Service

Workshop Manual
OCTAVIA

5-Speed Manual Gearbox 002

ProCarManuals.com

Service Department. Technical Information

S00.5129.50.20 Edition 04.99
ProCarManuals.com

The Service Manual is intended only for use within the Škoda Organisation;
it is not permitted to pass it onto third persons. Printed in CR
© 1999 ŠKODA AUTO a. s.
 Service

List of Supplements to
OCTAVIA Workshop Manual Edition: 09.00

5-Speed Manual Gearbox 002

Replaces List of Supplements - Edition: 04.99

Supple- Edition Subject Article Number

ment
04.99 Basic Edition of Workshop Manual S00.5129.50.20
1 09.00 Supplement to Basic Edition S00.5129.51.20
2
3
ProCarManuals.com

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Contents ⇒ next page.

The Service Manual is intended only for use within the

Škoda Organisation; it is not permitted to pass it onto
third persons. Printed in CR
© 2000 ŠKODA AUTO a. s. S00.5129.51.20
ProCarManuals.com
 OCTAVIA Service
Contents

00 Technical Data Page

Identification of gearbox ............................................................................................................. 00-1
- Code letters, component assignment, ratios, capacities .......................................................... 00-2
Survey of power transmission ................................................................................................... 00-3
General repair information ......................................................................................................... 00-4

30 Clutch Page
Servicing clutch mechanism ...................................................................................................... 30-1
- Summary of components of pedal assembly ........................................................................... 30-1
- Removing and installing over-centre spring ............................................................................. 30-3
- Removing and installing clutch pedal ....................................................................................... 30-4
- Summary of components of hydraulic system ......................................................................... 30-5
- Removing and installing master cylinder .................................................................................. 30-6
- Bleeding clutch system ............................................................................................................. 30-8
Servicing clutch release mechanism ........................................................................................ 30-9
Servicing clutch ........................................................................................................................... 30-11

34 Shift Mechanism/Housing Page

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Servicing shift mechanism ......................................................................................................... 34-1

- Installation position of shift mechanism .................................................................................... 34-1
- I - Summary of components of shift relay/operating cables ..................................................... 34-3
- II - Summary of components of shift housing ........................................................................... 34-6
- Removing and installing shift housing ...................................................................................... 34-7
- III - Summary of components of operating cables/shift lever ................................................... 34-10
- Setting shift mechanism ........................................................................................................... 34-12
Removing and installing gearbox .............................................................................................. 34-14
- Inspecting gear oil .................................................................................................................... 34-22
Disassembling and assembling gearbox .................................................................................. 34-23
- I - Removing and installing cover for gearbox housing and 5th gear ....................................... 34-24
- II - Removing and installing gearbox housing, input shaft, output shaft (drive pinion),
differential and shift rods .......................................................................................................... 34-25
- Sequence of removal and installation operations ..................................................................... 34-28
Servicing gearbox housing ........................................................................................................ 34-35
Servicing clutch housing ............................................................................................................ 34-37
Disassembling and assembling shift rods with shift forks ..................................................... 34-44

35 Gears/Shafts Page
Disassembling and assembling input shaft ............................................................................. 35-1
Disassembling and assembling output shaft (drive pinion) ................................................... 35-5

39 Final Drive/Differential Page

Replacing seals for flange shafts (gearbox installed) ............................................................. 39-1
Disassembling and assembling differential ............................................................................. 39-5
Setting differential ....................................................................................................................... 39-12

Edition 04.99 ------------1 ------------

S00.5129.50.20
ProCarManuals.com
 OCTAVIA Technical Data 00

Identification of gearbox

K Location on gearbox

The manual gearbox 002 is installed as a

5-speed gearbox in combination with the 1.4-
ltr./44 kW engine in the Škoda Octavia.

Code letters of gearbox (arrow 1)

Date of construction of gearbox (arrow 2)

K Date of construction of gearbox

a = Production number of gearbox

b = Identification of year of manufacture

ProCarManuals.com

Character Year Character Year

T 1996 1 2001
V 1997 2 2002
W 1998 3 2003
X 1999 4 2004
Y 2000 5 2005

c = Month of manufacture

Character Month Character Month

L January C July
U February S August
B March Z September
D April R October
K May T November
N June P December

d = Gearbox ratio

Character Transmission ratio of final drive

7 4.235

Edition 04.99 ------------ 00-1 -------------

S00.5129.50.20
 00 Technical Data OCTAVIA

Code letters, component assignment, transmission ratios, capacities

Code letters DTQ FHW

Manufactured from 01.99 09.00
to 08.00
Assignment: Engine 1.4-ltr./44 kW 1.4-ltr./44 kW
Transmission ratio: Final drive 72 : 17 = 4.235 72 : 17 = 4.235
1st gear 45 : 13 = 3.462 45 : 13 = 3.462
2nd gear 45 : 23 = 1.957 45 : 23 = 1.957
3rd gear 38 : 28 = 1.357 38 : 28 = 1.357
4th gear 40 : 38 = 1.053 40 : 38 = 1.053
5th gear 36 : 42 = 0.857 36 : 42 = 0.857
Reverse 29 : 13 x 38 : 29 = 2.923 29 : 13 x 38 : 29 = 2.923
Speedo 16 : 27 = 0.593 16 : 27 = 0.593
Capacity 2.4 ltr. 2.4 ltr.
Gear oil specification Gear oil G50 SAE 75W90 Gear oil G50 SAE 75W90
(synthetic oil) (synthetic oil)
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Gear oil change interval filled for life filled for life
Clutch control hydraulic hydraulic
Clutch plate ∅ 190 mm 190 mm
Drive shaft flange ∅ 90 mm 90 mm

------------ 00-2 ------------- Edition 09.00

S00.5129.51.20
 OCTAVIA Technical Data 00

Survey of power transmission

Designation

1 - Engine

2 - Clutch

3 - Manual gearbox

4 - Input shaft

5 - Output shaft/drive pinion

6 - Differential

       

Ratio

    
ProCarManuals.com

    

    

    

    

    

   

     

Edition 04.99 ------------ 00-3 -------------

S00.5129.50.20
 00 Technical Data OCTAVIA

General repair information

Extreme care and scrupulous cleanliness, as
well as proper tools are essential requirements
for conducting proper and successful repairs to
the gearbox. The general applicable basic rules
of safety naturally also apply to repair work.

