skoda octavia mk1 - 06 - power transmission gearbox 02k
TRANSCRIPT
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SKODA OCTAVIAMK1
Power transmission5 speed Manual gearbox !K
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POWER TRANSMISSION.....................................................................................................4
5 SPEED MANUAL GEARBOX 02K........................................................................................4
TECHNICAL DATA.............................................................................................................. 4
ID"#TI$ICATIO# O$ T%" &"A'(O)******************************************************************************************************************+
Location on the gearbox up to 06.99.................................................................................................4Location on the gearbox as of 07.99.................................................................................................6
Identication characters, aggregate assignment, ratios, capacities..................................................7
OV"'VI", O$ T'A#SMISSIO# S -ST"M**********************************************************************************************************11
&"#"'A. '"PAI' I#$O'MATIO#*******************************************************************************************************************1/
CLUTCH, CONTROL..........................................................................................................18
'"PAI'I#& C.0TC% CO#T'O.**********************************************************************************************************************1
Overvie......................................................................................................................................... !"
#ummar$ of components % &oot contro's.........................................................................................!9
(emoving and insta''ing the over%centre he'per spring...................................................................))
(emoving and insta''ing the c'utch peda'........................................................................................)*
(emoving and insta''ing c'utch peda' sitch %&*6%..........................................................................)4
'emo2ing and installing t3e 4lut43 pedal swit43 $/6 7angular 3ousing8*****************************************************!+
'emo2ing and installing t3e 4lut43 pedal swit43 $/6 7round 3ousing8******************************************************* !5
#ummar$ of components % +$drau'ics.............................................................................................)
-hec h$drau'ic c'utch contro'........................................................................................................)"
(emoving and insta''ing the master c$'inder..................................................................................*0
(emoving and insta''ing the s'ave c$'inder.....................................................................................*4
/'eeding the c'utch s$stem.............................................................................................................*
'"PAI'I#& C.0TC%***********************************************************************************************************************************/9
&au't nding poer transmission % prob'ems ith the c'utch and c'utch contro'.............................*7
#ummar$ of components % repairing the c'utch...............................................................................4)
(emoving and insta''ing c'utch.......................................................................................................44
GEARBOX MECHANICS,OPERATION, CONSTRUCTION,DIFF..................................................48
'"PAI'I#& T%" &"A'S%I$T M"C%A#ISM********************************************************************************************************+
&itting 'ocation of shift mechanism..................................................................................................4"
#ummar$ of components % shift housing shift 'ever......................................................................0
(emoving and insta''ing shift housing ith shift 'ever and shift rod................................................*
(emoving and insta''ing shift 'ever from shift housing....................................................................7
#ummar$ of components % reverse%shift mechanism at the gearbox.............................................."
#etting the shift mechanism............................................................................................................6*
'"MOVI#& A#D I#STA..I#& T%" &"A'(O)****************************************************************************************************6
(emoving the gearbox.................................................................................................................... 6" Transporting t3e gearbox***************************************************************************************************************************** 99
Insta''ing the gearbox...................................................................................................................... 7"
Tig3tening tor:ues*************************************************************************************************************************************** 9;
I#SP"CT &"A' OI.************************************************************************************************************************************ +
DISASS"M(.I#& A#D ASS"M(.I#& T%" &"A'(O)********************************************************************************************6
1earbox overvie........................................................................................................................... "6
#ummar$ of components % disassemb'ing and assemb'ing the gearbox........................................."7
#ummar$ of components % (emoving and insta''ing gearbox housing cover and th gear.............""
#ummar$ of components % removing and insta''ing gearbox housing and shift mechanism...........90
#ummar$ of components % (emoving and insta''ing the drive shaft, output shaft, di2erentia' gear
and shift fors................................................................................................................................. 94
3ounting seuence % disassemb'ing and assemb'ing the gearbox..................................................9"
Disassembling gearbox******************************************************************************************************************************** ;
Assembling gearbox*********************************************************************************************************************************** 11
(epairing gearbox housing and gearshift shaft.............................................................................!))
!
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(epairing c'utch housing...............................................................................................................!)7
(epairing gearbox housing cover..................................................................................................!*4
DISASS"M(.I#& A#D ASS"M(.I#& T%" D'IV" S%A$T*************************************************************************************1/;
5isassemb'ing and assemb'ing the drive shaft.............................................................................!*9
O0TP0T S%A$T************************************************************************************************************************************** 15
5isassemb'ing and assemb'ing the output shaft...........................................................................!0
#etting output shaft...................................................................................................................... !"
FINAL DRIVE, DIFFERENTIAL, DIFFERENTIAL LOCK..........................................................12
'"P.ACI#& T%" $.A#&" S%A$T &ASK"T 'I#&S 7&"A'(O) ASS"M(."D8*************************************************************16!
(ep'acing the 'eft ange shaft gaset ring....................................................................................!6)
'emo2ing*************************************************************************************************************************************************** 16!
Install********************************************************************************************************************************************************* 16/
(ep'acing the right ange shaft sea' ring......................................................................................!6*
'emo2ing*************************************************************************************************************************************************** 16+
Install********************************************************************************************************************************************************* 16+
DI$$"'"#TIA. &"A'******************************************************************************************************************************* 166
5isassemb'ing and assemb'ing the di2erentia' gear.....................................................................!66
d8usting the di2erentia' gear....................................................................................................... !7
S"TTI#& OV"'VI",******************************************************************************************************************************** 1
/
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Power transmission
5 speed Manual gearbox !K
Te43ni4al Data
Identi C3apter*
.o4ation on t3e gearbox as o= 9*;;
Identi
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Identification characters and manufacturing data
of the gearbox on the bottom of the clutch
housing -arrow 1-
Gearbox 02K -arrow 2-
Identification characters and manufacturing data
of the gearbox -arrow 1-
Example: C! 2" 0# $
I I I I
I I I I
Identification characters !a% &onth &anufacturing %ear -1''$-
(dditional data depend on the manufacturing)
*ote
+he gearbox identification characters also appear on the ,ehicle data sticers)
5
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Gearbox 02K -arrow 2-
.o4ation on t3e gearbox as o= 9*;;
Identification characters and manufacturing data
of the gearbox on the top of the clutch housing
-arrow 1-
Gearbox 02K -arrow 2-
Identification characters and manufacturing data
of the gearbox -arrow 1-
6
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Example: !.. 1/ 0' '
I I I I
I I I I
Identification characters !a% &onth &anufacturing %ear 1'''
(dditional data depend on the manufacturing)
*ote
+he gearbox identification characters also appear on the ,ehicle data sticers)
Gearbox 02K -arrow 2-
Identi
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Clut43 4ontrol 3Edrauli4
Clut43 dis4 diameter F > "le4troni4 Catalogue o= Original Parts
Dri2e s3a=t Gange F ; mm
Identi "le4troni4 Catalogue o= Original Parts
Dri2e s3a=t Gange F ; mm
Identi
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+t3 gear /! /1 1?/! /1 /! ?;6; /! /1 1?/!
