch release lever
❑ with guide bushing and
clutch release bearing
❑ removing and installing
⇒ page 78
7 - Screw
❑ after removing, replace
⇒ Electronic Catalogue
of Original Parts
❑ 5 Nm + 90°
1 - Differential gear
❑ disassembling and as‐
sembling ⇒ page 205
2 - Gearbox housing
❑ repairing ⇒ page 153
⇒ page 178
3 - Oil drain plug
❑ Tightening torque
⇒ page 153
❑ different versions; as‐
sign via the ⇒ Electronic
Catalogue of Original
Parts
4 - Flange shaft with pressure
spring
❑ removing and installing
⇒ page 166
❑ complete ⇒ page 202
5 - Conical screw
❑ 25 Nm
6 - Self-locking screw
❑ to secure the bearing
support with grooved
ball bearings for the
drive and output shaft
❑ after removing, replace
⇒ Electronic Catalogue
of Original Parts
❑ 5 Nm + 90°
7 - Hexagon nut with collar
❑ for shift mechanism
❑ self-locking
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
❑ 23 Nm
8 - O-ring
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
9 - Bearing pins
10 - Screw
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
❑ 5 Nm + 90°
11 - Gearshift shaft with cover
❑ (Gearshift unit)
❑ disassembling and assembling ⇒ page 164
12 - Screw
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
❑ 5 Nm + 90°
13 - Screw
❑ 6 Nm
1 - Bushing
❑ for the gearshift shaft
❑ extracting and inserting
⇒ page 178 flush
2 - Gearshift shaft with cover
❑ replace jointly
3 - Locking bolt
❑ for setting the gearshift
mechanism
❑ removing ⇒ page 164
❑ inserting ⇒ page 165
4 - Reversing lever
❑ Fitting position
⇒ page 100
❑ after installing set shift
mechanism ⇒ page 122
❑ remove and install to‐
gether with cable lock
for selector cable
⇒ page 118
❑ on certain vehicles, the
relay lever is secured
with the clip on the gear‐
shift cover ⇒ page 166
5 - Sealing ring
❑ for the gearshift shaft
❑ lever out with screwdriv‐
er
❑ inserting ⇒ page 165
6 - Cap
❑ for gearbox bleeder
7 - Gearshift lever
❑ with balancing weight
❑ insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft ⇒ page 165
❑ may be replaced with the gearshift mechanism mounted
❑ Fitting position ⇒ page 100
8 - Hexagon nut
❑ self-locking
❑ replace ⇒ Electronic Catalogue of Original Parts
❑ 20 Nm
Note
The gearshift fork group Pos. 1 does not have to be disassembled for the disassembly and assembly of the
shift segments, circlips and if necessary angular ball bearings.
Note
It must still be possible to rotate the shift segment freely once the
circlip has been fitted.
Note
Do not bend the shift forks when removing and installing the an‐
gular ball bearings.
Insert the angular ball bearing up to the stop into the gearshift fork
The recess in the pressure plate - 3290/1- from the assembly de‐
vice - 3290- points towards the ball bearing.
Note
– Insert the relay lever together with the cable lock up to the stop
in the gearshift cover.
– Inser the clip -arrow 1- in the hole of the relay lever.
• Pay attention to secure catch of the clip.
Drive in the bushing -A- for the shift rod up to the stop
– Pull out the bearing bolt -1- for the 5th/6th gear shift fork -2- in
-direction of arrow- and remove gearshift fork.
– Unscrew screws -A- for inner rings of the bearing on the input
and output shaft, to this end engage the 5th gear -arrow 1- and
the 1st gear -arrow 2- and -arrow 3-.
– The input and output shafts are blocked after enagaging both
gears. Now it is possible to release the two bolts.
Note
If the shafts are not replaced, carefully clean the threaded holes
e.g. using a screw-tap in order to remove locking agent residues.
– If necessary, heat the gear pinion using the hot air blower -
V.A.G 1416- .
– Insert the separating device - Kukko 17/1- -A- below the syn‐
chronizer ring of the 5th gear -1-. The synchronizer ring is
thereby pressed onto the synchronizer body -2-.
A - Separating device - Kukko 17/1-
B - Allen screw - M8 x 15-
C - Extractor - Kukko 18/1-
– Heat 5th/6th gear synchronizer body and inner ring for needle
bearing 6th Heat gear with hot-air blower - V.A.G 1416- where
necessary.
