Skoda Fabia II 2007 Instruction manual

Workshop Manual
Fabia II 2007 ➤ , Fabia II 2009 ➤ ,
Fabia II 2011 ➤ , Rapid 2011 ➤ ,
Rapid NH 2013 ➤ , Rapid NH 2014 ➤ ,
Roomster 2006 ➤
Gearbox 02T
Edition 05.2014
Service
Service Department. Technical Information

List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Service

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification characters, aggregate assignment, ratios, filling capacities (Fabia II) . . . . . . 1
1.2 Identification characters, aggregate assignment, ratios, filling capacities (Roomster) . . . . 6
1.3 Identification characters, aggregate assignment, ratios, filling capacities (Rapid) . . . . . . . . 10
1.4 Identification characters, aggregate assignment, ratios, filling capacities (Rapid NH) . . . . 11
2 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Designation of components and transmission ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1 Clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Summary of components - foot controls (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . 19
1.2 Removing and installing, setting angular clutch pedal switch F36 , (Fabia II 2007 ►; Roomster
2006 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.3 Removing and installing, setting cylindrical clutch pedal switch F36 , (Fabia II 2007 ►;
Roomster 2006 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Removing and installing the crash strut for the clutch pedal (Fabia II 2007 ►; Roomster 2006
►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5 Removing and installing the over-centre helper spring (Fabia II 2007 ►; Roomster 2006 ►)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.6 Removing and installing the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . 27
1.7 Summary of components - foot controls (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013
►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.8 Summary of components - Foot controls (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.9 Removing and installing the bracket with the master cylinder (Fabia II 2011 ►; Roomster 2011
►; Rapid NH 2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.10 Removing and installing the bracket with the master cylinder (Rapid 2011 ►) . . . . . . . . . . 41
1.11 Removing and installing the bracket without the master cylinder (Fabia II 2011 ►; Roomster
2011 ►; Rapid NH 2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.12 Removing and installing the bracket without the master cylinder (Rapid 2011 ►) . . . . . . . . 44
1.13 Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ►;
Roomster 2011 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.14 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) . . . . 48
1.15 Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster
2011 ►; Rapid NH 2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.16 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) . . . . . . . . . . . . 51
1.17 Summary of components - Hydraulic (Rapid 2011 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.18 Check hydraulic clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.19 Removing and installing the master cylinder (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . 58
1.20 Removing and installing the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH
2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.21 Removing and installing the slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.22 Bleeding the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2 Repairing the clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1 Fault finding power transmission - problems with the clutch and clutch control . . . . . . . . . . 70
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.2 Summary of components - Gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.3 Summary of components - Gearshift knob with shift lever collar . . . . . . . . . . . . . . . . . . . . 79
1.4 Removing and installing gearshift knob and shift lever collar (Fabia II, Roomster) . . . . . . 79
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
Contents i

1.5 Remove and install gearshift knob and shift lever collar (Rapid) . . . . . . . . . . . . . . . . . . . . 80
1.6 Remove and install gearshift knob and shift lever collar (Rapid NH) . . . . . . . . . . . . . . . . . . 81
1.7 Summary of components - Shift lever and shift housing . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.8 Summary of components - Control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH) . . . . . . . . . . . . . . . . . . . . . . 87
1.10 Remove and install shift mechanism (Fabia II, Roomster, Rapid NH) . . . . . . . . . . . . . . . . 89
1.11 Removing and installing shift mechanism (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.12 Setting the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.1 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.2 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3 Inspect the gear oil level in the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.1 Gearbox - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.3 Removing and installing gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . . . 115
4.4 Detaching and attaching clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.5 Removing and installing the drive shaft, output shaft, differential gear, shift mechanism and
gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.6 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6 Repairing shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7 Disassembling and assembling the gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.1 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.1 Disassembling and assembling the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1 Replacing the flange shaft gasket rings (gearbox assembled) . . . . . . . . . . . . . . . . . . . . . . 151
1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2 Differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.1 Disassembling and assembling differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.2 Adjusting the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
ii Contents