A number of general applicable notes for indi-

vidual repair operations - which are otherwise
listed at various points in the workshop manual
- are summarized here. They apply to this work-
shop manual.

Gearbox

♦ When installing, ensure the dowel sleeve

between engine and gearbox are correctly
located.

♦ If the gearbox is replaced, pour in gearbox


oil up to the lower edge of the filler hole.

♦ Capacity and specification ⇒ page 00-2.

Seals, gaskets
ProCarManuals.com

♦ Thoroughly clean contact surfaces and ap-

ply THREE BOND 1104 sealant.

♦ Apply sealant evenly - not too thick.

♦ Replace O-rings.

♦ Replace radial shaft seals.

Before installing:

K Lightly oil outer diameter and pack space be-

tween sealing lips (arrow) with grease.

After installing:

Inspect gear oil level; top up if necessary to lower

edge of filler hole. Specification ⇒ page 00-2.

------------ ------------- Edition 04.99

S00.5129.50.20
 




 





OCTAVIA Technical Data 00

♦ Replace circlips.

♦ Do not over-tension circlips.

♦ Circlips must be resting in the base of the

slot.

K ♦ Replace roll pins.

Installation position: slot lengthwise to power
flow.

♦ Slacken and tighten nuts and bolts for at-

taching covers and the housings diagonally
across.

♦ Do not twist particularly sensitive parts - for


example clutch pressure plates - and slacken
and tighten in stages diagonally across.

♦ The tightening torques apply to non-oiled

nuts and bolts.
ProCarManuals.com

♦ Always replace self-locking nuts and bolts.

♦ Insert all bearings in the gearbox with gear

oil.

♦ Always replace all the tapered roller bear-

ings mounted on a shaft. Use the same
makes if possible!

♦ Heat inner races to about 100 °C for install-

ing.

♦ Do not mix up the outer and inner races of

bearings of the same size. Bearings are
matched.

♦ Position needle bearing with the inscribed

side (larger metal thickness) facing the in-
sertion drift.

Edition 04.99 ------------ -------------

S00.5129.50.20
 00












Technical Data

♦ Re-gauge shims at several points with a mi-

crometer. Different tolerances make it pos-

♦ Inspect for burrs or damage.

OCTAVIA

sible to exactly gauge the required thickness

of shim.

♦ Install only shims which are in perfect condi-

tion.

♦ Do not mix up. Assign synchronizer rings to

the same gear when re-installing.

♦ Inspect for wear, replace if necessary.

♦ Insert with gear oil.


♦ Clean and heat on a hot plate to approx.
100 °C before pressing on.
ProCarManuals.com

♦ The temperature can be checked with a tem-

perature measuring instrument (e.g. V.A.G
1558).

------------ ------------- Edition 04.99

S00.5129.50.20
 OCTAVIA Clutch 30

Servicing clutch mechanism

Summary of components of pedal assembly


ProCarManuals.com

Special tools, testers and aids required ♦ Before disconnecting the battery, determine
the coding of radio set fitted with anti-theft
♦ Poly resin grease G 052 142 A2 coding.
♦ When the battery is re-connected, check the
Notes:
vehicle equipment:
♦ Summary of components of hydraulic sys- - Encode radio
tem ⇒ page 30-5. - Re-set clock
- Initialise power windows
♦ Disconnect earth strap of battery.
⇒ Inspection and Maintenance

Edition 04.99 ------------ -------------

S00.5129.50.20
 30 Clutch OCTAVIA


ProCarManuals.com

♦ Coat all bearing and contact surfaces with 4 - Bolt

poly resin grease G 052 142 A2.
5 - Accelerator/brake pedal assembly
♦ Before carrying out work on the pedal as-
sembly, remove storage compartment on
6 - 25 Nm
driver’s side:
♦ Always replace
⇒ Body Fitting Work; Repair Group 70; Re-
moving and installing dash panel.
7 - Connecting plate
1 - Mount at bulkhead
8 - 20 Nm
♦ For master cylinder and bearing
♦ Always replace
bracket
9 - Spacer bush
2 - Gasket
♦ Always replace

3 - Bearing bracket

------------ ------------- Edition 04.99

S00.5129.50.20
 
OCTAVIA
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⇒ page 30-4

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⇒ page 30-5

♦ Always replace

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⇒ page 30-6


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♦ Insert into bearing bracket
♦ Always replace

♦ Always replace

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♦ Assembly clip 3317

ProCarManuals.com

- Remove storage compartment at bottom left

on driver side:
⇒ Body Fitting Work; Repair Group 70; Re-
moving and installing dash panel.

K- Tension overcentre spring with clutch pedal

and press on assembly clip 3317 from above.

Note:

       

- Move clutch pedal into rest position; at the

same time, take off overcentre spring to-
gether with assembly clip 3317.

- Move clutch pedal into rest position.

K- First of all, position overcentre spring in

mount -B- then depress clutch pedal fully until
the locating stud of the clutch pedal -A- is
positioned against overcentre spring.

- Tension overcentre spring with the clutch

pedal and take off assembly clip 3317.

Edition 04.99 ------------ -------------

S00.5129.50.20
 30






 



 
 Clutch

K-
-

-
clutch

Remove overcentre spring ⇒ page 30-3.

Separate clutch pedal from master cylinder

⇒ page 30-6 and press operating rod as far
as the stop toward engine compartment.