5t3 gear /+ + ?5 // +1 ?5 /+ + ?5
'e2erse gear / 1! /?169
Speedometer !?1+
Capa4itE 1*; litres
Spe4i "le4troni4 Catalogue o= Original Parts
&ear oil 43ange inter2al $illed =or li=e
Clut43 4ontrol 3Edrauli4
Clut43 dis4 diameter F > "le4troni4 Catalogue o= Original Parts
Dri2e s3a=t Gange F ; mm
Identi
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1
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O2er2iew o= Transmission SEstem
!esignation
*ote
-(rrows- in direction of tra,el
1 - Engine
2 - Clutch
- &anual gearbox
/ - !ri,e shaft
3 - 4utput shaft
$ - !ifferential gear
-(rrows- in direction of tra,el
11
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I - 1st gear
II - 2nd gear
III - rd gear
I5 - /th gear
5 - 3th gear
6 - 6e,erse gear
( - 7inal dri,e
+ - 8peedometer dri,e
&eneral repair in=ormation
To 4arrE out gearbox repairs su44ess=ullE and 4orre4tlE? s4rupulous 4are and 4leanliness? as
well as t3e proper tools? are essential re:uirements* Ob2iouslE? t3e generallE 2alid basi4sa=etE rules applE to repair wor*
A number o= generallE 2alid notes =or indi2idual repair operations w3i43 are ot3erwise listed
1!
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se2eral times at numerous points in t3e wors3op manual are summariHed 3ere*
&earbox
t,3en installing? ensure t3e dowel slee2es are 4orre4tlE lo4ated between t3e engine and
gearbox*
t ,3en repla4ing t3e gearbox 43e4 t3e oil le2el and i= ne4essarE top up> C3apter*
t $illing 4apa4itE > C3apter*
t Spe4i ele4troni4 4atalogue o= original parts*
Orings? gaset rings? gasets? sealant
On gearboxes wit3 paper gasets
t 'epla4e paper gasets*
On gearboxes wit3 sealants
T3oroug3lE 4lean t3e 3ousing 4onta4t sur=a4es be=ore applEing t3e sealant*
ApplE sealant AMV 1 ! / e2enlE and not too t3i4lE*
AlwaEs repla4e Orings? gaset rings and gasets*
A=ter remo2ing gasets? 43e4 t3e 4onta4t sur=a4e on t3e 3ousing or s3a=t =or burrs or
damage w3i43 o44ured during t3e disassemblE*
.ig3tlE oil radial s3a=t seals at outside
diameter be=ore mounting and C3apter*
Cir4lips and tensioning slee2es
Do not o2ertension t3e 4ir4lips*
AlwaEs repla4e damaged or o2ertensioned4ir4lips*
Cir4lips must be positioned in t3e base o=
1/
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43152http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44400http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45648http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56096http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43152http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44400http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45648http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56096
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t3e groo2e*
'epla4e roll pins* $itting position Slot A
longitudinal to power Gow arrow*
S4rews? nuts
t Sla4en t3e bolts and nuts against t3etig3tening se:uen4e*
t
Sla4en and tig3ten nuts and bolts =or
atta43ing 4o2ers and 3ousings wit3out
tig3tening se:uen4e diagonallE a4ross in
stages*
t
Do not twist parti4ularlE sensiti2e parts
e*g* 4lut43 pressure plates and sla4en
and tig3ten diagonallE a4ross in stages*
t Tig3tening tor:ues applE =or nonoiled
nuts and bolts*
tAlwaEs repla4e t3e sel=lo4ing nuts and
s4rews*
t
Clean t3e t3read o= t3e s4rews t3at are
inserted wit3 a lo4ing agent wit3 a wire
brus3* Insert bolts wit3 lo4ing agent
AMV 15 11 A1*
t T3e t3readed 3oles into w3i43 sel=lo4ing
s4rews or s4rews wit3 lo4ing agent were
s4rewed in 7e*g* wit3 a s4rewtap8 must
1+
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be 4leaned* Ot3erwise t3ere is a ris t3at
t3e s4rews will s3ear at t3e next
disassemblE*
(earings
tPosition needle bearing wit3 t3e lettered
side 7t3i4er end8 towards t3e dri=t pin*
t$it all bearings to t3e gearbox wit3 some
gearbox Guid*
t
ointlE repla4e taperedroller bearings on
t3e same s3a=t and use produ4ts o= t3e
same manu=a4turer*
t
(e=ore installing? 3eat t3e inner rings o=
t3e taperedroller bearings on a 3eating
plate or wit3 t3e indu4tion 3eater unit?
e*g* VAS 6+1+? to approx* 1JC* ,3enassembling? press up to t3e stop until
t3ere is no axial plaE*
t
Do not ex43ange t3e outer and inner
rings o= bearings o= t3e same siHe
bearings go in pairs*
S3ims
t
&auge s3ims at se2eral points wit3 a
mi4rometer* Dierent toleran4es allow tomeasure t3e re:uired t3i4ness =or ea43
was3er 2erE pre4iselE*
t Inspe4t =or burrs and damage*
tInstall onlE s3ims w3i43 are in per=e4t
4ondition*
SEn43roniHer rings
t
T3ese are not inter43angeable* I= re
using? allo4ate sEn43roniHer rings to t3e
same gear*
tInspe4t =or wear? repla4e i= ne4essarE
> "le4troni4 Catalogue o= Original Parts*
t Insert wit3 some gearbox Guid*
&ear pinions and sEn43roniHer bodE
t
Clean and 3eat on a 3eating plate or wit3
t3e indu4tion 3eater unit e*g* VAS 6+1+to approx* 1JC be=ore pressing on*
t ,3en assembling? press up to t3e stop
15
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp72160http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp72160
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until t3ere is no axial plaE*
t C3e4 C3apter8*
t
In order to redu4e unpleasant odours i=
t3e 4lut43 is burnt? t3oroug3lE 4lean t3e
4lut43 3ousing as well as t3e GEw3eel and
t3e engine on t3e side o= t3e gearbox*
16
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp78768http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp78768
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Clut43? 4ontrol
'epairing 4lut43 4ontrol
O2er2iew
#ote
tI= t3e master or sla2e 4Elinder s3ould be repla4ed due to a suspe4ted de=e4t? C3apter*
tI= t3e batterE eart3 strap is dis4onne4ted and 4onne4ted? 4arrE out additional operations
> "le4tri4al SEstem > 'ep* &r*!9*
t On models (odE
,or > 'ep* &r*9*
I SummarE o= 4omponents $oot 4ontrols > C3apter
19
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38096http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39456http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp39840http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp42528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44432http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38096http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39456http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp39840http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp42528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44432
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II SummarE o= 4omponents %Edrauli4s > C3apter
SummarE o= 4omponents $oot 4ontrols
1 (ul3ead
: wit3 mount =or bra4et and master 4Elinder
! &aset
: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
/ (ra4et
: =or support o= 4lut43 pedal
+ S4rew
1
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45936http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp38864http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45936http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp38864
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5 (ra4et
: =or support o= a44elerator pedal and brae pedal
6 !5 #m
: sel=lo4ing
: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
9 Conne4ting plate
!5 #m
: sel=lo4ing
: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
; (us3ing
1 (earing bolt
11 Clut43 pedal
: remo2ing and installing > C3apter
1! Support
: remo2ing and installing > C3apter
1/ !5 #m
: sel=lo4ing
: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
1+ Master 4Elinder
: remo2ing and installing > C3apter
15 Tubing
16 O2er4entre 3elper spring
: remo2ing and installing > C3apter
19 (earingBo2er3elper 4entre spring
: insert in bra4et
: to repla4e? remo2e and install t3e master 4Elinder > C3apter
1 Clut43 pedal swit43 $/6
: remo2ing and installing > C3apter
1; .imit stop Eoe
: =or t3e 4lut43 pedal
: $itting position > C3apter
1;
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp41808http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43472http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45264http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46768http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp48528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49552http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp51440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp53200http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55216http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56976http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp41808http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43472http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45264http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46768http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp48528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49552http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp51440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp53200http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55216http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56976
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! !5 #m
: sel=lo4ing
: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
'emo2ing and installing t3e o2er4entre 3elper spring
Spe4ial tools and wors3op e:uipment re:uired
t AssemblE 4lamps //19
'emo2ing
'emo2e t3e bottom le=t storage area on t3e dri2erLs side > (odE ,or > 'ep* &r*9*
0sing t3e 4lut43 pedal stret43 t3e o2er
4entre 3elper spring and w3ile doing so
pus3 down t3e assemblE 4lamp //19
=rom abo2e*
#ote
T3e bore 3ole arrow points towards t3e
4lut43 pedal*
Position t3e 4lut43 pedal in 3ome position
and remo2e t3e o2er4entre 3elper spring
toget3er wit3 assemblE 4lamp //19
Install
Put t3e 4lut43 pedal in 3ome position*
$irst position t3e o2er4entre 3elper
spring in t3e o2er4entre 3elper spring
bearing (? t3en press t3e 4lut43 pedal
down until t3e 4entering pin o= t3e 4lut43
pedal A tou43es t3e o2er4entre 3elper
spring*
0sing t3e 4lut43 pedal stret43 t3e o2er
4entre 3elper spring? w3ile doing so
remo2e t3e assemblE 4lamp //19*
!