– Pull off 5th/6th °gear synchronizer body with inner ring for 6th
°gear needle bearing and 5th °gear synchronizer ring.
Note
– Unscrew the fixing screw for the left flange shaft -1-, to this end
insert two screws in the flange and counterhold the flange
shaft using a tyre iron.
– Afterwards, remove the oil drip pan -A- and the oil guide part
-B- with the solenoid from the gearbox housing.
Vehicles with start-stop system
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Manual gearbox 0AJ - Edition 05.2014
Note
– Press off the drive shaft and output shaft together with the 5th
°gear sliding gear -A-, bearing support, gearshift mechanism
(shift forks) and reverse gear.
Note
– Pressing off the drive and output shafts from the bearing sup‐
port with grooved ball bearings and 5th gear pinion
⇒ page 185 .
Assembling gearbox
– Press the drive and output shaft into the bearing support for
grooved ball bearings ⇒ page 185 .
– Pressing the sleeve of the 5th gear sliding gear needle bearing
onto the drive shaft ⇒ page 185 .
Note
– Fit the washer - T10083/1- onto the drive shaft and carefully
press in the bearing support together with the drive shaft and
the output shaft up to the stop.
– Carefully press on the bearing support with the drive and out‐
put shaft up to the arrester.
– Use new screws -A- to secure the bearing support to the drive
shaft and output shaft.
Note
Fitting position press on 5th °gear pinion and 5th °gear pinion
The highest collar -arrow- points to the gearbox housing cover.
– Pressing on 5th °gear pinion.
– Mount the 5th gear sliding gear with needle bearing.
– Position the 5th gear synchronizer ring on the sliding gear.
– Heat the inner ring for the 6th gear needle bearing to max. 100
°C and press on.
WARNING
– Mount the 6th °gear sliding gear with needle bearing and syn‐
chronizer ring.
Note
WARNING
– Heat the inner ring for the cylindrical-roller bearing -B- to max.
100°C and press onto the drive shaft.
WARNING
– Heat the inner ring for the cylindrical-roller bearing -A- to max.
100°C and press onto the output shaft.
– Afterwards, insert the oil drip pan -A- into the recess -1- and
into the hole -2- of the gearbox housing.
– Now position the oil guide part -B- into the gearbox housing.
– Insert solenoid into the oil guide part -B-.
– Insert the 5th/6th gear shift fork -2- and push the bearing bolt
-1- up to the stop -direction of arrow-.
– Apply sealant - AMV 188 200 03- uniformly on the sealing sur‐
face.
– Tighten cover for gearbox housing.
– Install both flange shafts with pressure springs, stop discs and
conical rings.
– Install the clutch release lever together with the release bear‐
ing and guide bushing ⇒ page 78 .
– Pour in gear oil ⇒ page 153 .
1 - Clutch housing
❑ when used: Adjusting
differential gear
⇒ page 208
2 - Gasket ring for drive shaft
❑ removing and installing
⇒ page 190
3 - Ball pin
❑ remove previous grease
❑ grease with grease for
plug serration of clutch
disc - G 000 100-
❑ 20 Nm
4 - Sealing ring
❑ for right flange shaft
❑ replace with installed
gearbox ⇒ page 200
5 - Oil filler plug
❑ Tightening torque
⇒ page 153
❑ different versions
⇒ page 153
❑ if necessary screw and
unscrew with socket
wrench insert - T30023-
6 - Adjusting washer
❑ for the differential gear
❑ Determine thickness
⇒ page 208
7 - Outer ring/tapered-roller
bearing
❑ for the differential gear
❑ removing and installing ⇒ page 205
❑ when used: Adjusting differential gear ⇒ page 208
8 - Screw
❑ always replace ⇒ Electronic Catalogue of Original Parts
❑ 5 Nm + 90°
9 - Outer ring/tapered-roller bearing
❑ for the differential gear
❑ removing and installing ⇒ page 205
❑ when used: Adjusting differential gear ⇒ page 208
10 - Fitting sleeve
❑ 2 pieces
11 - Gearbox housing
❑ when used: Adjusting differential gear ⇒ page 208
12 - Oil drain plug
❑ Tightening torque ⇒ page 153
❑ different versions ⇒ page 153
❑ if necessary screw and unscrew with socket wrench insert - T30023-
13 - Sealing ring
❑ for left flange shaft
❑ replace with installed gearbox ⇒ page 199