Unscrew hexagon nut -A- and pull hexagon

bolt out of the bearing bracket.

Remove clutch pedal.

OCTAVIA


Installation is carried out in the reverse order.
Pay attention to the following points:
ProCarManuals.com

K- The mount -A- must be located on the oper-

ating rod -B- of the master cylinder.

- To lock the mount in place, press clutch pedal

toward bulkhead (direction of arrow); ensure
it is correctly locked.

------------ ------------- Edition 04.99

S00.5129.50.20
 

 

  
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ProCarManuals.com

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♦ Bleeding ⇒ page 30-8

♦ Removing ⇒ page

Edition 04.99 ------------ -------------

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♦ Release tool 3309

♦ Pliers 10-208 A

Note:
Unbolt master cylinder by working from the pas-
senger compartment.

K- Detach feed hose -A- to the brake fluid res-

ervoir and seal.

- Pull out locking clip -B- at master cylinder.

- Pull out pipe -C- at master cylinder and seal.

------------ ------------- Edition 04.99

S00.5129.50.20
 $
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OCTAVIA Clutch 30

- Remove

⇒ Re-

Note:
To remove the master cylinder, take out the com-
plete clutch pedal assembly. Before removing,
however, the master cylinder must be separated
from the clutch pedal.


-
C-
ProCarManuals.com

K- U

- U 2-
move

- Remove ⇒

-
⇒

Edition 04.99 ------------ -------------

S00.5129.50.20
 30




 



 


 

Clutch

K-

-
operating rod -B- of the master cylinder.

To engage the mount in place, press clutch

pedal toward bulkhead (direction of arrow);
OCTAVIA

Installation is carried out in the reverse order.

Pay attention to the following points:

The mount -A- must be positioned on the

ensure it is correctly locked for this step.

After installing the master cylinder, bleed

clutch system ⇒ page 30-8.

clutch


♦ Brake filling and bleeding appliance
ROMESS S15
ProCarManuals.com

♦ Bleeder hose 670 mm

- Use the ROMESS S15 brake filling and

bleeding appliance and bleed the clutch sys-
tem.

- Use a 670 mm bleeder hose for bleeding the

system.

- Fit the bleeder hose onto the connection of

the bottle of the brake bleeding appliance.

K- Fit on bleeder hose at slave cylinder -arrow-

and open bleeder valve.

- After completing the bleeding operation, de-

press the clutch pedal several times.

------------ ------------- Edition 04.99

S00.5129.50.20
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OCTAVIA Clutch 30

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Servicing clutch

♦ Apply THREE BOND 1324 sealant

before installing

3 Clutch lever
♦ When replacing, release bearing must
also be replaced (lugs on release
bearing do not operate after bearing
is removed from clutch release lever)
♦ Removing and installing ⇒ page
30-10; remove and install clutch re-
lease lever together with release bear-
ing and guide sleeve

4
♦ Attach to clutch release lever

♦ Removing and installing ⇒ page

30-10; remove and install clutch re-
lease lever together with release bear-
ing and guide sleeve
ProCarManuals.com

♦ Coat contact surface of release bear-

ing with MoS2 grease

♦ Replacing ⇒ page 34-39, item 18

t t

♦ Tool for removing valve stem seal MP 1-174 ♦ Grease with MoS2 grease
♦ If clutch housing is replaced, knock in
♦ MoS2 grease as far as the stop using extraction tool
for valve stem seal MP 1-174
♦ THREE BOND 1324 sealant

Note:
9
Remove and install release bearing -1- together
with clutch release lever -3- and guide sleeve
for release bearing -5- in order to avoid damag-
ing the lugs on the release bearing. cylinder
♦ Removing and installing ⇒ page
30-5
♦ Do not wash out bearing, only wipe ♦ Grease end of tappet with MoS 2
off grease
♦ Replace loud bearings
♦ Grease contact points at release le-
ver with MoS2 grease
♦ Removing and installing ⇒ page
30-10; remove and install clutch re-
lease lever with release bearing and
guide sleeve

Edition 04.99 ------------ -------------

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------------ ------------- Edition 04.99

S00.5129.50.20
 

 







 
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OCTAVIA Clutch 30

Servicing clutch






♦ Ensure tightly fitted on centering pins
♦ Contact surface for clutch lining free
of grooves, oil and grease
♦ Removing and installing:
⇒ 1.4-ltr./44 kW Engine, Mechanical Compo-
nents; Repair Group 13; Disassembling and
assembling cylinder block, crankshaft and
flywheel

♦ Diameter ⇒ page 00-2

♦ Pay attention to installation position,
spring cage points toward pressure
plate
♦ Centering ⇒ Fig. 1
♦ Apply thin film of grease to splines

Note:
Clean splines of input shaft and also, if clutch
plates are used, splines of hub, remove corro-
ProCarManuals.com

sion and apply only a very thin film of grease

G 000 100 to the splines of the input shaft. After
this, move clutch plate back and forward on the
input shaft until the hub moves freely on the
shaft. It is essential to remove excess grease.
t testers and aids
3
♦ Grease G 000 100 ♦ Removing and installing ⇒ Fig. 1
♦ Inspecting ends of diaphragm spring
♦ Counterholder MP 1-504 ⇒ Fig. 3

♦ Centering drift MP 2-501 Note:

(Gearbox removed) Pressure plates are protected against corrosion

and grease. They must only be cleaned at the
Notes: contact surface otherwise the life of the clutch
will be considerably reduced.
♦ Replace clutch plates and pressure plates if
riveted connection is damaged or loose. 4
♦ Assign clutch plate and pressure plate by
referring to Parts List and engine code.
♦ Slacken and tighten in stages diago-
nally across
♦ Removing and installing ⇒ Fig. 2

Edition 04.99 ------------ -------------

S00.5129.50.20
 




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Note:
Contact surface of pressure plate and lining of
clutch plate must be making contact with fly-
wheel over complete surface. Only then, insert
securing bolts. On no account pull on pressure
plate. Otherwise centering holes of pressure
plate and centering pins of flywheel will be dam-
aged.