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp58736http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp39728http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp58736http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp39728
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'emo2ing and installing t3e 4lut43 pedal
'emo2ing
'emo2e t3e bottom le=t storage area on t3e dri2erLs side > (odE ,or > 'ep* &r*9*
'emo2e 4lut43 pedal swit43 $/6 7i= present8 > C3apter*
'emo2ing t3e o2er4entre 3elper spring > C3apter*
Separate t3e 4lut43 pedal =rom t3e master 4Elinder > C3apter*
0ns4rew t3e nut A and pull s4rew out o=
t3e bra4et*
'emo2e 4lut43 pedal*
Install
Installation is per=ormed in t3e re2erse
order? paE attention to t3e =ollowing points
T3e support A must
be lo4ated on t3e
a4tuating rod ( o=
t3e master 4Elinder*
Press t3e 4lut43
pedal until its lo4s
in dire4tion o=
arrow and mae
sure it 4at43es
4orre4tlE*
Installing t3e o2er
4entre 3elper spring
> C3apter*
I= present? install
4lut43 pedal swit43
$/6 > C3apter*
Tig3tening tor:ue
Component #m
!1
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp37952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp38336http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp40368http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp52272http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp37952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp38336http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp40368http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp52272
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Clut43 pedal to bra4et !518
18 AlwaEs repla4e nut > "le4troni4 Catalogue o= Original Parts
'emo2ing and installing 4lut43 pedal swit43 $/6
*ote
+he clutch pedal switch ma% onl% be installed once to ensure that it has an ade9uatel% tight fit)
'emo2ing and installing t3e 4lut43 pedal swit43 $/6 7angular 3ousing8
;ress down clutch pedal up to the stop b% hand)
+urn clutch pedal switch '0< to the left and
remo,e from its bracet=clutch pedal -arrows-)
;ress down clutch pedal up to the stop b%
hand)
Insert clutch pedal switch into the assembl%
opening)
+hen turn the switch '0< to the right for
securing)
;ut the clutch pedal in home position)
+he clutch pedal must be in end position)
'emo2ing and installing t3e 4lut43 pedal swit43 $/6 7round 3ousing8
+urn clutch pedal switch /3< to the left and remo,e from the bracet=clutch pedal)
;ull out the tappet -arrow- completel% before
assembl% of the clutch pedal switch)
Insert the switch with the catch pegs -1- and -2-
in the recesses pro,ided for it in the assembl%
opening and attach b% turning it /3< to the right)
l+he clutch pedal must be put into home position
do not depress)
l+he clutch pedal must not be operated when
installing it)
l
+he plunger is ad>usted automaticall% when
inserting the clutch pedal switch)
!!
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp67632http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp67632
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SummarE o= 4omponents %Edrauli4s
1 (rae Guid reser2oir
! Tubing
/ Master 4Elinder
: remo2ing and installing > C3apter
+ Support
onlE repla4e i= t3e master 4Elinder 3as been remo2ed
remo2ing > $ig*
installing > $ig*
5 Clut43 pedal
: remo2ing and installing > C3apter
6 !5 #m
: sel=lo4ing
!/
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38992http://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/clutch_control/repairing_clutch_control/summary_of_components_hydraulics/#xys-twe348roemhttp://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/clutch_control/repairing_clutch_control/summary_of_components_hydraulics/#xls-twedcroemhttp://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44096http://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/clutch_control/repairing_clutch_control/summary_of_components_hydraulics/#xys-twe348roemhttp://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/clutch_control/repairing_clutch_control/summary_of_components_hydraulics/#xls-twedcroemhttp://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38992http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44096
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: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
9 Support
: Mounted at t3e stru4ture
'elease s3a=t
: remo2ing and installing > C3apter
; Sla2e 4Elinder
: remo2ing and installing > C3apter
1 Collar s4rew? !5 #m
11 Support
: =or tube3ose line pos* 1!
1! Tube3ose line
: assign a44ording to > "le4troni4 Catalogue o= Original Parts
1/ Pipe 4onne4tionBplug 4onne4tion
1+ Dust 4ap
15 (leed 2al2e
: (leed t3e 4lut43 sEstem > C3apter
16 Oring
: pull onto line 4onne4tion
: insert wit3 brae Guid
19 Clamp
1 &earbox
!+
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp47520http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49024http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp51552http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp53344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp47520http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49024http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp51552http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp53344
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.i=t o t3e support A in t3e dire4tion o=
t3e arrow*
Pus3 t3e a4tuator rodBmaster 4Elinder in
t3e support A in dire4tion o= t3e arrow*
C3e4 3Edrauli4 4lut43 4ontrol
l T3e pedal a4tuation must not be obstru4ted bE mo2ed or additional =oot mats*
l (leed t3e 4lut43 sEstem i= ne4essarE > C3apter*
!5
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37600http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37600
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$irst o= all 43e4 t3e brae Guid le2el in
t3e brae Guid reser2oir*
#ote
t
T3e 4lut43 3Edrauli4 is 4onne4ted to one
o= t3e 43ambers arrow ! o= t3e braeGuid reser2oir bE t3e return 3ose arrow
1*
tI= t3ere is no or little brae Guid in t3is
43amber? t3ere is a lea in t3e sEstem*
Subse:uentlE 43e4 t3e =ollowing
4omponents o= t3e 3Edrauli4 4lut43
4ontrol =or external lea
t'eturn 3ose between brae Guid reser2oir
and master 4Elinder
t Master 4Elinder
t Tube3ose line between master and sla2e
4Elinder
tConne4tion points 7plug and s4rew
4onne4tions8 also in a non2isible area
t Sla2e 4Elinder
#ote
t
SEmptoms o= an external lea are?