14 - Bushing
❑ for the gearshift shaft
❑ extracting ⇒ page 166
❑ inserting ⇒ page 166
15 - Screw cap
❑ Before screwing down apply -AMV 188 200 03- to the sealing surface
16 - Circlip
❑ insert in the nut of the cylinder roller bearing groove Pos. 19
17 - Circlip
❑ insert in the nut of the cylinder roller bearing groove Pos. 18
18 - Cylindrical-roller bearing
❑ for drive shaft
❑ removing and installing ⇒ page 185
19 - Cylindrical-roller bearing
❑ for output shaft
❑ removing and installing ⇒ page 194
20 - Plug
❑ present on certain gearboxes
❑ insert in the holes of the clutch housing
1 - Countersunk screw
❑ tighten crosswise
❑ 2 Nm
2 - Bearing plate
❑ for cylindrical-roller
bearing
❑ Fitting position: counter‐
sunks for countersunk
screws point to the gear‐
box housing
3 - Cylindrical-roller bearing
❑ for drive shaft
❑ do not interchange with
cylindrical-roller bearing
for output shaft
❑ can be replaced sepa‐
rately
❑ removing ⇒ page 180
❑ installing ⇒ page 181
4 - Cylindrical-roller bearing
❑ for output shaft
❑ do not interchange with
cylindrical-roller bearing
for input shaft
❑ can be replaced sepa‐
rately
❑ removing ⇒ page 180
❑ installing ⇒ page 181
5 - Cover for gearbox housing
Note
35 – Gears, shafts
1 Drive shaft
⇒ “1.1 Summary of components - Drive shaft”, page 182
⇒ “1.2 Disassembling and assembling the drive shaft”,
page 185
⇒ “1.3 Replace gasket ring for drive shaft”, page 190
Note
1 - Screw
❑ removing and installing
⇒ page 156
2 - Inner ring/cylindrical-roller
bearing
❑ combined with thrust
washer Pos. 3 on some
gearboxes ⇒ page 156
❑ identify before removing
❑ do not interchange with
inner ring/cylindrical-
roller bearing of output
shaft
❑ can be replaced sepa‐
rately
❑ removing and installing
⇒ page 166
3 - Thrust washer
❑ combined with inner
ring/cylindrical-roller
bearing Pos. 2 on some
gearboxes ⇒ page 156
4 - 6th gear sliding gear
❑ No. of teeth ⇒ page 2
5 - 6th gear synchronizer ring
❑ check for wear
⇒ page 187
6 - Needle bearing
❑ for 6th gear
❑ replace together with
Pos. 7
❑ on certain gearboxes
two-piece, assign via
the ⇒ Electronic Catalogue of Original Parts
7 - Bushing
❑ for 6th gear needle bearing
❑ replace together with Pos. 6
❑ removing and installing ⇒ page 166
8 - Sliding sleeve with 5th and 6th gear synchronizer body
❑ removing and installing ⇒ page 166
❑ disassembling ⇒ page 189
❑ Assembly of the sliding sleeve/5th/6th °gear synchronizer body ⇒ page 189 and ⇒ page 190
❑ Fitting position ⇒ page 189
9 - 5th gear synchronizer ring
❑ is damaged by the drive shaft when removing
❑ always replace ⇒ Electronic Catalogue of Original Parts
❑ check for wear ⇒ page 187
10 - 5th gear sliding gear
❑ No. of teeth ⇒ page 2
11 - Needle bearing
❑ for 5th gear
❑ replace together with Pos. 12
12 - Bushing
❑ for 5th gear needle bearing
❑ replace together with Pos. 11
❑ press off with bearing support for grooved ball bearing Pos. 14
❑ pressing on ⇒ page 189
13 - Gearbox housing
❑ repairing ⇒ page 178
14 - Bearing support with grooved ball bearing
❑ Always replace grooved ball bearing together with the bearing support
❑ If the bearing support is released, it must always be replaced ⇒ Electronic Catalogue of Original Parts
❑ pressing off with 5th°gear pinion ⇒ page 186
❑ pressing on ⇒ page 189
15 - Drive shaft
❑ Clean the threaded hole in the drive shaft e.g with a thread tap from the locking agent residues
16 - Needle bearing
❑ for 3rd gear
17 - 3rd gear sliding gear
❑ No. of teeth ⇒ page 2
18 - 3rd gear synchronizer ring
❑ check for wear ⇒ page 187
19 - Sliding sleeve with 3rd and 4th gear synchronizer body
❑ press off with 3rd gear sliding gear ⇒ page 186
❑ disassembling ⇒ page 186
❑ Fitting position sliding sleeve/synchronizer body ⇒ page 187
❑ assembling ⇒ page 186
❑ pressing on ⇒ page 187
20 - Bushing
❑ for 4th gear needle bearing
❑ replace together with Pos. 21
Press off the bearing support with the grooved ball bearing and
the 5th gear° pinion -A-
– Sliding sleeve for 1st and 2nd gear to 2nd gear.