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ProCarManuals.com

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------------ ------------- Edition 04.99

S00.5129.50.20
 OCTAVIA

Servicing shift mechanism




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Shift Mechanism/Housing











 34

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Installation position of shift mecha-
nism
A - Shift cable for shift movement

B - Selector cable for selector movement

C - Heat shield
♦ T

1 - Gearbox shift lever

2 - Shift relay mechanism

Notes:
♦ Disconnect earth strap from the battery when
ProCarManuals.com

working on the shift mechanism in the en-

gine compartment.
♦ Before disconnecting the battery, determine
the coding of radio sets with anti-theft code.
♦ When the battery is re-connected, check the
vehicle equipment:
- Encode radio
- Re-set clock
- Initialise power windows
⇒
♦ Take out shift mechanism in order to replace
the operating cables ⇒ page 34-7.
♦ Do not kink operating cables.

Special tools, testers and aids required

♦ T

Edition 04.99 ------------ -------------

S00.5129.50.20
 34 Shift Mechanism/Housing OCTAVIA
ProCarManuals.com

I - Assembly overview - shift relay me- Removing and installing shift housing ⇒ page
chanism, shift mechanism cables 34-7.
⇒ page 34-3
Setting shift mechanism ⇒ page 34-12.
II - Assembly overview - shift housing
⇒ page 34-6

III - Assembly overview - shift mechanism

cables, shift lever ⇒ page 34-10

------------ 34-2 ------------- Edition 09.00

S00.5129.51.20
 OCTAVIA Shift Mechanism/Housing 34

I - Assembly overview - shift relay mechanism, shift mechanism cables

ProCarManuals.com

Note: 4 - Spring
♦ Models 03.99 ä
Grease bearing points and contact surfaces with
poly resin grease G 052 142 A2.
5 - 25 Nm
1 - Shift cable
6 - 20 Nm
♦ Fitting location ⇒ page 34-1
7 - Support
2 - Selector cable
♦ Fitting location ⇒ page 34-1
8 - 25 Nm
♦ 2 in total
3 - Circlip
♦ Do not damage boot when removing
9 - Supporting angle bracket

Edition 09.00 ------------ 34-3 -------------

S00.5129.51.20
 34 Shift Mechanism/Housing OCTAVIA
ProCarManuals.com

10 - PAS gear 14 - 25 Nm
♦ With heat shield ♦ Tighten after setting shift mechanism

11 - Boot 15 - Gearbox

12 - Gearbox shift lever 16 - Ball stud

♦ Grease guide for ball stud/shift relay
lever (item 42) with poly resin grease 17 - Seal
G 052 142 A2
♦ After installing, set shift mechanism 18 - Selector rod
⇒ page 34-12 ♦ Grease ball sockets with poly resin
grease G 052 142 A2 before install-
13 - 20 Nm ing
♦ Before installing, apply Loctite 648
locking fluid

------------ 34-4 ------------- Edition 09.00

S00.5129.51.20





























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OCTAVIA Shift Mechanism/Housing 34
9- 33 - oot
♦ Carefully pull over shift cable and end
- Seal piece
♦ Grease with MoS2 grease
-
34 -
- angle
-
3-
3 -
4-
3 -
- Seal
3 -
-
39 -
-
40 -
- Mounting
4 -
9-
♦ For attaching mounting bracket to 4 - l
transmission
43 -
30 -
♦ For attaching mounting bracket to 44 -
transmission
ProCarManuals.com

4 - Shield
3 -
♦ For attaching mounting bracket to 4 -
transmission

3 - oot
♦ Carefully pull over selector cable and
end piece
♦ Grease with MoS2 grease

Edition 09.00 ------------ 34-5 -------------

S00.5129.51.20

     OCTAVIA

    


ProCarManuals.com

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♦ When removing also take off cover ♦ For attaching gearshift knob to gear-
-item 2- shift lever

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♦ When removing also take off gearshift
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♦ Separating cover from gearshift knob
⇒ page 34-9 * ! 
♦ Self-adhesive

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♦ Connects cover to gearshift knob
♦ Removing ⇒ page 34-9

------------ -------------  

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OCTAVIA Shift Mechanism/Housing 34
Shift housing
♦ Removing and installing ♦ elded to
⇒ page

9
♦ 3
♦

♦ and
♦
♦ onto

and shift
ing


- Remove ⇒ page

K-
ProCarManuals.com

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⇒

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Edition 04.99 ------------ -------------

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OCTAVIA Shift Mechanism/Housing 34

Notes:
♦ Replace

♦ ⇒
♦
⇒ 1.4-ltr./44 kW Engine, Mechanical Compo-
nents; Repair Group 26; Removing and in-
stalling parts of exhaust system

ightening

Shift housing to body 25 Nm

M8 bolt
Shift housing to body 25 Nm
M8 nut
Cross member to body 25 Nm


Bolt of shift cable to shift intermediate lever 25 Nm
ProCarManuals.com

- Turn the cover inside out.

K- Use a screwdriver to lever off connection part

-arrow-.

- Pull connection part off gearshift knob.

- Turn gearshift knob to the outside and pull it

off the cover.

- Turn cover inside out.

- Insert gearshift knob into cover.

- Push connection part over gearshift knob and

cover and compress until it locks in place.