amongst ot3ers? tra4es o= brae Guid on
or below t3e gearbox? as well as on t3e
noise insulation under t3e gearbox*
t
C3e4 t3e 4orre4t routing o= t3e tube
3ose line between t3e master and sla2e
4Elinder* T3e line must not be ined or
trapped*
Subse:uentlE depress t3e 4lut43 pedal
4are=ullE? at t3e same time 3old t3e pedal
in An43or* At t3esame time t3e
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w3ile being 3eld*
'emo2e t3e sla2e 4Elinder =rom t3e
gearbox last? do not open t3e linesEstem and 43e4 t3e 4ollar =or brae
Guid lea*
To t3is end tae o t3e 4ollar =rom t3e
tappet arrow*
'emo2ing and installing t3e master 4Elinder
Spe4ial tools and wors3op e:uipment re:uired
t %ose 4lamps up to !5 mm MP96! 7/;+8
t Pliers T15
'emo2ing
#ote
tI= t3e master 4Elinder must be repla4ed? C3apter*
t 0ns4rew t3e master 4Elinder =rom wit3in t3e passenger 4ompartment*
t
,3en per=orming t3e =ollowing wor? mae sure t3at no brae Guid 4omes into 4onta4t wit3
t3e =rame side rail or t3e gearbox* I= t3is is t3e 4ase? t3ese points must be 4leaned
t3oroug3lE*
'emo2e air "ngine > 'ep* &r*!/ or > "ngine > 'ep* &r*!+*
I= ne4essarE? remo2e A(S 4ontrol unit wit3 3Edrauli4 unit > C3assis > 'ep* &r*+5*
!9
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp40848http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43056http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp43440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp44208http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44592http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp46240http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp40848http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43056http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp43440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp44208http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44592http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp46240
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Dis4onne4t t3e return 3ose A to t3e
brae Guid reser2oir wit3 t3e 3ose 4lamp
MP96! 7/;+8 and deta43*
Pull 4lamp ( out o= t3e master 4Elinder*
'elease and 4ut o t3e tube3ose line C
=rom t3e master 4Elinder*
'emo2e t3e bottom le=t storage area on
t3e dri2erLs side > (odE ,or > 'ep*
&r*9*
'emo2e 4lut43 pedal swit43 $/6 7i=
present8 > C3apter*
#ote
To remo2e t3e master 4Elinder 4ompletelE
remo2e t3e 4lut43 4ontrol* (e=ore remo2ing
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0ns4rew nuts arrows 1 and remo2e
4onne4ting plate arrow A*
0ns4rew t3e nuts arrows ! and remo2e
t3e 4lut43 4ontrols arrow ( toget3er
wit3 t3e master 4Elinder*
Turn 4lut43 pedal stop A in dire4tion o=
arrow and remo2e*
!;
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T3en press t3e master 4Elinder up to t3e
stop in dire4tion o= arrow 1*
It must not be 4o2ered in t3e upper area
=rom t3e bearing =or o2er4entre 3elper
spring arrow !*
T3en swi2el t3e master 4Elinder in
dire4tion o= arrow / out o= t3e bra4et*
Install
Installation is per=ormed in t3e re2erse
order? paE attention to t3e =ollowing points
T3e support A must
be lo4ated on t3e
a4tuating rod ( o=
t3e master 4Elinder*
Press t3e 4lut43
pedal until its lo4s
in dire4tion o=
arrow and mae
sure it 4at43es
4orre4tlE*
/
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Pull t3e tube3ose line out o= t3e 3older
on t3e sla2e 4Elinder*
Subse:uentlE release t3e s4rews arrows
and remo2e t3e sla2e 4Elinder =rom t3e
release s3a=t o= t3e gearbox*
Pin43 o t3e tube3ose line to t3e sla2e
4Elinder wit3 t3e 3ose 4lamp MP96!7/;+8*
Pull out t3e 4lamp > Item and
subse:uentlE t3e tube3ose line =rom t3e
sla2e 4Elinder* Close t3e line*
Install
Installation is per=ormed in t3e re2erse
order? paE attention to t3e =ollowing points
Press t3e 4lamp > Item into t3e sla2e
4Elinder up to t3e stop*
Pus3 t3e tube3ose line into t3e sla2e
4Elinder until it 4an be 3eard to engage*
&rease tappet end wit3 grease =or plug
serration o= 4lut43 dis4 & 1*
Insert t3e sla2e 4Elinder in t3e release
s3a=t and s4rew it onto t3e gearbox*
A=ter installing t3e sla2e 4Elinder bleed
t3e 4lut43 sEstem > C3apter*
Install noise insulation below
engineBgearbox*
Tig3tening tor:ue
Sla2e 4Elinder to gearbox !5 #m
(leeding t3e 4lut43 sEstemSpe4ial tools and wors3op e:uipment re:uired
#ote
t ,3en per=orming t3e =ollowing wor? mae sure no brae Guid 4omes into 4onta4t wit3 t3e
/!
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp42928http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45360http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49264http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp42928http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45360http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49264
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gearbox*
t $irst open t3e bleeder 2al2e be=ore swit43ing on t3e bleeding de2i4e*
t A pre
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'epairing 4lut43
$ault C3apter*
(e=ore ea43 4lut43 repair? examine and re4onstru4t t3e 4omplaint o= t3e 4ustomer* In ea43
indi2idual 4ase? it must be determined i= indeed t3ere are problems wit3 t3e 4lut43 or t3e
in4orre4t setting o= t3e gears3i=t is 4ause =or 4omplaint*
$ault $ault tEpe Measure
Clut43 pedal does not
return to initial
position*
t Air in line sEstem*
Vent air =rom t3e line sEstemQ top up
wit3 brae Guid*
t
.ine sEstem? master
4Elinder or sla2e 4Elinder
leaing*
'epla4e de=e4ti2e 4omponent? 2ent air
=rom t3e line sEstemQ top up wit3 brae
Guid*
t
Membrane spring o= t3e
pressure plate broen*
'epla4e pressure plate*
$ault $ault tEpe Measure
A4tuating =or4e
on t3e 4lut43
pedal too 3ig3*
tO2er4entre 3elper
spring de=e4ti2e*
'epla4e o2er4entre 3elper spring*
t
Clut43 release =or4e
in4reased due to
wear o= 4lut43
linings*
In=orm 4ustomer 73ig3er release =or4e wit3
in4reased wear8*
'epla4e 4lut43 dis4? w3en t3e distan4e baseBri2et is
below *1 mm*
t
Pressure plate wit3
wrong spring
identi "le4troni4
Catalogue o= Original Parts*
t
Me43ani4al =ault at
t3e pressure plate or
t3e 4lut43 dis4*
'epla4e de=e4ti2e parts*
t
Clut43 dis4 on t3e
serrationsluggis3BRams*
C3e4 serration o= t3e 3ub =or damage 7burrs8*
'epla4e t3e 4lut43 dis4 i= ne4essarE*
Clean t3e 3ub and t3e dri2e s3a=t serration =rom
4orrosion and residues o= lubri4ant and grease wit3
/+
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38048http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp83104http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp83104http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp38048http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp83104http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp83104
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grease =or plug serration o= 4lut43 dis4 & 1 *
Mo2e 4lut43 dis4 ba4 and =ort3? remo2e ex4ess
grease*
t
Clut43 pus3 rod and
release plate
7pressure plate8
sluggis3*
.ig3tlE grease 4onta4t points wit3 grease =or plug
serration o= 4lut43 dis4 & 1*
.ig3tlE grease 4lut43 pus3 rod*
$ault $ault tEpe Measure
Clut43
4ontrol
noises*
t'elease bearing
de=e4ti2e*
'epla4e release bearing*
t
Centre displa4ement o=
engineBgearbox*
C3e4 dowel slee2es*
t
Clut43 dis in4orre4tlE
mounted*
Corre4t t3e "le4troni4 Catalogue o= Original Parts
=or t3e assignment o= t3e 4lut43 dis4*
$ault $ault tEpe Measure
S4rat43 noises w3en t3e
=orward or re2erse gear is
engaged? gears43i=t Rams?
