Skoda Octavia II 2004 Instruction manual

Workshop Manual
Octavia II 2004 ➤
Octavia II 2010 ➤
Octavia III 2013 ➤
Octavia III 2014 ➤
Gearbox 0AF
Edition 09.2013
Service
Service Department. Technical Information
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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
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.
Service
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification characters, aggregate assignment, ratios, filling capacities (Octavia II) . . . . 2
1.2 Identification characters, aggregate assignment, ratios, filling capacities (Octavia III) . . . . 4
2 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Designation of components and transmission ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Safety measures for working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . 6
4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Summary of components: Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 General repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Summary (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Overview of the fitting positions: Clutch control (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Summary of components - Foot controls (Octavia ll) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Summary of components: Foot controls (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Removing and installing bearing bush (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6 Removing and installing retractor spring (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Removing and installing retractor spring (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.8 Removing and installing over-centre helper spring (Octavia III) . . . . . . . . . . . . . . . . . . . . . . 22
1.9 Removing and installing clutch pedal (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.10 Removing and installing clutch pedal (Octavia IlI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.11 Removing and installing bearing bracket (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.12 Removing and installing bearing bracket for clutch pedal (Octavia III) . . . . . . . . . . . . . . . . 30
1.13 Removing and installing master cylinder (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.14 Removing and installing master cylinder (Octavia IIl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.15 Removing and installing clutch position sender G476 (Octavia II) . . . . . . . . . . . . . . . . . . . . 36
1.16 Removing and installing clutch position sender G476 (Octavia IIl) . . . . . . . . . . . . . . . . . . 38
1.17 Summary of components - Hydraulic system (Octavia ll) . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.18 Summary of components: Clutch hydraulics (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.19 Checking the hydraulic clutch control (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.20 Checking the master and slave cylinder (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.21 Removing and installing slave cylinder (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.22 Removing and installing master cylinder (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.23 Removing and installing cables for clutch control (Octavia III) . . . . . . . . . . . . . . . . . . . . . . 47
1.24 Bleeding the clutch control (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.25 Bleeding the clutch control (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.1 Repairing the clutch control (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.2 Summary of components: Clutch control (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3 Repairing the clutch control (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1 Repairing the clutch (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2 Summary of components: Clutch (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.3 Removing and installing clutch (Octavia IlI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.4 Fault finding power transmission - problems with the clutch and clutch control (Octavia II)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Gearbox 0AF - Edition 09.2013
Contents i
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1.1 Fitting location of shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 Summary of components shift mechanism (Octavia ll) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.3 Summary of components - gearshift knob with shift lever collar (Octavia II) . . . . . . . . . . . . 71
1.4 Summary of components: Gear shift knob and shift lever collar (Octavia III) . . . . . . . . . . 72
1.5 Removing and installing gearshift knob and shift lever collar (Octavia II) . . . . . . . . . . . . . . 73
1.6 Removing and installing gear shift knob (Octavia IlI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.7 Summary of components - Shift mechanism up to 10.2006 (Octavia II) . . . . . . . . . . . . . . 74
1.8 Summary of components - Shift mechanism as of 11.2006 (Octavia II) . . . . . . . . . . . . . . 77
1.9 Disassembling and assembling shift mechanism as of 11.2006 (Octavia II) . . . . . . . . . . . . 78
1.10 Summary of components - Control cables up to 10.2006 (Octavia II) . . . . . . . . . . . . . . . . 82
1.11 Summary of components - Control cables as of 11.2006 (Octavia II) . . . . . . . . . . . . . . . . 85
1.12 Plastic relay lever (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.13 Summary of components: Gearshift mechanism (Octavia III) . . . . . . . . . . . . . . . . . . . . . . 89
1.14 Removing and installing shift mechanism (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.15 Removing and installing shift mechanism and selector cable (Octavia II) . . . . . . . . . . . . . . 97
1.16 Remove and install shift mechanism (Octavia IlI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.17 Setting shift mechanism (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.18 Setting shift mechanism (Octavia IlI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.1 Removing gearbox (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.2 Removing gearbox (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.3 Transporting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.4 Install gearbox (Octavia II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.5 Installing gearbox (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3 Check gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.1 Gearbox - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.3 Removing and installing gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . . . 130
4.4 Detaching and attaching clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.5 Removing and installing the drive shaft, output shaft, differential gear, shift mechanism and
gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.6 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6 Repairing shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.1 Replacing the gasket ring for the gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7 Disassembling and assembling the gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.1 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.2 Replace gasket ring for drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.1 Disassembling and assembling the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1 Gasket rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Overview of the fitting positions: Gasket rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.2 Replacing the left flange shaft gasket ring (on an installed gearbox) . . . . . . . . . . . . . . . . . . 168
1.3 Replacing the right flange shaft gasket ring (on an installed gearbox) . . . . . . . . . . . . . . . . 170
2 Differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.1 Disassembling and assembling differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.2 Adjusting the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Gearbox 0AF - Edition 09.2013
ii Contents
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00 – Technical data
1 Identification of the gearbox
(SRL000618; Edition 09.2013)
Edition 09.2013; version 2.0
Assignment (Octavia II) ⇒ page 2 .