Edition 04.99 ------------ -------------

S00.5129.50.20
 34
ProCarManuals.com

-









 Shift Mechanism/Housing

- shift mechanism shift

OCTAVIA


















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♦ To shift lever
Grease bearing points and contact surfaces with
poly resin grease G 052 142 A2.
-
-
-
♦ To selector angle bracket
7-
-
♦ Always replace
8-
♦ Always replace
3-

------------ ------------- Edition 09.00

S00.5129.51.20
 



















 


































 







OCTAVIA 34


Shift Mechanism/Housing

9 9
♦ Heat cap before fitting on (for exam- ♦ Removing and installing ⇒ Fig. 1
ple in hot water) ♦ For models 08.99 ä

0 0
♦ For models 08.99 ä
housing



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♦ Insert into bearing plate after assem-
bling complete shift lever ♦ For models 08.99 ä

♦ Shift lever and shift lever guide are

3 assembled to form single component
♦ Insert into bush item 10
3
4 ♦ Shift lever and shift lever guide are
assembled to form single component
♦ For models 08.99 ä

4
♦ Fits only in one position ♦ Clip onto shift lever
♦ Fitting location: the lug -arrow- points
toward shift lever mounting
ProCarManuals.com

- Pull shift lever in direction -arrow A- and at

the same time use a screwdriver to push the
spacer sleeve down fully in direction -arrow
B- and remove the circlip.

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Do not twist spacer sleeve when pushing down
with screwdriver. Carefully relieve pressure on
mounting slot in shift lever for circlip.

Edition 09.00 ------------ -------------

S00.5129.51.20




 

    

  

♦ Shift lever gauge 3422

♦ Sliding block T30006

K-

-
 
 

The shift lever gauge is composed of the

bottom part of the gauge 3422 and the slid-
ing block T30006.

Replace sliding block of shift lever gauge

3422 with sliding block T30006 after slack-
ening the screw (arrow).

Notes:
Requirements for correct setting of the shift
mechanism are as follows:
OCTAVIA


♦ Operating and transmission elements of shift
mechanism in proper condition.
♦ Insulating pieces for mounting shift and se-
lector cables in proper order at all operating
elements (not worn).
ProCarManuals.com

♦ Shift cable and selector cable operate freely.

In addition, the gearbox, clutch and clutch
mechanism must be in proper condition.

Gearbox in Neutral position.

- Detach gearshift knob together with cover

⇒ page 34-7.

K- Slacken bolt of shift cable of shift intermedi-

ate lever -arrow A-.

K- Slacken nut of selector rod of gearbox shift

lever -arrow B-.

- Shift cable and selector rod must now move

freely in the slots.

------------ -------------  

S00.5129.50.20
 
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Edition 04.99 ------------ -------------

S00.5129.50.20








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♦ Gearbox mount 3282

♦ Adapter MP 3-419/40


♦ Adjusting plate T30007

 

♦ Transporting device MP 3-478

♦ Assembly device MP 5-402

♦ Supporting device MP 9-200

♦ Grease G 000 100

♦ Loctite 648
OCTAVIA


- Remove engine trim panel.

- Seal oil filler neck.

ProCarManuals.com

- Before disconnecting the battery, determine

the coding of radio sets fitted with anti-theft
code.

- Disconnect earth strap of battery.

K- Detach intake hose -1- from lock carrier.

- Detach air hose -2- from warm air baffle of

exhaust manifold.

- Detach intake hose -3- from intake connec-

tion of throttle valve control unit -arrow-.

- Remove air filter housing complete by un-

screwing bolts -4- and -5-.

- Detach earth strap from top bolt connecting

engine and gearbox.

------------ -------------  

S00.5129.50.20
 
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ProCarManuals.com

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Edition 04.99 ------------ -------------

S00.5129.50.20
 


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Edition 04.99 ------------ -------------

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Pay attention to power steering line when low-
ProCarManuals.com

ering engine/gearbox unit.

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------------ -------------  

S00.5129.50.20
 OCTAVIA

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ProCarManuals.com

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Edition 04.99 ------------ -------------

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Notes:
♦ Clean splines of input shaft and apply a thin


film of grease G 000 100.
♦ When replacing the gearbox, ensure the in-
termediate plate between engine and gear-
box is correctly positioned.
♦ Check whether dowel sleeves are present
ProCarManuals.com

in cylinder block for centering engine/gear-

box; insert if necessary.
♦ Install starter/cable:
⇒

♦ Set shift mechanism ⇒ page 34-12.

♦ When re-connecting the battery, check the
vehicle equipment:
- Encode radio
- Re-set clock
- Initialise power windows
⇒

  

K to

  

------------ -------------  

S00.5129.50.20
 



OCTAVIA Shift Mechanism/Housing 34

K Supporting bracket and mounting bracket at top

of gearbox

Bolt -A- for mounting bracket and guide

bush (speedo) to gearbox 20 Nm


Bolt -B- and -C- 20 Nm

K Mounting bracket to bottom of gearbox

Bolt -A- 20 Nm
Bolt -B- for attaching shift lever -C- to shift
shaft 1) 20 Nm
ProCarManuals.com

1) Apply Loctite 648 locking fluid before install-

ing.

ightening

Supporting angle bracket - gearbox 25 Nm

PAS M8
Cover for gearbox housing - gearbox 80 Nm
mount1) M12
Pendulum support - gearbox1) M10 40 Nm + 90°
Pendulum support - subframe1) M8 20 Nm + 90°
Drive shaft - flange shaft1) (tighten
diagonally across in 2 stages) M8
⇒ Running Gear, Repair Group 40
Steering joint - track control arm 1) M8 20 Nm + 90°
Coupling rod - track control arm 45 Nm
Starter - gearbox M8 25 Nm
Wheel bolts - wheel hub 120 Nm
Nut for attaching double 40 Nm
clamp/exhaust system

1) Always replace these bolts.

Edition 09.00 ------------ -------------

S00.5129.51.20









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Specification of gearbox oil ⇒ page 00-2

K-
Turn steering to full left lock.

Unscrew plug for inspecting gearbox oil (ar-

row).

The oil is at the correct level if the gearbox is

OCTAVIA

filled up to the lower edge of the oil filler hole.