00 – Technical data
1 Identification of the gearbox
(SRL000700; Edition 05.2014)
Assignment Fabia II ⇒ page 1 .
Assignment Roomster ⇒ page 6 .
Assignment Rapid ⇒ page 10 .
Assignment Rapid NH ⇒ page 11 .
Location on the gearbox
Identification characters and production date -arrow 1-.
Identification of materials for the gearbox housing -arrow 2-.
Identification characters and production date of the gearbox
Example: JHN 17 11 6
I I I I
Identifica‐
tion charac‐
ters
Day Month Manufac‐
turing year
(2006)
Additional data depend on the manufacturing.
Note
The gearbox identification characters also appear on the vehicle
data stickers.
Identification of materials for the gearbox housing
There is lettering on aluminium gearboxes -arrow- -GD TL 023-,
or -AlSi9Cu3- or -AlSi6Cu4-.
One can also use the gearbox identification characters to deter‐
mine whether it is an aluminium or a magnesium gearbox.
1.1 Identification characters, aggregate assignment, ratios, filling capacities
(Fabia II)
Manual gearbox 5 speed 02T
Identification characters JHN LVC JUS LVG
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
1. Identification of the gearbox 1

Manual gearbox 5 speed 02T
Manufac‐
tured from 12.06 06.09 01.07 06.09
to 05.09 03.10 05.09 03.10
Assign‐
ment: Engine 1.2 ltr./44 kW 1.2 ltr./51 kW
Ratio: Final drive 67 : 16 = 4.188
Z2:Z11. gear 49 : 13 = 3.769
2. gear 44 : 21 = 2.095
3. gear 43 : 31 = 1.387
4. gear 40 : 39 = 1.026
5. gear 39 : 48 = 0.813 40 : 47 = 0.851
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 litre
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 90 mm 100 mm 90 mm 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Manual gearbox 5 speed 02T
Identification characters LVC LNR
Manufac‐
tured from 09.10 03.10
to
Assign‐
ment: Engine 1.2 ltr./55 kW 1.2 ltr./44 kW 1.2 ltr./51 kW
Ratio: Final drive 67 : 16 = 4.188
Z2:Z11. gear 49 : 13 = 3.769
2. gear 44 : 21 = 2.095
3. gear 43 : 31 = 1.387 41 : 32 = 1.281
4. gear 40 : 39 = 1.026 38 : 41 = 0.927
5. gear 39 : 48 = 0.813 37 : 50 = 0.74
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 litre
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
2 Rep. gr.00 - Technical data

Manual gearbox 5 speed 02T
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm 90 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Manual gearbox 5 speed 02T
Identification characters MFX LMG
Manufac‐
tured from 03.10 03.10
to
Assign‐
ment: Engine 1.2 ltr./63 kW TFSI 1.2 ltr./77 kW TFSI
Ratio: Final drive 58 : 16 = 3.625
Z2:Z11. gear 49 : 13 = 3.769
2. gear 43 : 22 = 1.955
3. gear 41 : 32 = 1.281
4. gear 38 : 41 = 0.927
5. gear 37 : 50 = 0.74
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 litre
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Manual gearbox 5 speed 02T
Identification characters JHQ LVE JHL LVA
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
1. Identification of the gearbox 3

Manual gearbox 5 speed 02T
Manufac‐
tured from 02.07 06.09 04.07 06.09
to 05.09 05.09 05.10
Assign‐
ment: Engine 1.4 ltr./63 kW 1.6 ltr./77 kW
Ratio: Final drive 66 : 17 = 3.882 59 : 15 = 3.933
Z2:Z11. gear 49 : 13 = 3.769
2. gear 44 : 21 = 2.095
3. gear 43 : 31 = 1.387
4. gear 40 : 39 = 1.026
5. gear 39 : 48 = 0.813
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 litre
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 90 mm 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Manual gearbox 5 speed 02T
Identification characters MAB LNJ
Manufac‐
tured from 06.10 09.10
to 01.12 01.11
Assign‐
ment: Engine 1.6 ltr./77 kW
Ratio: Final drive 68 : 15 = 4.533 59 : 15 = 3.933
Z2:Z11. gear 38 : 11 = 3.455 49 : 13 = 3.769
2. gear 43 : 22 = 1.955 44 : 21 = 2.095
3. gear 41 : 32 = 1.281
4. gear 37 : 42 = 0.881
5. gear 35 : 52 = 0.673
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 litre
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
4 Rep. gr.00 - Technical data