Assignment (Octavia III) ⇒ page 4 .
Location on the gearbox
Identification characters and production date -arrow 1-.
Identification of gearbox 0AF -arrow 2-.
Gearbox 0AF -arrow-
Identification characters and production date of the gearbox
Example: FVH 18 07 2
I I I I
Identifica‐
tion charac‐
ters
Day Month Manufac‐
turing year
(2002)
Additional data gives information about the manufacturing facto‐
ry.
Note
The gearbox identification characters also appear on the vehicle
data stickers.
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Gearbox 0AF - Edition 09.2013
1. Identification of the gearbox 1
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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
(Octavia II)
Manual gearbox 5 speed 0AF
Identification characters FVH GYT FXQ
Manufactured from
through 02.2004 10.2006 05.2004 10.2006 05.2004 10.2006
Assignment: Engine 1.6 ltr./75 kW 1.6 ltr./85 kW FSI 1.4 ltr./55 kW
1.4 ltr./59 kW
Ratio: Final drive 68 : 15 = 4,533
Z 2 : Z 11st gear 38 : 11 = 3,455 49 : 13 = 3,769
2nd gear 43 : 22 = 1,955 44 : 21 = 2,095
3rd gear 41 : 32 = 1,281 43 : 31 = 1,387
4th gear 39 : 40 = 0,975 40 : 39 = 1,026
5th gear 39 : 48 = 0,813 38 : 49 = 0,776 39 : 48 = 0,813
Reverse gear 35 : 24 x 24 :11 = 3.182
Filling capacity 2.0 ltr.
Specification ⇒ Electronic Catalogue of Original Parts
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm 90 mm
Manual gearbox 5 speed 0AF
Identification characters JHT JHW JHU
Manufactured from
through 11.2006 05.2009 11.2006 11.2008 11.2006 05.2009
Assignment: Engine 1.6 ltr./75 kW 1.6 ltr./85 kW FSI 1.4 ltr./59 kW
Ratio: Final drive 68 : 15 = 4,533
Z 2 : Z 11st gear 38 : 11 = 3,455 49 : 13 = 3,769
2nd gear 43 : 22 = 1,955 44 : 21 = 2,095
3rd gear 41 : 32 = 1,281 43 : 31 = 1,387
4th gear 39 : 40 = 0,975 40 : 39 = 1,026
5th gear 39 : 48 = 0,813 38 : 49 = 0,776 39 : 48 = 0,813
Reverse gear 35 : 24 x 24 :11 = 3.182
Filling capacity 2.0 ltr.