- Screw in plug (arrow) with new seal, 35 Nm.

   


- Unscrew plug (arrow).

- Pour in gearbox oil up to lower edge of filler

hole.
ProCarManuals.com

- Screw in plug (arrow).

- Start engine, engage a gear and allow gear-

box to rotate for about 2 minutes.

- Switch off engine and unscrew plug (arrow).

- Once again pour in gearbox oil up to lower

edge of filler hole.

- Screw in plug (arrow) with new seal, 35 Nm.

------------ -------------  

S00.5129.50.20
 

OCTAVIA

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Shift Mechanism/Housing 34


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Edition 04.99 ------------ -------------

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♦ Removing and installing ⇒ from page
34-28


♦ For input shaft
ProCarManuals.com

♦ Always replace
♦ Pay attention to removal and installa-
tion sequence for slackening and tight-
ening the nut ⇒ from page 34-28

Notes: 
♦ Installation position ⇒ page 34-33
♦ The gearbox must be lowered with the sup-
porting device MP 9-200 in order to be able   
to remove and install the cover of the gear- ♦ Servicing ⇒ page 34-35
box housing.
♦ If the cover of the gearbox housing is fitted +
on with the gearbox installed, top up gear oil ♦ Installation position: oil pockets -ar-
and check oil level ⇒ page 34-22. row- point toward 5th gear synchro-
nizer body

♦ 4 total -

  

 
♦ Replace

 ♦ Prevents locking pieces from moving
out

♦ 5 in total  6 
♦ Installation position: the higher outer
+ diameter points toward the cover for
gearbox housing


♦ For output shaft
♦ Always replace
♦ Pay attention to removal and installa-
tion sequence for slackening and tight-
ening the nut ⇒ from page 34-28

------------ -------------  

S00.5129.50.20
 

OCTAVIA
 
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Shift Mechanism/Housing

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shaft 5
♦ Removing and installing ♦
⇒ page sealant
♦ ⇒ page

♦ 6
♦ Removing and installing ♦
⇒ page sealant

3 7 housing
♦ ♦ ⇒ page

4
♦ magnet

Edition 04.99 ------------ -------------

S00.5129.50.20

     OCTAVIA





 





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♦ 13 in total


 ♦ Disassembling and assembling
⇒ page 35-1
  
♦ Disassembling and assembling 
⇒ page 35-5

   
+  
♦ Disassembling and assembling ♦ Installation position of roll pin in re-
⇒ page 34-44 verse idler gear shaft ⇒ Fig. 1

------------ -------------  

S00.5129.50.20
 
OCTAVIA

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♦ 2 in total

housing
♦ Servicing ⇒ page 34-37

♦ Disassembling and assembling

⇒ page 39-5
Shift Mechanism/Housing

4 M
M
34


K Fig. of in
shaft

- Use extractor MP 3-508 to knock roll pin -3-

into reverse idler gear shaft -1- to maintain
dimension -a- = 6 mm.
ProCarManuals.com

2 - Reverse idler gear

Edition 04.99 ------------ -------------

S00.5129.50.20
 



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♦ Universal tool MP 3-419

♦ Adapter MP 3-419/40

♦ Gearbox holder MP 3-501

♦ Extractor for roll pin MP 3-509

♦ Cross-cut chisel MP 3-533


♦ Special tool for securing nut MP 3-605

♦ Repair stand MP 9-101

♦ Sealant, e.g. THREE BOND 1104

ProCarManuals.com

♦ Sealant, e.g. THREE BOND 1305

♦ Sealant, e.g. THREE BOND 1324

- Drain gear oil.

K- Attach gearbox to repair stand (arrows).

- Remove clutch release lever, release bear-

ing and guide sleeve ⇒ page 30-9.

------------ -------------  

S00.5129.50.20
  


 

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OCTAVIA Shift Mechanism/Housing 34

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------------ -------------  

S00.5129.50.20
 
   



   
 
 

OCTAVIA Shift Mechanism/Housing 34

K- Remove
move


ProCarManuals.com

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When inserting the locking bolt, ensure that the
sleeve of the shift finger is not at the level of the
hole. If this is the case, raise sleeve of shift fin-
ger slightly in order to avoid damage to the
thread.

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ProCarManuals.com

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Edition 04.99 ------------ -------------

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ProCarManuals.com

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♦
♦ Universal tool MP 3-419 ♦ ⇒ 39-13

♦ MP S
♦
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♦ ♦ sealant

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♦ ⇒ 1 ♦ ⇒ 39-1

♦ sealant

Edition 04.99 ------------ -------------

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------------ -------------  

S00.5129.50.20
 OCTAVIA

Servicing  housing

Shift Mechanism/Housing 34

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Edition 04.99 ------------ -------------

S00.5129.50.20

     OCTAVIA

























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ProCarManuals.com


 
♦ Apply THREE BOND 1324 sealant ♦ Apply THREE BOND 1305 sealant
before installing before installing

    
♦ Removing and installing ⇒ Fig. 1



  

♦ For reverse gear lever 

   
♦ 4 x 25 mm
♦ Use extractor for locking pin ∅ 4 mm
MP 3-508 for installing

------------ -------------  

S00.5129.50.20
 

 
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♦ Removing and installing ♦ Can be replaced with gearbox in-


⇒ page 35-7, item 32 stalled
♦ Installation position ⇒ Fig. 2 ♦ Use screwdriver to lever out



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♦ Removing and installing ♦ For removing, knock roll pins -item 33-
⇒ page 35-1, item 9 and -item 34- down and out
♦ Installation position ⇒ Fig. 2 ♦ For installing, knock in roll pins from
above
housing
33
tube ♦ 5 x 22 mm
♦ Use pliers for removing ♦ Installation position ⇒ Fig. 8
♦ Use drift to knock in as far as stop
34
♦ 3 x 22 mm
♦ For gearbox breather ♦ Installation position ⇒ Fig. 8