– Slide the pressure plate - T10084 A- sideways up to stop onto
the drive shaft.
Note
Disassembling and assembling the sliding sleeve and 3rd and 4th
gear synchronizer body
1 - Spring
2 - Sliding sleeve
3 - Synchronizer body
4 - Arresters for synchronizer body
– Slide the sliding sleeve over the synchronizer body.
The deeper recesses -arrow A- of the arresters in the synchron‐
izer body and the recesses -arrow B- in the sliding sleeve must
be positioned above one another.
Press on the synchronizer body with the 3rd and 4th gear sliding
sleeve
Fitting position: The wide collar points to the 3rd gear sliding gear.
Press on the bushing -A- for the 4th °gear needle bearing
– Subsequently place 4th gear needle bearing with 4th gear
sliding gear and thrust washer.
Note
Circlips available
Measured value Circlip thickness Axial play (mm)
(mm) (mm)
0.05…0.14 2.0 0.05…0.15
0.15…0.24 2.1 0.05…0.15
0.25…0.34 2.2 0.05…0.15
0.35…0.44 2.3 0.05…0.15
0.45…0.51 2.4 0.05…0.10
Press the bearing support for grooved ball bearings onto the input
and output shafts
Note
WARNING
Press on the bushing -A- for the 5th gear needle bearing
Caution
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
– Slightly moisten the outer circumference of the gasket ring with
gearbox oil.
Insert the gasket ring for the drive shaft until flush
– Mount clutch release lever with release bearing ⇒ page 78 .
– Installing the gearbox ⇒ page 128 .
2 Output shaft
⇒ “2.1 Summary of components - Output shaft”, page 192
⇒ “2.2 Disassembling and assembling the output shaft”,
page 194
Note
♦ When installing new pinions or a new shaft observe the technical data ⇒ page 2 .
♦ Insert all bearings, sliding gears and synchronizer rings onto the output shaft with gear oil.
♦ Do not interchange the synchronizer rings, if re-used always assign to the original sliding gear.
1 - Clutch housing
❑ repairing ⇒ page 178
2 - Cylindrical-roller bearing
❑ with circlip
❑ removing ⇒ page 194
❑ installing ⇒ page 195
❑ Fitting position: The cir‐
clip in the bearing points
towards the output shaft
3 - Output shaft
❑ if an inner ring is fitted as
a bearing assembly for
the cylindrical-roller
bearing Pos. 2, it cannot
be removed from the
output shaft
❑ Inspect bearing assem‐
bly or inner ring for cy‐
lindrical-roller bearing
for scoring and damage
❑ Replace output shaft
and cylindrical-roller
bearing together if there
is scoring and damage
on the bearing assem‐
bly or inner ring
4 - 4th gear pinion
❑ Fitting position: The col‐
lar points to the 3rd gear
⇒ page 195
❑ No. of teeth ⇒ page 2
5 - Circlip
6 - Circlip
7 - 3rd gear pinion
❑ Fitting position: The collar points to the 4th gear ⇒ page 195
❑ No. of teeth ⇒ page 2
8 - Circlip
9 - 2nd gear sliding gear
❑ No. of teeth ⇒ page 2
10 - Needle bearing
❑ for 2nd gear
11 - Inner ring for 2nd gear
❑ check for wear ⇒ page 196
❑ Fitting position ⇒ page 196
12 - Outer ring for 2nd gear
❑ place onto the inner ring Pos. 11
❑ replace if there are any traces of scoring or friction
❑ Fitting position ⇒ page 196
13 - 2nd gear synchronizer ring
❑ check for wear ⇒ page 196
❑ Fitting position ⇒ page 196
14 - Sliding sleeve with 1st and 2nd gear synchronizer body
❑ after removing the circlip -Pos. 15- press off with the 2nd gear sliding gear ⇒ page 195
❑ disassembling and assembling ⇒ page 197
❑ Assemble sliding sleeve/synchronizer body ⇒ page 197
❑ Fitting position ⇒ page 197
❑ installing ⇒ page 197
15 - Circlip
❑ pushing out ⇒ page 195
❑ inserting ⇒ page 198
16 - 1st gear synchronizer ring
❑ check for wear ⇒ page 196