Specification ⇒ Electronic Catalogue of Original Parts
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Gearbox 0AF - Edition 09.2013
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Manual gearbox 5 speed 0AF
Drive shaft flange ∅ 100 mm 90 mm
Manual gearbox 5 speed 0AF
Identification characters LVN LVP LEG
Manufactured from
through 06.2009 12.2011 06.2009 11.2010 11.2010 04.2013
Assignment: Engine 1.6 ltr./75 kW 1.4 ltr./59 kW
Ratio: Final drive 68 : 15 = 4,533 61 : 14 = 4,357
Z 2 : Z 11st gear 38 : 11 = 3,455 49 : 13 = 3,769
2nd gear 43 : 22 = 1,955 44 : 21 = 2,095
3rd gear 41 : 32 = 1,281 43 : 31 = 1,387 41 : 32 = 1,281
4th gear 39 : 40 = 0,975 40 : 39 = 1,026 38 : 41 = 0,927
5th gear 39 : 48 = 0,813 39 : 48 = 0,813 37 : 50 = 0,74
Reverse gear 35 : 24 x 24 :11 = 3.182
Filling capacity 2.0 ltr.
Specification ⇒ Electronic Catalogue of Original Parts
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
On gearboxes as of production date 06.2009, the springs of the
sliding sleeve with synchro hub are changed in 3rd, 4th and 5th
gears (the springs are longer); from this date, the synchronizer
ring for 3rd and 4th gear is changed at the same time ⇒ Electronic
Catalogue of Original Parts .
Manual gearbox 5 speed 0AF
Identification characters NVT
Manufactured from
through 03.2012 04.2013
Assignment: Engine 1.6 ltr./75 kW
Ratio: Final drive 64 : 14 = 4,571
Z 2 : Z 11st gear 38 : 11 = 3,455
2nd gear 43 : 22 = 1,955
3rd gear 41 : 32 = 1,281
4th gear 39 : 40 = 0,975
5th gear 39 : 48 = 0,813
Reverse gear 35 : 24 x 24 :11 = 3.182
Filling capacity 2.0 ltr.
Specification ⇒ Electronic Catalogue of Original Parts
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
On gearboxes as of production date 06.2009, the springs of the
sliding sleeve with synchro hub are changed in 3rd, 4th and 5th
gears (the springs are longer); from this date, the synchronizer
ring for 3rd and 4th gear is changed at the same time ⇒ Electronic
Catalogue of Original Parts .
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Gearbox 0AF - Edition 09.2013
1. Identification of the gearbox 3
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1.2 Identification characters, aggregate assignment, ratios, filling capacities
(Octavia III)
Manual gearbox 5th gear 0AF
Identification characters MYE PKG PTA
Manufactured from
through 11.2012 11.2012 11.2012 11.2013 11.2013
Assignment: Engine 1.2 ltr./63 kW TSI
Ratio: Final drive 59 : 15 = 3,933 73 : 18 = 4,055 59 : 15 = 3,933
Z 2 : Z 11st gear 49 : 13 = 3,769
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
Filling capacity 2.1 l
Specification ⇒ Electronic Catalogue of Original Parts
Clutch control hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Gearbox 0AF - Edition 09.2013
4 Rep. gr.00 - Technical data
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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 - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
T - Speedometer drive
❑ with speed sensor, only
on older gearboxes
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Gearbox 0AF - Edition 09.2013
2. Overview of Transmission System 5
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3 Safety instructions
Safety precautions when working on vehicles with start-stop sys‐
tem ⇒ page 6 .
3.1 Safety measures for working on vehi‐
cles with start/stop system
WARNING
On vehicles with start-stop system, there is the risk of injury
from automatic engine start.
♦ Deactivate the start-stop system when working on the ve‐
hicle. Switch off ignition.
♦ If required switch on the ignition for a short period of time.
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Gearbox 0AF - Edition 09.2013
6 Rep. gr.00 - Technical data
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4 Electrical components
Summary of components: Electrical components ⇒ page 7 .
4.1 Summary of components: Electrical
components
Summary of components: Electrical components, manual gear‐
box ⇒ page 7 .
Summary of components: Electrical components, clutch control
⇒ page 7 .
4.1.1 Summary of components: Electrical components, manual gearbox
1 - Reversing light switch - F4-
❑ Fitting position: under
the starter
❑ removing and installing
⇒ page 132
2 - Gearbox neutral position
sender - G701-
❑ Fitting position: in the re‐
gion of the gearshift unit
under the bracket used
to secure the gearshift
shaft
❑ removing and installing
⇒ page 132
4.1.2 Summary of components: Electrical
components, clutch control
Clutch position sender - G476- -arrow-
Fitting position: in passenger compartment at master cylinder.
