Skoda OCTAVIA Instruction manual
Service
Workshop Manual
OCTAVIA
Service Department. Technical Information
S00.5116.50.20 Edition 08.96
Automatic Gearbox
The Workshop Manual is intended only for use within the ŠKODA
Organisation; it is not permitted to pass it on to third parties.
© 1996 ŠKODA, automobilová a.s. Printed in Czech Republic
Service
List of Supplements to
OCTAVIA Workshop Manual Edition: 06.03
Automatic Gearbox
Replaces List of Supplements - Edition: 01.01
Supple- Edition Subject Article Number
ment
08.96 Basic Edition of Workshop Manual S00.5116.50.20
1 03.97 Supplement to Basic Edition S00.5116.51.20
2 01.98 Supplement of New Gearbox Types S00.5116.52.20
3 04.98 Supplement of New Gearbox Type S00.5116.53.20
4 08.98 CAN Databus S00.5116.54.20
5 12.98 Modifications to Shift Elements S00.5116.55.20
6 03.99 Low-friction Bearings S00.5116.56.20
7 06.99 Supplement of New Gearbox Types S00.5116.57.20
8 04.00 Modifications to Repair Groups 00, 01, 32, 37, 38 S00.5116.58.20
and 39
9 01.01 Modifications to Repair Groups 00, 01, 34, 37 and 39 S00.5116.59.20
10 06.03 Modifications to Repair Groups 00, 01, 37, 38 and 39 S00.5116.60.20
11
12
13
14
15
16
17
18
19
20
Contents ⇒next page.
This Service Manual is intended only for use within
the Škoda Organisation; it is not permitted to pass it
on to third persons.
© ©
© ©
©
2003 ŠKODA AUTO a. s.2003 ŠKODA AUTO a. s.
2003 ŠKODA AUTO a. s.2003 ŠKODA AUTO a. s.
2003 ŠKODA AUTO a. s.
Printed in CR
S00.5116.60.20
Edition 06.03
S00.5116.60.20
------------
I ------------
OCTAVIA Service
Contents
00 Technical Data Page
Identification of gearbox ............................................................................................................. 00-1
Code letters, component assignment, ratios, equipment ....................................................... 00-2
Capacities..................................................................................................................................... 00-4
General repair information ......................................................................................................... 00-5
01 Self-Diagnosis/Electrical Test Page
Self-diagnosis .............................................................................................................................. 01-1
- Technical data of self-diagnosis ............................................................................................... 01-3
Conducting self-diagnosis ......................................................................................................... 01-4
- Connecting vehicle system tester V.A.G 1552 and selecting function ..................................... 01-4
- List of available functions ......................................................................................................... 01-6
- Interrogating fault memory ....................................................................................................... 01-6
- Fault table ................................................................................................................................. 01-7
- Erasing fault memory ............................................................................................................... 01-14
- Initiating basic setting ............................................................................................................... 01-15
- Reading measured value block ................................................................................................ 01-16
- Test table .................................................................................................................................. 01-17
Function of CAN databus ........................................................................................................... ✳
- Test of „Two cable databus system“ ......................................................................................... ✳
Gearbox: Electrical test .............................................................................................................. 01-29
- Test table .................................................................................................................................. 01-32
- Inspecting cable connection between 68-pin gearbox control unit and gearbox ...................... 01-36
Electrical and electronic components - fitting locations ........................................................ 01-37
32 Torque converter Page
Torque converter ......................................................................................................................... 32-1
- Identification of torque converter .............................................................................................. 32-2
- Draining torque converter ......................................................................................................... 32-3
- Removing and installing gasket ring for torque converter ........................................................ 32-3
- Installing torque converter ........................................................................................................ 32-4
37 Shift Mechanism/Housing Page
Servicing shift mechanism ......................................................................................................... 37-1
- Inspecting shift mechanism ...................................................................................................... 37-1
- Disassembling and assembling shift mechanism .................................................................... 37-2
- Removing and installing and setting selector lever control cable ............................................. 37-4
Inspecting gearbox...................................................................................................................... 37-6
- Inspecting shifting points .......................................................................................................... 37-6
- Shifting points in km/h .............................................................................................................. 37-6.1
- Measure limit speed of hydraulic converter .............................................................................. 37-6.2
- Limit speed of hydraulic converter in rpm ................................................................................ 37-6.2
- Measure main pressure ........................................................................................................... 37-7
- Nominal values of main pressure in bar (MPa) overpressure .................................................. 37-8
- Causes for deviations from nominal value ............................................................................... 37-8