❑ insert in such a way that the recesses lock into the arresters of the sliding sleeve Pos. 14
17 - Outer ring for 1st gear
❑ insert into synchronizer ring Pos. 16
❑ Fitting position ⇒ page 198
❑ replace if there are any traces of scoring or friction
18 - Inner ring for 1st gear
❑ check for wear ⇒ page 196
❑ Check pegs for traces of wear
❑ Fitting position ⇒ page 198
19 - Needle bearing
❑ for 1st gear
20 - 1st gear sliding gear
❑ Fitting position ⇒ page 198
❑ No. of teeth ⇒ page 2
21 - Bearing support with grooved ball bearing
❑ Always replace grooved ball bearing together with the bearing support
❑ If the bearing support is released, it must always be replaced ⇒ Electronic Catalogue of Original Parts
❑ removing and installing ⇒ page 185
22 - Gearbox housing
❑ repairing ⇒ page 178
23 - Screw
❑ removing and installing ⇒ page 156
24 - Inner ring/cylindrical-roller bearing
❑ identify before removing
❑ do not interchange with inner ring/cylindrical-roller bearing of input shaft
❑ can be replaced separately
❑ removing and installing ⇒ page 166
25 - 6th gear pinion
❑ Fitting position: The collar points to the bushing Pos. 26
❑ removing and installing ⇒ page 166
❑ No. of teeth ⇒ page 1
26 - Bushing
❑ removing and installing ⇒ page 166
27 - 5th gear pinion
❑ Fitting position ⇒ page 166
❑ press off together with bearing support Pos. 21 ⇒ page 185
❑ pressing on ⇒ page 166
❑ No. of teeth ⇒ page 1
28 - Spring
❑ Fitting position ⇒ page 197
29 - Sliding sleeve
30 - Synchronizer body
31 - Arresters (3 pieces)
WARNING
Press off sliding sleeve with 1st and 2nd gear synchronizer body
– After removing the circlip jointly press off the 2nd gear sliding
gear and the sliding sleeve/synchronizer body.
Fitting position of the outer ring, inner ring and 2nd gear syn‐
chronizer ring
– Position the inner ring -A- on the 2nd gear sliding gear.
The angled lands -arrow 1- point towards the outer ring -B-.
– Position the outer ring -B-.
Lock the lands -arrows 2- in the recesses -arrows 3- of the
sliding gear.
– Insert the synchronizer ring -C-.
Lock the recesses -arrows 4- in the lands -arrows 1- of the
inner ring -A-.
Disassembling and assembling the sliding sleeve and 1st and 2nd
gear synchronizer body
1 - Spring
2 - Sliding sleeve
3 - Synchronizer body
4 - Arresters for synchronizer body
– Slide the sliding sleeve over the synchronizer body.
Fitting position:
After assembly the groove on the front side -arrow A- and the
higher collar -arrow B- of the synchronizer body point towards the
outer serration of the sliding sleeve -arrow C-. The deeper re‐
cesses -arrow D- of the arresters in the synchronizer body and
the recesses -arrow E- in the sliding sleeve must be positioned
above one another.
Press on the sliding sleeve and 1st and 2nd gear synchronizer
body
Fitting position:
The slot for the shift fork in the sliding sleeve points towards the
1st gear, the serration of the reversing gear points towards the
2nd gear.
– Rotate the synchronizer ring in such a way that the slots are
flush with the arresters.
– Drive the new seal ring in up to the stop, do not twist the seal
ring.
– Fill half the space between the sealing lip and dust lip with
sealing grease - G 052 128 A1- .
– Insert the flange shaft.
– Secure the flange shaft with the conical screw.
– Bolt drive shaft to flange shaft ⇒ Chassis; Rep. gr. 40 .
– Install the wheelhouse liner into the left wheelhouse ⇒ Body
Work; Rep. gr. 66 .
– Install wheel ⇒ Chassis; Rep. gr. 44 .
– Check gear oil level, if necessary fill up to lower edge of filler
hole ⇒ page 153 .
– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
Tightening torques
Component Nm
Flange shaft on gearbox (conical screw) ⇒ page 202
– Remove protection plate for drive shaft from the engine (if
present) -arrows-.
– Unscrew the drive shaft from the flange shaft.
– Tie up the drive shaft as far as possible. Avoid damaging the
paintwork on the drive shaft during this operation.
– Position the catch pan under the gearbox.
– Unscrew the fixing screw for the flange shaft, to this end insert
two screws in the flange and using a tyre iron hold the shaft.
– Remove the flange shaft with pressure spring.
– Pull out seal ring for flange shaft with -VW 771 (MP9-501)- and
-VW 771/37 (MP3-419/37)- .
Install
– Drive the new seal ring in up to the stop, do not twist the seal
ring.
– Fill half the space between the sealing lip and dust lip with
sealing grease - G 052 128 A1- .
– Insert the flange shaft.
– Secure the flange shaft with the conical screw.
– Screw the right drive shaft onto the flange shaft ⇒ Chassis;
Rep. gr. 40 .
– Check gear oil level, if necessary fill up to lower edge of filler
hole ⇒ page 153 .
– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
Tightening torques
Component Nm
Flange shaft on gearbox (conical screw) ⇒ page 202
Protective cap for drive shaft on engine ⇒ Chassis; Rep. gr. 40
2 Differential gear
⇒ “2.1 Summary of components - Differential”, page 202 .
⇒ “2.2 Disassembling and assembling differential gear”,
page 205 .
⇒ “2.3 Adjusting the differential gear”, page 208 .
2.1.1 Differential gear - Summary of components (Octavia II, Superb II and Yeti) .
1 - Conical screw
❑ screw into threaded
piece Pos. 8
❑ 25 Nm
2 - Right flange shaft
3 - Pressure spring for flange
shaft
❑ fitted behind flange
shaft
4 - Thrust washer
❑ Fitting position: Collar
for compression spring
5 - Conical ring
❑ Fitting position: Cone for
differential gear housing
6 - Circlip
❑ holds the conical ring,
stop disc and pressure
spring in position when
the flange shaft is re‐
moved
7 - Large differential bevel gear
❑ installing ⇒ page 208
8 - Threaded part
❑ installing ⇒ page 208
9 - Differential bevel gear shaft
❑ upon removal, the ten‐
sioning sleeve is cut out
pos. 17 ⇒ page 207
❑ installing ⇒ page 208
10 - Small differential bevel
gear
❑ installing ⇒ page 208
11 - Stop disc compound
❑ insert with gear oil
1 - Conical screw
❑ 25 Nm
2 - Right flange shaft
3 - Pressure spring for flange
shaft
❑ fitted behind flange
shaft
4 - Thrust washer
❑ Fitting position: Collar
for compression spring
5 - Conical ring
❑ Fitting position: Cone for
differential gear housing
6 - Circlip
❑ holds the conical ring,
stop disc and pressure
spring in position when
the flange shaft is re‐
moved
7 - Flange shaft left
8 - Sealing ring
❑ for left flange shaft
❑ replace with installed
gearbox ⇒ page 199
9 - Outer ring/tapered-roller
bearing
❑ removing ⇒ page 205
❑ pressing on
⇒ page 206
10 - Inner ring/tapered-roller
bearing
❑ remove ⇒ page 206
❑ pressing on ⇒ page 206
11 - Differential gear
❑ with gear pinion for final drive
12 - Inner ring/tapered-roller bearing
❑ remove ⇒ page 206
❑ pressing on ⇒ page 206
13 - Outer ring/tapered-roller bearing
❑ removing ⇒ page 206
❑ pressing on ⇒ page 207
14 - Adjusting washer
❑ for the differential gear
❑ Determine thickness ⇒ page 208
15 - Sealing ring
❑ for right flange shaft
❑ replace with installed gearbox ⇒ page 200
16 - Clutch housing
❑ repairing ⇒ page 178
17 - Gearbox housing
❑ repairing ⇒ page 178
Note
Note
Note
Note
Note
The inner and outer rings of the tapered-roller bearing are paired.
Do not interchange!
Note
– Remove the clutch housing and press out the outer ring/ta‐
pered-roller bearing -A-.
-B- Interior extractor 46 ... 58 mm , e.g. -Kukko 21/7-
– Position pipe - 2040 (T30041)- directly on the feet of the inte‐
rior extractor -B- and press out the outer ring/tapered-roller
bearing -A-.
Note