3oos? is sluggis3? s3i=ting
not possible? 4lut43 wit3out
operation*
tAir in t3e sEstem? 4lut43
does not separate =ullE*
C3e4 and bleed sEstem? top
up wit3 brae Guid*
t
Master 4Elinder or sla2e
4Elinder is leaing? line is
leaing*
'epla4e de=e4ti2e 4omponent?
top up wit3 brae Guid? 2ent air
=rom t3e sEstem*
t
T3e tra2el o= t3e 4lut43
pedal is not su4ent
74arpet? =oot mat under t3e
pedal8? pedal is not =ullE
depressed*
In=orm 4ustomer*
t Pressure plate une2en due
to in4orre4t installation?
4lut43 dis4 warped due to
C3e4 4omponents? i=
ne4essarE repla4e? mae sure
t3e 4entering pins are 4orre4tlE
/5
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp124848http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp124848
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improper 3andling* "le4troni4 Catalogue
o= Original Parts =or t3e
assignment o= t3e 4lut43 dis4*
t
.ining glued to t3e GEw3eel
7long immobiliHation time?
3ig3 3umiditE8*
Slig3tlE rub down t3e =ri4tion
sur=a4es o= t3e 4lut43 lining? i=
ne4essarE w3en 4orrosion
o44urs in a larger area? repla4e
t3e 4omponent 4ompletelE*
t
Clut43 dis4 on t3e serration
sluggis3BRams* Corroded 3ub?
damaged during assemblE*
%ub pro
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t
,3en starting? linings are
spalled o t3roug3 slipping
=or too long a time*
t
Clut43 pus3 rod too s3ort
due to wear*
'epla4e 4lut43 pus3 rod* C3e4
release bearing? repla4e i=
ne4essarE*
.ig3tlE grease 4onta4t points o=
4lut43 pus3 rod to release
bearing wit3 grease =or plug
serration o= 4lut43 dis4
& 1 *
$ault $ault tEpe Measure
.oad alteration s3o4s w3en
pus3ing t3e a44elerator pedal
down s3arplE and w3en t3e
engine speed drops suddenlE*
tAssemblE bra4et is
too so=t*
In=orm 4ustomer* 0se t3e
> "le4troni4 Catalogue o=
Original Parts =or t3e
assignment o= t3e 3anger*
t
Irregular engine
running*
C3e4 engine setting? 4orre4t*
t
Clut43 dis4 wit3
predamper is built inagainst gear rattling*
In=orm 4ustomer*
t
Centre displa4ement o=
engineBgearbox*
Test dowel slee2es? repla4e i=
ne4essarE*
$ault $ault tEpe Measure
Clut43 slips?
no or poor
a44eleration
t,rong 4lut43 dis4 "le4troni4
Catalogue o= Original Parts
=or t3e assignment o= t3e
4lut43 dis4 and t3e pressure
plate*
t
Clut43 dis4 worn out? burnt? pressure plate
o2er3eated? s4oring? pressure plate warped
t3roug3 in4orre4t assemblE? 4onta4t pressure
o= t3e pressure plate too low? dri2ing error?natural wear*
'epla4e 4lut43 dis4*
'epla4e pressure plate*
In=orm 4ustomer*
t Clut43 dis4? pressure plate? GEw3eel oilE*
/9
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp197952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp197952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp224736http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp224736http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp197952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp197952http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp224736http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp224736
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S3a=t seal o= t3e engine or t3e gearbox
de=e4ti2e* &rease on t3e 4onta4t sur=a4e
t3roug3 ex4ess greasing o= t3e 3ub*
t Clut43 dis in4orre4tlE mounted*
Corre4t t3e "le4troni4 Catalogue o= Original
Parts =or t3e assignment o= t3e assemblE
bra4et*
t
Clut43 lining oilE? 4onta4t sur=a4e o=
pressure plate and GEw3eel oilE 7oil
leaage =rom t3e 4lut43 3ousing8*
C3e4 s3a=t seal o= t3e dri2e s3a=t =or
4lut43 or 43e4 4rans3a=t? i= ne4essarE
repla4e*
'epla4e 4lut43 dis4? 4lean pressure plate
and GEw3eel*
t
Dri2e s43a=t too 3ea2ilE greased
7tra4es o= grease on t3e 4lut43 dis4?
pressure plate and GEw3eel8*
Clean pressure plate and GEw3eel =ree o=
grease? repla4e in t3e e2ent o= damage
7tra4es o= wear? o2er3eating? groo2es8*
'emo2e tra4es o= grease =rom 3ub and
s3a=t? grease s3a=t lig3tlE wit3 grease =or
/
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp274144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp274144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp278656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp278656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp274144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp274144http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp278656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp278656
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plug serration o= 4lut43 dis4 & 1*
Mo2e 4lut43 dis4 ba4 and =ort3? remo2e
ex4ess grease*
$ault $ault tEpe Measure
A4ousti4 load alteration
s3o4 4li4ing w3en
4oupling 7release 4lut43
pedal8*
t
Carrier eart3Bdri2e s3a=t is a44elerated wit3 sudden
4oupling* T3e dri2e s3a=t serration o= t3e pinions in
mes3 no4sQ =or 4lut43 dis4s wit3 predamper t3e
noise in4reases as t3e predamper rea43es t3e stop*
In=orm
4ustomer*
$ault $ault tEpe Measure
#oises
in idle*
t Torsional damper spring broen* 'epla4e 4lut43 dis4*
t
Clut43 dis4 "le4troni4 Catalogue o=
Original Parts =or t3e assignment o= t3e
4lut43 dis4*
t
Pressure plate warped? broen?
imbalan4e*
'epla4e pressure plate*
t Irregular engine running*
C3e4 engine setting? 4orre4t i=
ne4essarE*
t
T3e displa4ement o= t3e engine to t3e
gearbox is too large 7dowel slee2es are
missing8*
(e=ore installing t3e gearbox? insert t3e
dowel slee2es*
t Intermediate plate rubs on t3e GEw3eel*
Insert intermediate plate on sealing
Gange and pus3 onto t3e dowel slee2es*
SummarE o= 4omponents repairing t3e 4lut43
Spe4ial tools and wors3op e:uipment re:uired
t &rease =or t3e plug serration o= t3e 4lut43 dis4 & 1
#ote
t (e=ore repla4ing t3e 4lut43 dis4 and pressure plate =ault
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obser2e 4omplaints o= t3e 4lut43 and 4lut43 4ontrol > C3apter*
tI= t3e dowel slee2es are not present? t3is 4an result in di4ulties to s3i=t? 4lut43 problems
and i= ne4essarE noises =rom gearbox 7gear rattling8*
t 'epla4e t3e 4lut43 dis4s and pressure plates i= t3e ri2eting is damaged or loose*
tAssign t3e 4lut43 dis4 and t3e pressure plate a44ording to t3e > "le4troni4 4atalogue o=
original parts and engine identi
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: T3e lo4ating =a4e =or t3e 4lut43 lining must be =ree =rom groo2es? oil and grease
:
T3e insertion dept3 o= t3e TDC sender must be adapted to t3e 2arious siHes o= t3e
GEw3eels* T3ere=ore two s4rew plugs in t3e 4lut43 3ousing mared in dierent 4olours*
Assignment > C3apter
/ Clut43 dis4
: 4enter > C3apter
: Diameter > "le4troni4 Catalogue o= Original Parts
+ Clut43 pus3 rod
: grease in t3e area o= t3e bearing bus3ing in t3e dri2e s3a=t
5 'etaining loop
6 'elease plate
: ApplE a 2erE t3in laEer o= grease =or plug serration o= 4lut43 dis4 & 1 to t3e 4onta4tsur=a4e and support =or t3e 4lut43 pus3 rod*
9 $ixing s4rew o= pressure plate at 4rans3a=t
: remo2ing and installing > "ngine > 'ep* &r*1/
Intermediate plate
: $itting position > C3apter
; Pressure plate
: remo2ing and installing > C3apter
: Distortion o= t3e inner pressure plate max* *! mm
: 'epla4e t3e pressure plate i= t3e ri2eting is damaged or loose
'emo2ing and installing 4lut43
Spe4ial tools and wors3op e:uipment re:uired
t &rease =or t3e plug serration o= t3e 4lut43 dis4 & 1
t Counter3older MP1!!1 7V, 558
t .o4ating dis4 T1!6
t Centering de2i4e MP!+
'emo2ing
'emo2ing t3e gearbox > C3apter*
+1
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46688http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48256http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49504http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp53520http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp53936http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55312http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56992http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41616http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46688http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48256http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49504http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp53520http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp53936http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55312http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56992http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41616
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'emo2e GEw3eel? to do so lo4 wit3
4ounter3older MP1!!1 7V, 558*
'emo2e 4lut43 dis4*
.e2er and remo2e t3e retaining ring A
=or t3e release plate ( out o= t3e 3oles
using a s4rewdri2er arrows*
'emo2e release plate (*
0ns4rew pressure plate? to t3is end lo4
4ounter 3older MP1!!1 7V, 558 at
pressure plate wit3 s4rew A*
'emo2e pressure plate and intermediateplate*
Install
Position pressure plate*
$it t3e intermediate plate*
+!