3
♦ Removing ⇒ Fig. 3 ♦ Apply THREE BOND 1305 sealant
♦ Installing ⇒ Fig. 4 before installing
♦ Removing and installing ⇒ Fig. 9
ProCarManuals.com

9
3 Magnet
0 ♦ Is held by the contact surface of the
♦ Apply THREE BOND 1324 sealant housing
before installing
3 uide gate
S
3
S
39
S
♦ For right flange shaft 40 of t
♦ Replacing ⇒ page 39-1 ♦ For differential
♦ Removing and inserting ⇒ from page
4 39-5
♦ If replaced: set differential
⇒ page 39-12

bush 4
♦ Setting position of shift lever
⇒ Fig. 10
♦ Always replace
4
♦ Apply Loctite 648 before installing
♦ For speedometer
43
9 bush
♦ For shift shaft 44
♦ Removing ⇒ Fig. 5 ♦ Removing ⇒ Fig. 11
♦ Inserting ⇒ Fig. 6 ♦ Inserting ⇒ Fig. 12

Edition 04.99 ------------ -------------

S00.5129.50.20
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ProCarManuals.com

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------------ -------------  

S00.5129.50.20
 OCTAVIA


 



Shift Mechanism/Housing

 
 


 

 34

  




K 4 seal input shaft
not as as

The seal is in its correct installation position once

the guide sleeve has been installed.

K shift
shaft
A - Internal extractor 14 ... 19 mm, e.g. Kukko
21/2
ProCarManuals.com

K shift

Use special tool MP 3-606 as this at the same

time prevents the bearing bush from wandering
out.

Edition 04.99 ------------ -------------

S00.5129.50.20
 
 
 
 
 

 





 




 

 


     OCTAVIA

K  

K 


Both roll pins -A- and -B- fit into one another.
Both slots must be opposite and be facing lon-
gitudinally to the power flow -arrow-.
ProCarManuals.com

K  

- Connect wrench for threaded bush T30009

to threaded bush in clutch housing.

- Turn out threaded bush.

- Connect threaded bush to wrench for

threaded bush T30009.

- Coat the outer thread of the threaded bush

with THREE BOND 1305 sealant.

- Turn threaded bush into the clutch housing

and tighten to the specified torque.

------------ -------------  

S00.5129.50.20
 OCTAVIA


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ProCarManuals.com

K bush shift

Edition 04.99 ------------ -------------

S00.5129.50.20
 



 

 
 


 


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♦ Extractor for locking pin MP 3-509

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♦ 5 x 22 mm
♦ Use extractor for locking pin 5 mm
MP 3-509 for removing





------------ -------------  

S00.5129.50.20
 OCTAVIA Gears/Shafts 35

Disassembling and assembling input shaft

Note:

        
  ⇒

1 - Nut, 60 Nm
♦ Always replace
♦ Pay attention to removal and installa-
tion sequence for slackening and tight-
ening the nut ⇒ page 34-28

2 - 5th speed gearwheel

♦ Removing and installing ⇒ from page
34-28

3 - Gearbox housing


4 - Grooved ball bearing
♦ Pressing off ⇒ Fig. 1
♦ Pressing on ⇒ Fig. 2

5 - 4th speed gearwheel

ProCarManuals.com

♦ Pressing off ⇒ Fig. 3

♦ Pressing on ⇒ Fig. 6
♦ Collar points toward 3rd gear

Special tools, testers and aids required 6 - Spacer sleeve

♦ Pressure plate MP 3-406 7 - 3rd speed gearwheel

♦ Pressing off ⇒ Fig. 4
♦ Pressure plate MP 3-407 ♦ Pressing on ⇒ Fig. 5
♦ Collar points toward 4th gear
♦ Thrust piece MP 3-411
8 - Input shaft
♦ Plunger MP 3-448
9 - Cylinder roller bearing
♦ Tube section MP 3-450 ♦ Removing ⇒ Fig. 7
♦ Inserting ⇒ Fig. 8
♦ Tube section MP 3-451 ♦ Installation position: designation on
bearing points up ⇒ page 34-40,
♦ Thrust washer MP 3-4014 Fig. 2

♦ Separating device Kukko 17/1 10 - Clutch housing

♦ Separating device Kukko 17/2 11 - Washer

♦ Workshop press, e.g. V.A.G 1290 A 12 - 10 Nm

Edition 04.99 ------------ -------------

S00.5129.50.20



 
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ProCarManuals.com

K 4th s to
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------------ -------------  

S00.5129.50.20
 OCTAVIA


Disassembling and assembling   Gears/Shafts

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t testers and aids Notes:

♦
       
♦ Thrust piece MP 3-411
 
♦ Adapter for setting tool (of MP 9-501) MP
⇒
3-507 ♦    
   
♦ Insertion drift for roller bearing MP 3-513
♦       
 
♦ Puller MP 3-520

♦ Setting tool MP 9-501

Edition 04.99 ------------ -------------

S00.5129.50.20

    OCTAVIA






 

 
ProCarManuals.com

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♦ Always replace ♦ Removing and installing ⇒ from page
♦ Pay attention to removal and installa- 34-28
tion sequence for slackening and tight- ♦ Disassembling and assembling slid-
ening the nut ⇒ page 34-28 ing sleeve and synchronizer body
⇒ Fig. 3 and Fig. 4
  
♦ Installation position: the higher outer %& '(%  "
diameter points toward cover for gear- ♦ Removing and installing ⇒ from page
box housing 34-28
♦ Disassembling and assembling slid-

ing sleeve and synchronizer body
⇒ Fig. 3 and Fig. 4
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♦ Installation position ⇒ Fig. 4

------------ -------------  

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4 Washer
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ProCarManuals.com

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S 34 Washer

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♦ ⇒

Edition 04.99 ------------ -------------

S00.5129.50.20
 
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ProCarManuals.com

K
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K n sta a tion of s
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ProCarManuals.com

Edition 04.99 ------------ -------------

S00.5129.50.20
ProCarManuals.com
 
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♦ Universal tool MP 3-419

♦ Additional part MP

♦ Adapter MP

♦ tool seal MP

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tions ⇒ p

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K- -A- and separate
ProCarManuals.com

K- - 1-

  ------------ -------------

S00.5129.50.20



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ProCarManuals.com

Note:
Push brake hose at brake caliper to the side
when pulling out flange shaft.