Manual gearbox 5 speed 02T
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Manual gearbox 5 speed 02T
Identification characters NVS
Manufac‐
tured from 02.12
to
Assign‐
ment: Engine 1.6 ltr./77 kW
Ratio: Final drive 64 : 14 = 4.571
Z2:Z11. gear 38 : 11 = 3.455
2. gear 43 : 22 = 1.955
3. gear 41 : 32 = 1.281
4. gear 37 : 42 = 1.881
5. gear 35 : 52 = 0.673
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 litre
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Manual gearbox 5 speed 02T
Identification characters JQM LVF
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
1. Identification of the gearbox 5

Manual gearbox 5 speed 02T
Manufac‐
tured from 02.07 06.09
to 05.09 09.10
Assign‐
ment: Engine 1.4 ltr./51 kW TDI-PD
Ratio: Final drive 64 : 19 = 3.368
Z2:Z11. gear 49 : 13 = 3.769
2. gear 44 : 21 = 2.095
3. gear 43 : 31 = 1.387
4. gear 40 : 39 = 1.026
5. gear 38 : 49 = 0.776
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 litre
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 90 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
1.2 Identification characters, aggregate assignment, ratios, filling capacities
(Roomster)
Manual gearbox 5 speed 02T
Identification characters HZK JHM JHM LVB
Manufac‐
tured from 05.06 11.06 01.07 06.09
to 11.06 12.06 05.09 03.10
Assign‐
ment: Engine 1.2 ltr./47 kW 1.2 ltr./51 kW
Ratio: Final drive 69 : 14 = 4.929
Z2:Z11st gear 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095
3rd gear 43 : 31 = 1.387
4th gear 40 : 39 = 1.026
5th gear 38 : 49 = 0.776
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
6 Rep. gr.00 - Technical data

Manual gearbox 5 speed 02T
Filling capacity 2.0 l
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 90 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Manual gearbox 5 speed 02T
Identification characters MKG MFX LMG
Manufac‐
tured from 04.10 04.10
to
Assign‐
ment: Engine 1.2 ltr./51 kW 1.2 ltr./63 kW TFSI 1.2 ltr./77 kW TFSI
Ratio: Final drive 69 : 14 = 4.929 58 : 16 = 3.625
Z2:Z11st gear 49 : 13 = 3.769 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095 43 : 22 = 1.955
3rd gear 41 : 32 = 1.281 41 : 32 = 1.281
4th gear 37 : 42 = 0.881 38 : 41 = 0.927
5th gear 35 : 52 = 0.673 37 : 50 = 0.74
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 ltr.
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 90 mm 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
1. Identification of the gearbox 7

Manual gearbox 5 speed 02T
Identification characters HZM JHN LVC
Manufac‐
tured from 05.06 11.06 06.09
to 11.06 05.09
Assign‐
ment: Engine 1.4 ltr./63 kW
Ratio: Final drive 67 : 16 = 4.188
Z2:Z11st gear 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095
3rd gear 43 : 31 = 1.387
4th gear 40 : 39 = 1.026
5th gear 39 : 48 = 0.813
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 ltr.
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 90 mm 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Manual gearbox 5 speed 02T
Identification characters HXL JHL LVA MAB
Manufac‐
tured from 05.06 11.06 06.09 06.10
to 11.06 05.09 05.10 01.12
Assign‐
ment: Engine 1.6 ltr./77 kW
Ratio: Final drive 59 : 15 = 3.933 68 : 15 = 4.533
Z2:Z11st gear 49 : 13 = 3.769 38 : 11 = 3.455
2nd gear 44 : 21 = 2.095 43 : 22 = 1.955
3rd gear 43 : 31 = 1.387 41 : 32 = 1.281
4th gear 40 : 39 = 1.026 37 : 42 = 0.881
5th gear 39 : 48 = 0.813 35 : 52 = 0.673
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 l
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
8 Rep. gr.00 - Technical data