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$itting lo4ation o= intermediate plate T3e
raised part arrow points awaE =rom t3e
pressure plate*
#ote
Insert new
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On 4ertain 2e3i4les t3e pre2ious 4entering
de2i4e MP!+ 7/198 4an also be used*
.o4 GEw3eel =or tig3tening t3e C3apter*
++
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp69344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp69344
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&earbox me43ani4s?operation? 4onstru4tion?di*
'epairing t3e gears3i=t me43anism
$itting lo4ation o= s3i=t me43anism
T3e 4oupling rod C ser2es as 4ountersupport =or t3e sele4tor mo2ements
Double arrow A s3i=t mo2ement
Double arrow ( sele4tor mo2ement
A &ear s3i=t rods =or s3i=t mo2ement
( Coupling rods =or sele4tor mo2ement
+5
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#ote
t On models "le4tri4al SEstem > 'ep* &r*!9*
t,3en t3e batterE is re4onne4ted? paE attention to t3e wor a=ter 4onne4ting t3e batterE
> "le4tri4al SEstem > 'ep* &r*!9*
t &rease all bearing and 4onta4t sur=a4es wit3 grease & +5 !*
I SummarE o= 4omponents s3i=t 3ousing B s3i=t le2er > C3apter
II SummarE o= 4omponents re2erses3i=t me43anism at t3e gearbox > C3apter
'emo2ing and installing s3i=t 3ousing > C3apter*
Setting t3e s3i=t me43anism > C3apter*
+6
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42864http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp43248http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp44384http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44768http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48000http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49728http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp51264http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp52928http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42864http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp43248http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp44384http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44768http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48000http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49728http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp51264http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp52928
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: onlE =or 2e3i4les $ig*
5 Open warmtEpe 4lamp
: =or se4uring t3e gears3i=t nob to t3e gears3i=t le2er
: open > $ig*
: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
: atta43 wit3 3ose binding 4law V*A*& 1!95 onto t3e gears3i=t nob
6 S3i=t le2er
: remo2ing and installing =rom s3i=t 3ousing > C3apter
9 Spa4er bus3
Collar s4rew? !5 #m
; S3i=t 3ousing
: remo2ing and installing > C3apter
1 &ear s3i=t rod
: remo2ing and installing > C3apter
: a=ter installing set s3i=t me43anism > C3apter
11 ! #m
1! !5 #m
1/ Pressure spring
1+ Stop
: a=ter installing set s3i=t me43anism > C3apter
15 !5 #m
: Coat t3read wit3 lo4ing agent D 6 A!
16 (all so4et
: remo2ing > C3apter
19 (us3ing
1 S3o4 absorber
1; 15 #m
+
http://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/gearbox_mechanicsoperation_constructiondiff./repairing_the_gearshift_mechanism/summary_of_components_shift_housing/shift_lever/#x-6gu1cuagrthttp://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/gearbox_mechanicsoperation_constructiondiff./repairing_the_gearshift_mechanism/summary_of_components_shift_housing/shift_lever/#x-qbxfyus7embhttp://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp52960http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp57856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp59536http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp60800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp63728http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp66800http://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/gearbox_mechanicsoperation_constructiondiff./repairing_the_gearshift_mechanism/summary_of_components_shift_housing/shift_lever/#x-6gu1cuagrthttp://workshop-manuals.com/skoda/octavia-mk1/power_transmission/5_speed_manual_gearbox_02k/gearbox_mechanicsoperation_constructiondiff./repairing_the_gearshift_mechanism/summary_of_components_shift_housing/shift_lever/#x-qbxfyus7embhttp://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp52960http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55344http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp57856http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp59536http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp60800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp63728http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp66800
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'emo2e gears3i=t nob and 4ollar
Pull out t3e 4ollar =or t3e s3i=t le2er
towards t3e top arrows*
Open warmtEpe 4lamp
Open t3e open warmtEpe 4lamp arrow
and pull o gears3i=t nob toget3er wit3
t3e 4ollar*
+;
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Separate gears3i=t nob =rom 4ollar and
assemble wit3 4ollar
Turn 4ollar inside out*
.e2er o 4lamping slee2e arrow wit3
s4rewdri2er*
Deta43 4lamping slee2e =rom s3i=t le2er*
Turn gears3i=t nob inside out and deta43
=rom 4ollar*
Install
Turn 4ollar inside out*
Insert gears3i=t nob into 4ollar*
Pus3 4lamping slee2e o2er gears3i=t
nob and 4ollar*
Press toget3er 4lamping slee2e until it
4li4s into pla4e*
'emo2ing and installing s3i=t 3ousing wit3 s3i=t le2er and s3i=t rod
Spe4ial tools and wors3op e:uipment re:uired
t %ose binding 4law V*A*& 1!95
'emo2ing
5
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Pull out t3e 4ollar =or t3e s3i=t le2er
towards t3e top arrows*
Pull t3e 4ollar upwards o2er t3e gears3i=t
nob*
Open t3e open warmtEpe 4lamp arrow
and pull o gears3i=t nob toget3er wit3
t3e 4ollar*
'emo2e sound absorption > Item? i=
present*
51
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp42512http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp42512
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'elease
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.oosen warmtEpe 4lamp arrow*
Separate t3e 4onne4tion o= t3e s3i=t
rodBsele4tor le2er*
'elease bot3 lower "ngine
> 'ep* &r*!6*
Cross member to bodE > "ngine > 'ep*
&r*!6*
Setting t3e s3i=t me43anism > C3apter*
Atta43 new warmtEpe 4lamp arrow
wit3 3ose binding 4law V*A*& 1!95 onto
t3e gears3i=t nob*
Tig3tening tor:ues
S3i=t 3ousing to bodE
s4rew M
!5 #m
S3i=t 3ousing to bodE
nut M
!5 #m
S3i=t rod to sele4tor le2er !5 #m
5/
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp53328http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp53744http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp55152http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp55568http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp55568http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56944http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp53328http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp53744http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp53744http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp55152http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp55568http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp55568http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp56944
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'emo2ing and installing s3i=t le2er =rom s3i=t 3ousing
'emo2ing
'emo2e s3i=t 3ousing > C3apter*
'elease s4rew arrow and remo2e s3i=t
rod =rom s3i=t le2er*
0ns4rew s4rew 1 and remo2e bus3ing