Fault finding table ....................................................................................................................... 37-8
Removing and installing gearbox .............................................................................................. 37-12.1
- Replacement component or „Component of shift elements“ ................................................... 37-12.1
✳Refer to Running Gear
Service OCTAVIA
Edition 06.03
S00.5116.60.20
------------
II ------------
Inspecting ATF level or top up ................................................................................................... 37-22
- Inspecting ATF level ................................................................................................................. 37-22
- Topping up ATF ........................................................................................................................ 37-24
- Fill with ATF after repair ........................................................................................................... 37-25
Gearbox with shift elements ...................................................................................................... 37-26
- Position of shift elements ......................................................................................................... 37-26
Disassembling and assembling gearbox .................................................................................. 37-28
- Regulations concerning cleanliness when working on automatic gearbox .............................. 37-28
- Removing and installing ATF radiator and filler tube ................................................................ 37-29
- Disassembling and assembling planetary gear - Summary of components ............................ 37-30
- I - Removing and installing ATF pump for large sun gear -B2- ................................................ 37-31
- II - Removing and installing reverse gear clutch -K2- for large sun gear ................................. 37-32
- III - Removing and installing free wheel and reverse gear brake -B1- ..................................... 37-33
- IV - Removing and installing planet carrier ............................................................................... 37-34
- Disassembling and assembling planetary gear ........................................................................ 37-35
- List of all adjusting work on planetary gear .............................................................................. 37-49
- I - Adjusting planetary carrier ................................................................................................... 37-50
- II - Adjusting reverse gear-brake -B1- ...................................................................................... 37-54
- III - Set clutch clearance between -K1- and -K2-...................................................................... 37-57
- IV - Adjust 2nd and 4th gear-brake -B2- .................................................................................. 37-61
38 Gear/Control Page
Disassembling and assembling ATF pump .............................................................................. 38-1
Disassembling and assembling free wheel with -B1- piston .................................................. 38-3
Disassembling and assembling 1st to 3rd gear clutch -K1- ................................................... 38-5
Disassembling and assembling reverse gear clutch -K2- ....................................................... 38-8
Disassembling and assembling 3rd to 4th gear clutch -K3- with turbine shaft .................... 38-10
Removing and installing slide valve body ................................................................................ 38-12
- Removing and installing slide valve body - overview ............................................................... 38-13
- Removing and installing oil pan ................................................................................................ 38-15
- Removing and installing ATF strainer....................................................................................... 38-16
- Removing and installing slide valve body ................................................................................. 38-16
- Removing and installing ribbon cable with connector .............................................................. 38-18
Disassembling and assembling parking position .................................................................... 38-20
39 Final Drive/Differential Page
Inspecting axle oil in final drive ................................................................................................. 39-1
Removing and installing seal for drive flange .......................................................................... 39-2
Disassembling and assembling final drive ............................................................................... 39-4
- Removing and installing drive gear .......................................................................................... 39-5
- Removing and installing input shaft .......................................................................................... 39-8
- Removing and installing differential .......................................................................................... 39-14
- Disassembling and assembling differential .............................................................................. 39-19
Setting final drive ........................................................................................................................ 39-23
- Setting final drive - overview ..................................................................................................... 39-23
- Adjusting works when replacing individual components .......................................................... 39-24
- Before disassembling final drive .............................................................................................. 39-24
- Setting input shaft ..................................................................................................................... 39-25
- Setting drive gear ..................................................................................................................... 39-28
- Setting differential ..................................................................................................................... 39-30
OCTAVIA
Edition 04.98
S00.5116.53.20
------------
00-1 ------------
Technical Data 00
Identification of gearbox
Location on gearbox
KCode letters (arrow 1)
Automatic gearbox 01M (arrow 2)
Example: DTB 02 08 7
III I
III I
Code Da Month Year (1997)
letters of manufacture
Note:
The code letters of the gearbox are also listed
on the vehicle data plates.