Manual gearbox 5 speed 02T
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Manual gearbox 5 speed 02T
Identification characters NVS
Manufac‐
tured from 02.12
to
Assign‐
ment: Engine 1.6 ltr./77 kW
Ratio: Final drive 68 : 15 = 4.533
Z2:Z11st gear 38 : 11 = 3.455
2nd gear 43 : 22 = 1.955
3rd gear 41 : 32 = 1.281
4th gear 37 : 42 = 0.881
5th gear 35 : 52 = 0.673
Reverse gear 35 : 24 x 24 : 11 =
3.182
Speedometer electronic
Filling capacity 2.0 ltr.
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
1. Identification of the gearbox 9

Manual gearbox 5 speed 02T
Identification characters HZL JHP LVD
Manufac‐
tured from 08.06 11.06 06.09
to 11.06 05.09 03.10
Assign‐
ment: Engine 1.4 ltr./51 kW TDI-PD
Ratio: Final drive 65 : 18 = 3.611
Z2:Z11st gear 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095
3rd gear 43 : 31 = 1.387
4th gear 40 : 39 = 1.026
5th gear 38 : 49 = 0.776
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 ltr.
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 90 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
1.3 Identification characters, aggregate assignment, ratios, filling capacities
(Rapid)
Manual gearbox 5 speed 02T
Identification characters MAB NVS
Manufac‐
tured from 09.11 04.12
to 03.12
Assign‐
ment: Engine 1.6 ltr./77 kW
Ratio: Final drive 68 : 15 = 4.533 64 : 14 = 4.571
Z2:Z11. gear 38 : 11 = 3.455
2. gear 43 : 22 = 1.955
3. gear 41 : 32 = 1.281
4. gear 37 : 42 = 0.881
5. gear 35 : 52 = 0.673
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
10 Rep. gr.00 - Technical data

Manual gearbox 5 speed 02T
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 litre
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
1.4 Identification characters, aggregate assignment, ratios, filling capacities
(Rapid NH)
Manual gearbox 5 speed 02T
Identification characters MKG MFX LGQ
Manufac‐
tured from 07.12 07.12 07.12
to
Assign‐
ment: Engine 1.2 ltr./55 kW MPI 1.2 ltr./63 kW TSI
Ratio: Final drive 69 : 14 = 4.928 58 : 16 = 3.625
Z2:Z11st gear 49 : 13 = 3.769 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095 43 : 22 = 1.954
3rd gear 41 : 32 = 1.281 41 : 32 = 1.281
4th gear 37 : 42 = 0.881 38 : 41 = 0.927
5th gear 35 : 52 = 0.673 37 : 50 = 0.74
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 ltr.
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 90 mm 100 mm
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
1. Identification of the gearbox 11

Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Manual gearbox 5 speed 02T
Identification characters MAB NVS
Manufac‐
tured from 07.12 07.12
to
Assign‐
ment: Engine 1.6 ltr./77 kW MPI
Ratio: Final drive 68 : 15 = 4.533 64 : 14 = 4.571
Z2:Z11. gear 38 : 11 = 3.455
2. gear 43 : 22 = 1.955
3. gear 41 : 32 = 1.281
4. gear 37 : 42 = 0.881
5. gear 35 : 52 = 0.673
Reverse gear 35 : 24 x 24 : 11 = 3.182
Speedometer electronic
Filling capacity 2.0 litre
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -
G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
12 Rep. gr.00 - Technical data

2 Overview of Transmission System
2.1 Designation of components and transmission ratio
Note
The arrow shows the direction of travel.
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
R - Reverse gear
A - Final drive
T - Speedometer drive
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
2. Overview of Transmission System 13