! wit3 s3o4 absorber /*
0ns4rew s4rews arrows =or stop +*
5+
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37920http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37920
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Press in 3oos o= t3e 76 pie4es8 ball
so4et arrows using a s4rewdri2er and
4are=ullE pull s3i=t le2er out o= t3e s3i=t
3ousing towards t3e top*
Press o ball so4et in dire4tion o=arrow =rom t3e s3i=t le2er*
Installing
Installation is 4arried out in t3e re2erse
order*
#ote
t Install s3i=t 3ousing > C3apter*
t Setting t3e s3i=t me43anism > C3apter*
Tig3tening tor:ues
S3i=t rod to s3i=t le2er ! #m
Stop =or s3i=t le2er to s3i=t 3ousing !5 #m
SummarE o= 4omponents re2erses3i=t me43anism at t3e gearbox
#ote
&rease bearing and =ri4tion sur=a4es wit3 grease & +5 !*
55
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49168http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50560http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp49168http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50560
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1 ! #m
: sel=lo4ing
: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
: S3i=t le2er on gearbox
! &earbox s3i=t le2er
: onlE
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: Installation o= t3e new 4onsole on t3e gearbox up to 9*; > $ig*
9 Coupling rod
S3i=t rod wit3 balan4ing weig3t
; S3ield
: is
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8/16/2019 Skoda Octavia Mk1 - 06 - Power Transmission Gearbox 02K
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+ (allQ press o using a s4rewdri2erQ press
out up to t3e stop
5 (ra4et
6 'e2ersing le2er
Setting t3e s3i=t me43anism
Spe4ial tools and wors3op e:uipment re:uired
t S3i=t le2er gauge /+!1
#ote
t T3e =ollowing are re:uired =or 4orre4t setting o= t3e s3i=t me43anism
t Operating and transmission elements o= t3e s3i=t me43anism are in per=e4t 4ondition*
t S3i=t me43anism operates =reelE*
t &earbox? 4lut43 and 4lut43 4ontrol must be in per=e4t 4ondition*
l &earbox in #eutral*
'emo2e gears3i=t nob wit3 4ollar > C3apter*
.oosen warmtEpe 4lamp arrow* T3e
s3i=t rodBsele4tor le2er s3ould mo2e
=reelE*
5;
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41216http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41216
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Tig3ten nut arrow =or warmtEpe 4lamp
to ! #m and tae out s3i=t le2er gauge
/+!1*
Install bus3ing =or s3i=t le2er > C3apter*
Depress 4lut43*
"ngage re2erse gear*
'elease s4rew 1*
#ote
T3en press down t3e le=t side o= t3e stop
dire4tion o= arrow*
Tig3ten s4rews1 and ! to !5 #m*
Tae out re2erse gear*
Depress 4lut43*
S3i=t t3roug3 all gears se2eral times* PaE
parti4ular attention to proper operation
o= t3e re2erse gear lo4*
I= a gear 4at43es w3en repeatedlE
engaging? pro4eed as =ollows
"ngage 1st gear*
"liminate t3e plaE in t3e s3i=t me43anism
bE 4are=ullE pressing t3e s3i=t le2er to t3ele=t*
61
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55792http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp55792
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> C3apter*
'emo2ing and installing t3e gearbox
Spe4ial tools and wors3op e:uipment re:uired
t Alignment rails MP/+59 7V, +598 743ange > An43or8
t Supporting de2i4e =or engine MP/+9 7// A8
t &earbox atta43ment de2i4e MP/+9 7///68
t Supporting de2i4e MP;! 71!!!A8
t &earbox mount /!!
t AdRusting plate /!!B5
t &rease =or t3e plug serration o= t3e 4lut43 dis4 & 1
t %exagon s4rew M x !5
C3ange alignment rail MP/+59 7V, +598
T3e alignment rail MP/+59 7V, +598 is re:uired w3en remo2ing and installing t3e
gearbox*
An additional 3ole arrow is ne4essarE =or
atta43ing t3e alignment rail MP/+59 7V,
+598 to t3e assemblE 4arrier*
Dimensions in mm*
I= t3is 3ole is not Eet present? a 3ole o=
*5 mm F arrow must be drilled into t3e
alignment rail MP/+59 7V, +598*
'emo2ing t3e gearbox
#ote
be
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Dis4onne4t t3e eart3 strap =rom t3e batterE wit3 t3e ignition o*
$or 2e3i4les wit3 1*6 lB9+ , and 1*; lB5 , engine
Deta43 air guide 3ose 1 and unplug
4onne4tor ! =rom air mass meter*
$or 2e3i4les wit3 1*; litreB5 , engine
'emo2e t3e air 3ose / =rom t3e air
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0nplug 4onne4tor =rom re2ersing lig3t
swit43 $+arrow*
As o= gearbox manu=a4turing date /
0nplug plug o= t3e re2ersing lig3t swit43
$+arrow /*
Ve3i4les wit3 1*+ ltr* engine
'emo2e t3e bra4et =or t3e wiring o= t3e
lambda probe arrow 1? to t3is end
release t3e
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t3e gearbox*
'elease s4rews ! and remo2e 4ontrol
4onsole / wit3 4oupling rods and
gearbox s3i=t le2er =rom gearbox*
0ns4rew t3e sla2e 4Elinder =rom t3e
gearbox arrows pla4e to t3e top and
se4ure wit3 wire? do not open t3e line
sEstem*
#ote
Do not depress t3e 4lut43 pedal*
'emo2e t3e eart3 strap =rom t3e
engineBgearbox 4onne4ting s4rew 1*
0ns4rew 4able 4lip / at top starter
arrow and laE aisde*
'elease top
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Install supporting de2i4e MP;! 71
!!!A8*
#ote
,3en installing t3e li=ting 3oos o= t3e
supporting de2i4e? paE attention to 3oseand 4able 4onne4tions in t3e area o= t3e
li=ting eEes to a2oid damaging t3em wit3
t3e engine*
Slig3tlE raise t3e engineBgearbox unit 2ia
t3e spindles o= t3e supporting de2i4e
MP;! 71!!!A8*
0ns4rew bra4et =or PAS line =rom t3e
double s4rew arrow 1*
0ns4rew t3e
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'emo2e noise insulation 4ompletelE* To
t3is end uns4rew s4rews arrows*
'emo2e t3e le=t w3eel3ouse liner > (odE
,or > 'ep* &r*66*
'emo2e t3e starter > "le4tri4al SEstem
> 'ep* &r*!9*
I= present? remo2e 3eat s3ield =or dri2e
s3a=t =rom t3e engine arrows*
Turn w3eels to =ull le=t*
'emo2e dri2e s3a=ts =rom Gange s3a=ts
and tie up as =ar as possibleQ do not
damage t3e sur=a4e prote4tion*
$or 2e3i4les wit3 1*6 lB9+ , and 1*; lB5
, engine
6
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp82800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp82800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp83216http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp84624http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp85040http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp82800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp82800http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp83216http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp84624http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp85040http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp85040
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'emo2e small 4o2er plate A =or GEw3eel
be3ind t3e rig3t Gange s3a=t arrows*
0nbolt pendulum support arrows*
0ns4rew rear engineBgearbox 4onne4ting
s4rew arrow A*
$or 2e3i4les wit3 1*6 litreB9+ , engine
'emo2e 4atalEti4 4on2erter > 1*6 lB9+ ,
"ngine? Me43ani4s > 'ep* &r*!6*
$or 2e3i4les wit3 1*6 lB55 , and 1*; lB5
, engine
6;
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp95136http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp95136http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp95568http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp95136http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp95136http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp95568
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'elease 4lamping slee2e A and
separate t3e ex3aust sEstem*
$or 2e3i4les wit3 1*6 litreB55 , engine
Separate =ront ex3aust pipe =rom
4atalEti4 4on2erter? to do so uns4rew
nuts arrows*
0nbolt pendulum support > An43or?