     

K-

- -

------------ ------------- 

S00.5129.50.20
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ProCarManuals.com

K-

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  ------------ -------------

S00.5129.50.20
 39 Final Drive/Differential OCTAVIA

K- Clamp flange shaft in a vice using protective

jaws. Press circlip out of groove of flange
shaft with new circlip -A-.

- Use plastic-headed hammer to knock in flan-

ge shaft.

- Bolt left drive shaft or right drive shaft, re-

spectively, to flange shaft.

- Further installation is carried out in the re-

verse order.

- Inspect gear oil level; top up to lower edge

of filler hole if necessary ⇒ page 34-22.

Tightening torques

Component Tightening
torque

Drive shaft - flange shaft1) (tighten

diagonally across in 2 stages) M8
⇒ Running Gear, Repair Group 40
ProCarManuals.com

Steering joint - track control arm 1) M8 20 Nm + 90°

Coupling rod - track control arm 45 Nm
Pendulum support - subframe1) M8 20 Nm + 90°
Wheel bolts - wheel hub 120 Nm
Nut for attaching double 40 Nm
clamp/exhaust system

1) Always replace these bolts.

------------ 39-4 ------------- Edition 09.00

S00.5129.51.20
 

OCTAVIA








  
   







ProCarManuals.com

 ♦ Tube section MP 3-4013

♦ Counterholder MP 1-223 ♦ Two-legged puller Kukko 20/10

♦ Pressure plate MP 3-407 ♦ Extraction hook Matra V/170

♦ Thrust piece MP 3-431 ♦ Internal extractor Kukko 21/7

♦ Tube section MP 3-450 ♦ Countersupport Kukko 22/2

♦ Insertion drift MP 3-511

  ------------ -------------

S00.5129.50.20

     OCTAVIA





 



















ProCarManuals.com

Notes: 
♦ For differential
♦ Heat inner race of taper roller bearing to
♦ Determining thickness ⇒ page 39-13
100 °C before installing.
♦ Always replace both taper roller bearings.

♦ Removing ⇒ Fig. 1
♦ If taper roller bearings, differential housing,
♦ Inserting ⇒ Fig. 2
gearbox housing and clutch housing are re-
placed, set differential ⇒ page 39-12.
 %  # $   
♦ Pulling off ⇒ Fig. 3
♦ Pressing on ⇒ Fig. 4

&  

------------ ------------- 

S00.5129.50.20
 





 














 


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OCTAVIA
     
%
♦ Fit on to differential housing before ♦ Insert with gear oil
pressing on inner race
%+    
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♦ Pulling off ⇒ Fig. 3
♦ Pressing on ⇒ Fig. 4 % &
♦ Installing ⇒ Fig. 10
   
♦ Removing ⇒ Fig. 5 %
♦ Pressing in ⇒ Fig. 6 ♦ Replace

 % 
♦ Shaft has different diameters, face
% &  end with centering hole -arrow- indi-
♦ Replacing ⇒ from page 39-1 cates smaller diameter
♦ Removing ⇒ Fig. 9
%% ♦ Inserting ⇒ Fig. 10
♦ Removing and installing ⇒ from page
39-1 % -
♦ Is matched with output shaft; always
%' replace together


♦ For flange shaft
♦ Pulling off ⇒ Fig. 7 '    
♦ Pressing on ⇒ Fig. 8 ♦ Bolted to gearwheel for final drive

% '% .
ProCarManuals.com

♦ Always replace

K   

A - Countersupport, e.g. Kukko 22/2

B - Internal extractor 46...58 mm, e.g. Kukko
21/7

  ------------ -------------

S00.5129.50.20
 
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No shim is installed on the clutch housing side.

K   

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------------ ------------- 

S00.5129.50.20
 OCTAVIA
 

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  ------------ -------------

S00.5129.50.20



 

   



♦ End gauge MP 3-405/17

♦ Pressure plate MP 3-407

♦ Tube section MP 3-450


  

♦ Universal dial gauge holder MP 3-447

♦ Insertion drift MP 3-511

♦ Internal extractor Kukko 21/7

♦ Countersupport Kukko 22/2

♦ Dial gauge

It is necessary to re-set the differential if

OCTAVIA


♦ gearbox housing

♦ clutch housing

♦ differential housing
ProCarManuals.com

or the

♦ taper roller bearings of the differential

are replaced.

Notes:
♦ New taper roller bearings for the differential
have a low friction. For this reason, the fric-
tion torque can only be used as a means of
inspection to a limited extent. It is only pos-
sible to correctly set the bearing preload by
determining the thickness of the shim.
♦ The inner and outer races of taper roller bear-
ings are matched. Do not mix up.

K- Use tube section MP 3-450 to support clutch

housing directly below bearing mount.

- Use insertion drift MP 3-511 to press outer

race of taper roller bearing into clutch hous-
ing.

Note:
No shim is fitted on the side of the clutch hous-
ing.

------------ ------------- 

S00.5129.50.20
 


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K-

-
ProCarManuals.com

Note:
When carrying out the measurement, do not
rotate the differential otherwise the bearings will
settle and the result of the measurement will be
falsified.

  ------------ -------------

S00.5129.50.20
 
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ProCarManuals.com

------------ ------------- 

S00.5129.50.20