3 General repair instructions
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
A number of generally valid notes for individual repair operations
- which are otherwise listed several times at numerous points in
the workshop manual - are summarized here. They apply for this
particular workshop manual.
Gearbox
Gearboxes are constructed of aluminium and of magnesium
⇒ page 1 .
♦ Gearbox housing and clutch housing are made of the same
materials.
♦ Bolts and other attachments that come into direct contact with
the gearbox can have varying finishes depending on whether
the gearbox is made of aluminium or magnesium.
♦ On gearboxes which are made of magnesium, the screws
must always be replaced for the following screw connections:
Cover for gearbox housing at gearbox housing and clutch
housing at gearbox housing.
♦ The use of substitute components causes contact corrosion.
This will result in damage to the gearbox.
♦ Bolts and other attachments should have a classification in the
⇒ Electronic Catalogue of Original Parts .
♦ When installing, ensure the dowel sleeves are correctly loca‐
ted between the engine and gearbox.
♦ When replacing the gearbox, pour in gear oil up to lower edge
of filler hole.
♦ Filling capacity and specification (Fabia II) ⇒ page 1 .
♦ Filling capacity and specification (Roomster) ⇒ page 6 .
♦ Filling capacity and specification (Rapid) ⇒ page 10 .
♦ Filling capacity and specification (Rapid NH) ⇒ page 11 .
Gaskets and seals
♦ Clean contact surfaces thoroughly and apply sealant -
AMV 188 200 03- .
♦ Apply sealant evenly - not too thickly.
♦ Replace O-rings.
♦ Replace radial shaft seals.
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
14 Rep. gr.00 - Technical data

Before installing
Lightly lubricate the outside diameter of the gasket ring. Fill half
the space between the sealing lips -arrow- with grease - G 052
128 A1- .
After installing
Check gear oil level, if necessary pour in oil up to lower edge of
filler hole ⇒ page 112 , specification:
♦ Fabia II ⇒ page 1 .
♦ Roomster ⇒ page 6 .
♦ Rapid ⇒ page 10 .
♦ Rapid NH ⇒ page 11 .
Locking elements
♦ Replace circlips.
♦ Do not over-tension the circlips.
♦ Circlips must be positioned in the base of the groove.
♦ Replace roll pins. Fitting position: Slot longitudinal to power
flow -arrow-.
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
3. General repair instructions 15

Nuts and bolts
♦ Slacken and tighten fixing screws and nuts of covers and
housings diagonally across in stages.
♦ Do not twist particularly sensitive parts - e.g. clutch pressure
plates - slacken and tighten diagonally across in stages.
♦ Specified torques given are for unlubricated nuts, bolts and
screws.
♦ Always replace the self-locking screws and nuts ⇒ Electronic
Catalogue of Original Parts .
♦ It is important to ensure at all bolted connections that the con‐
tact surfaces as well as the nuts and bolts are waxed only after
being installed, should this be necessary.
♦ Clean all threaded holes into which self-locking bolts were
screwed in, using a suitable thread tap to remove old locking
agent residues. Otherwise there is the risk that the self-locking
screw will shear when removing.
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.
♦ Before installing, heat the inner rings of the bearing on a heat‐
ing plate or with the hot-air blower , e.g. -V.A.G 1416- , to
approx. 100°C, when installing press in axial and play-free up
to the stop.
♦ The temperature can be checked with a temperature measur‐
ing instrument.
♦ Do not exchange the outer and inner rings of bearings of the
same size. The bearings are matched in pairs.
♦ Position needle bearing with the lettered side (thicker end) to‐
wards the drift pin.
Shims
♦ Gauge shims at several points with a micrometer. Different
tolerances allow to measure the required thickness for each
washer very precisely ⇒ electronic catalogue of original parts .
♦ Inspect washers for burrs and damage.
♦ Install only adjusting washers which are in perfect condition.
Synchronizer rings
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02T - Edition 05.2014
16 Rep. gr.00 - Technical data