Removing and installing clutch position sender - G476-
⇒ page 16 .
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ...
Gearbox 0AF - Edition 09.2013
4. Electrical components 7
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5 General repair information
Scrupulous care and cleanliness as well as the proper tools are
essential requirements for carrying out proper and successful
gearbox repairs. Obviously, the generally valid basic safety rules
apply to repair work.
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 to this
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 installing carriers as well as waxed components, the
contact surfaces must be cleaned. Contact surfaces must be
free of wax and grease.
♦ When replacing the gearbox, pour in gear oil up to lower edge
of filler hole ⇒ page 127 .
♦ Capacity and specification:
♦ Octavia II ⇒ page 2 .
♦ Octavia III ⇒ page 4 .
Gaskets, seals
♦ Thoroughly clean the separator surfaces and apply sealant -
AMV 188 200 03- .
♦ Apply sealant evenly - not too thickly.
♦ No sealant must get into the ventilation holes.
♦ Replace O-rings⇒ Electronic Catalogue of Original Parts .
♦ Replace radial shaft seals.
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Before installing
Lightly oil the outer diameter. Fill half the space between the seal‐
ing lips -arrow- with sealant - G 052 128 A1- .
After installing:
Check gear oil level, if necessary fill up to lower edge of filler hole
⇒ page 127 .
Gear oil specification:
♦ Octavia II ⇒ page 2 .
♦ Octavia III ⇒ page 4 .
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-.
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5. General repair information 9
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Screws, nuts
♦ Slacken and tighten securing bolts and nuts of covers and
housings diagonally across in stages.
♦ Do not twist particularly sensitive parts - e.g. clutch pressure
plates - and slacken and tighten diagonally across in stages.
♦ Tightening torques apply for non-oiled nuts and bolts.
♦ Always replace the self-locking 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.
♦ Please check the correct incline of the thread to ensure the
correct thread cutter is used when cleaning so as not to dam‐
age the thread.
Bearings
♦ Install the new taper roller bearings as delivered. In other
words, do not provide extra greasing before installation.
♦ Fit needle bearings to the gearbox with some gearbox fluid.
♦ Replace all taper roller bearings belonging to one shaft at the
same time. As far as possible use bearings of the same make.
♦ Heat the inner rings of the bearing for installation on a heating
plate or with a hot air blower - V.A.G 1416- , or with induction
heater unit - VAS 6414- to approx. 100 °C, when installing
press in axially as far as 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 - bearings go 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 for burrs and damage.
♦ Install only adjusting washers which are in perfect condition.
Synchronizer rings
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♦ 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 before pressing on and heat on a heating plate or with the
hot air blower - V.A.G 1416- or with the induction heater unit - VAS
6414- to approx. 100 °C.
The temperature can be checked with a temperature measuring
instrument.
Check fitting position.
Sliding gears
♦ After installing, check the gear wheels for small axial play/
clearance.
Clutch control
♦ When removing gearbox, remove slave cylinder, do not de‐
tach the hoses.
♦ If the slave cylinder with connected hydraulic line is removed,
do not depress the clutch pedal. Otherwise the tappet 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 43 ).
♦ 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.
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5. General repair information 11
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30 – Clutch
1 Repairing clutch control
Summary (Octavia II) ⇒ page 13 .
Overview of the fitting positions: Clutch control (Octavia III)
⇒ page 14 .
Summary of components - Foot controls (Octavia ll)
⇒ page 15 .
Summary of components: Foot controls (Octavia III)
⇒ page 16 .
Removing and installing bearing bush (Octavia III) ⇒ page 18 .
Removing and installing retractor spring ⇒ page 18 .
Removing and installing retractor spring (Octavia III)
⇒ page 20 .
Removing and installing over-centre helper spring (Octavia III)
⇒ page 22 .
Removing and installing clutch pedal (Octavia II) ⇒ page 24 .
Removing and installing clutch pedal (Octavia IlI) ⇒ page 26 .
Removing and installing bearing bracket (Octavia II)
⇒ page 28 .
Removing and installing bearing bracket for clutch pedal (Octavia
III) ⇒ page 30 .