KThe vehicle data plate is located at the rear left
on the floor of the luggage compartment.
OCTAVIA
S00.5116.59.20
Code letters
Manufactured from 01.97 01.97
to 07.98 07.98
Code letters
Code letters
Inner Outer Inner Outer
Clutch -K1- 4 4 4 4
Clutch -K2- 3 3 3 3
Clutch -K3- 5 4 5 4
rake - 1- 4 4 4 4
rake - 2- 4 5 4 5
Engine
1st gear 2.714 2.714
2nd gear 1.441 1.441
3rd gear 1.000 1.000
4th gear 0.742 0.742
Reverse 2.884 2.884
No. of teeth Input 45 61
gear
Output 44 63
gear
Ratio 0.978 1.033
No. of teeth Drive 14 16
pinion
Crown 73 78
wheel
Ratio 5.214 4.875
∅124 mm
1) Control valve body with code letters is supplied as a replacement part by the Parts Sector.
------------
00-2 ------------
OCTAVIA
S00.5116.59.20
Code letters
Manufactured from 0
.9
0
.99
to
Code letters
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------------
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as a replacement part by
Parts Sector.
OCTAVIA
S00.5116.59.20
------------
00-2.2 ------------
Code letters
Manufactured from 0
.99 0
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to
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OCTAVIA
Edition 06.03
S00.5116.60.20
Technical Data 00
Automatic gearbox 01M
Gearbox Code letters ESJ FDH
Manufactured from 01.00 02.00
to 02.00
Torque converter Code letters QADD QADD
Slide valve body Code letters QFB1) QFB1)/QLB1)
Number of disks Inner Outer Inner Outer
Clutch -K1- 4 4 4 4
Clutch -K2- 3 3 3 3
Clutch -K3- 5 4 5 4
Brake -B1- 4 4 4 4
Brake -B2- 4 5 4 5
Assignment: Engine 1.6 l/74 kW 1.6 l/74 kW, 75 kW
Transmission ratio: 1st gear 2.714 2.714
2nd gear 1.441 1.441
3rd gear 1.000 1.000
4th gear 0.742 0.742
R/Reverse gear 2.884 2.884
Intermediate gear Number of teeth Drive 45 61
gear
Output 44 63
gear
Transmission ratio 0.978 1.033
Final drive Number of teeth Input 16 16
shaft
Crown 78 78
wheel
Transmission ratio 4.875 4.875
Drive shaft flange ∅108 mm
1) In the Service Workshop the slide valve body is supplied as replacement part with the code letters KD.
------------
00
2
.
3
------------
OCTAVIA
S00.5116.59.20
Code letters
Manufactured from 0
.97 0
.9
to
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gear
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gear
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pinion
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wheel
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mm
mm
12
Control valve body with code letters is supplied as a replacement part by the Parts Sector.
------------
33
4
5
6
7
------------
OCTAVIA
S00.5116.59.20
------------
------------
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OCTAVIA
S00.5116.59.20
------------
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OCTAVIA
S00.5116.59.20
------------
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OCTAVIA
S00.5116.59.20
------------
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OCTAVIA
S00.5116.59.20
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to
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------------
SS
T
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V
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------------
OCTAVIA
S00.5116.59.20
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to
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C$
by
Parts Sector.
------------
00-2.10 ------------
OCTAVIA
S00.5116.59.20
------------
------------
OCTAVIA
00 Technical Data
Edition 06.03
S00.5116.60.20
Capacities
Planetary gear
------------
00
4
------------
Capacities Planetary gear
New filling 5.3 l
Change Filled for life, no top-up
required
Lubricant ATF G 052 162 ..
Note:
For the planetary gear in automatic gearbox 01M
only lubricant ATF G 052 162 .. should be used.
ATF G 052 162 .. is available as spare part in
the following sizes of can:
♦0.5 l - Spare part no. G 052 162 A1
♦1.0 l - Spare part no. G 052 162 A2
♦20.0 l - Spare part no. G 052 162 A6
Final drive
Capacities Final drive
New filling 0.75 l
Change Filled for life, no top-up
required
Lubricant Transmission oil (synthetic)
G 005 000 .. SAE 75W90
Warning!
Under no circumstances must there be a mix-up
of both fillings. Otherwise both fillings must be
changed.
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