Removing and installing master cylinder (Octavia II)
⇒ page 34 .
Removing and installing master cylinder (Octavia IIl)
⇒ page 35 .
Removing and installing clutch position sender -G476- (Octavia
II) ⇒ page 36 .
Removing and installing clutch position sender - G476- (Octavia
III) ⇒ page 38 .
Summary of components - Hydraulic system (Octavia ll)
⇒ page 38 .
Summary of components: Clutch hydraulics (Octavia III)
⇒ page 41 .
Checking the hydraulic clutch control (Octavia II) ⇒ page 43 .
Checking the master and slave cylinder (Octavia III)
⇒ page 44 .
Removing and installing slave cylinder (Octavia II) ⇒ page 44 .
Removing and installing master cylinder (Octavia III)
⇒ page 46 .
Removing and installing cables for clutch control (Octavia III)
⇒ page 47 .
Bleeding the clutch control (Octavia II) ⇒ page 49 .
Bleeding the clutch control (Octavia III) ⇒ page 50 .
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1.1 Summary (Octavia II)
Note
♦ If 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- .
1 - Summary of components -
Foot controls ⇒ page 15
2 - Summary of components -
Hydraulics ⇒ page 38
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1. Repairing clutch control 13
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1.2 Overview of the fitting positions: Clutch control (Octavia III)
I - Summary of components:
Foot controls (Octavia III)
⇒ page 16
II - Summary of components:
Clutch hydraulics (Octavia III)
⇒ page 41
❑ Left-hand drive
III - Summary of components:
Clutch hydraulics (Octavia III)
⇒ page 41
❑ Right-hand drive
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1.3 Summary of components - Foot controls (Octavia ll)
1 - Front wall
❑ with mount for bracket
2 - Gasket
❑ between bracket and
front wall
❑ self-adhesive
❑ glue to bracket
❑ always replace ⇒ Elec‐
tronic Catalogue of
Original Parts
3 - Bearing bracket
❑ for attaching clutch ped‐
al
❑ removing and installing
⇒ page 28
4 - Screw
5 - Retractor spring
❑ removing and installing
⇒ page 18
6 - Bushing
7 - Bearing bolt
8 - Clutch pedal
❑ removing and installing
⇒ page 24
9 - Support
❑ removing and installing
⇒ page 24
10 - Gasket
❑ between master cylin‐
der and bracket
❑ always replace ⇒ Electronic Catalogue of Original Parts
11 - Master cylinder
❑ removing and installing after removing the bracket ⇒ page 34
❑ test tightness ⇒ page 43
12 - Clutch position sender -G476-
❑ removing and installing ⇒ page 36
❑ check ⇒ Vehicle diagnostic tester
13 - Clamp
❑ to remove and install the tube-hose line pull out retaining clip up to the stop
14 - Tubing
❑ out of rubber
❑ as of 12.2005 made of plastic on certain vehicles ⇒ page 40
❑ if the return hose is made out of plastic, do not use hose clamp - MP7–602-
❑ test tightness ⇒ page 43
15 - 20 Nm
❑ 3 pieces
❑ self-locking
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1. Repairing clutch control 15
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❑ for bracket on front wall
❑ always replace ⇒ Electronic Catalogue of Original Parts
16 - 25 Nm
❑ always replace ⇒ Electronic Catalogue of Original Parts
17 - Stop
❑ for the clutch pedal
1.4 Summary of components: Foot controls (Octavia III)
1 - Master cylinder
❑ removing and installing
⇒ page 35
2 - Bearing bush
❑ removing and installing
⇒ page 18
❑ is not lubricated
3 - Clamp
❑ to remove and install the
tube-hose line pull out
retaining clip up to the
stop
4 - Gasket
❑ self-adhesive
❑ replace after removing
the master cylinder
❑ 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 38
6 - Carrier bolt
❑ after removing, replace
⇒ Electronic Catalogue
of Original Parts
❑ is not lubricated
7 - Spring stop
8 - Hexagon nut, 25 Nm
❑ Pillar to front wall
❑ 3 pieces
❑ self-locking
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
9 - Bearing shell
❑ 2 pieces
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16 Rep. gr.30 - Clutch
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