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0ns4rew rear engineBgearbox 4onne4ting
s4rews A and ( and remo2e small 4o2er
plate =o GEw3eel C*
#ote
PaE attention to t3e 4orre4t
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Position gearbox Ra4 below 2e3i4le?
arrow sEmbol ( 7 > An43or? $ig* V/+
!5998 on adRusting plate points in t3e
dire4tion o= tra2elB2e3i4le*
Align adRusting plate parallel to t3egearbox and lo4 se4uring mount at
gearbox*
'emo2e t3e bottom
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(d>ust supporting arm at slide with locing pin
-arrow-)
*umber of ,isible holes ? #)
6aise gearbox with worshop crane andgearbox suspension de,ice -&;-/"# $-)
;lace down gearbox@ e)g) in a transport
container)
Installing t3e gearbox
T3e installation o= t3e gearbox o44urs in re2erse order* Install engineBgearbox mounting =ree
o= stress > 'ele2ant "ngine? Me43ani4sQ 'ep*&r* 1*
#ote
tI= t3e gearbox is repla4ed? i= pro2ided alwaEs re C3apter*
tClean spline o= dri2e s3a=t and applE a t3in C3assis > 'ep* &r*+*
t Installing starter and 4able > "le4tri4al SEstem > 'ep* &r*!9*
t C3e4 gear oil le2el > C3apter*
t Setting t3e s3i=t me43anism > C3apter*
t AdRust assemblE bra4et > "ngine > 'ep* &r*1*
tI= t3e batterE eart3 strap is dis4onne4ted and 4onne4ted? 4arrE out additional operations
> "le4tri4al SEstem > 'ep* &r*!9*
Tig3tening tor:ues
9/
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp37440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39200http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42272http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp42656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43680http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44064http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45088http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46336http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp47584http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp47968http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49104http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp49488http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp45088http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp37440http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39200http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp42272http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp42656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp43680http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp44064http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp46336http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp47584http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp47968http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49104http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp49488
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&earbox to engine
Ve3i4les wit3 1*6 ltr*B55 ,
engine
Position S4rew tE #m
1 M1! x 55 1
!?/ 18 M1! x 55 1
+ 18 M1! x 1! 1
5 M1! x 55 1
6?9 M1 x 5 1 +5
M1! x /5 1 !
; M1! x 55 1
A Dowel slee2es =or 4entering
18 S4rew wit3 t3readed pin M
9+
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&earbox to engine
Ve3i4les wit3 1*6 ltr*B9+ , and 1*6 ltrB95, engine
Position S4rew tE #m
1 M1! x 65 1
! 18 M1! x 65 1
/?+ 18 M1! x 1+ 1
5? 6? 9 M1 x 5 1 +5
M1! x 1
A Dowel slee2es =or 4entering
18 S4rew wit3 t3readed pin M
&earbox to engine
Ve3i4les wit3 1*; ltr*B5 , engine
Position S4rew tE #m
1 M1! x 55 1
95
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! 18 M1! x 55 1
/?+ 18 M1! x 1+ 1
5? 6? 9 M1 x 5 1 +5
M1! x 55 1
A Dowel slee2es =or 4entering
18 S4rew wit3 t3readed pin M
&earbox to engine
Ve3i4les wit3 1*+ ltr*B55 ,
engine
Position S4rew tE #m
1 M1! x 65 1
!?/ 18 M1! x 65 1
+ 18 M1! x 1+ 1
5 M1! x 65 1
6?9 M1 x 5 1 +5
M1! x /5 1 !
; M1! x 65 1
A Dowel slee2es =or 4entering
18 S4rew wit3 t3readed pin M
96
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&earbox to bodE
'epla4e s4rews A and (*
S4rews A 6 #m ;J18
S4rews ( + #m ;J18
l 18 ;J 4orresponds to a :uarter turn*
Component Tig3tening tor:ue
Co2er plate =or GEw3eel 1 #m
Sla2e 4Elinder to gearbox !5 #m
Console =or s3i=t me43anism on gearbox up to 9*; !5 #m
Console =or s3i=t me43anism on gearbox as o= *; 18 !5 #m
S3i=t rod to gearbox 18 ! #m
&earbox s3i=t le2er to gearbox 18 ! #m
Dri2e s3a=t to Gange s3a=t > C3assis > 'ep* &r*+
Pendulum support > "ngine > 'ep* &r*1
%eat s3ield o= dri2e s3a=t to engine > C3assis > 'ep* &r*+
18 'epla4e nut > "le4troni4 Catalogue o= Original Parts
99
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp308064http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp308528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp311680http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp312096http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp315120http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp315536http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp317024http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp308064http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp308528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp311680http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp312096http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp315120http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-rl=idp315536http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp317024
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Inspe4t gear oil
&earbox oil spe4i "le4troni4 Catalogue o= Original Parts*
Turn steering to =ull le=t lo4*
'emo2e t3e le=t noise insulation? i= present? below t3e engineBgearbox > (odE ,or
> 'ep* &r*5*
0ns4rew s4rew arrow =or inspe4ting
gear oil*
T3e gear oil le2el is at t3e 4orre4t le2el i=
t3e gear is
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Disassembling and assembling t3e gearbox
&earbox o2er2iew
1 Clut43 3ousing
: repairing > C3apter
! Dierential gear
: disassembling and assembling > C3apter
/ Output s3a=t
disassembling and assembling
+ Dri2e s3a=t
: disassembling and assembling > C3apter
5 1st gear
6 'e2erse gear
9 !nd gear
9;
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37984http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39488http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41872http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37984http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39488http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41872
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Co2er =or gearbox 3ousing
: repairing > C3apter
; 5t3 gear
1 +t3 gear
11 /rd gear
1! &earbox 3ousing
SummarE o= 4omponents disassembling and assembling t3e gearbox
Mounting se:uen4e disassembling and assembling t3e gearbox > C3apter
I SummarE o= 4omponents 'emo2ing and installing gearbox 3ousing 4o2er and 5t3 gear
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37424http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp44528http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp37424
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> C3apter
II SummarE o= 4omponents remo2ing and installing gearbox 3ousing and gears3i=t s3a=t
> C3apter
III SummarE o= 4omponents 'emo2ing and installing t3e dri2e s3a=t? output s3a=t?
dierential gear and s3i=t =ors > C3apter
SummarE o= 4omponents 'emo2ing and installing gearbox 3ousing 4o2er and 5t3 gear
1 !5 #m
: M x 6!
: + pie4es
! S4rew 4ap
: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
1
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39424http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41024http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp42656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39120http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39424http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41024http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp42656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp39120
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: installing > An43or
/ !5 #m
: M x 5
: ! pie4es? one s4rew is lo4ated under t3e s4rew 4ap Pos* !
+ Co2er =or gearbox 3ousing
: repairing > C3apter
5 Sliding slee2eBsEn43roniHer bodE =or 5t3 gear wit3 stop ring
: disassembling and assembling > C3apter
6 Cir4lip
: alwaEs repla4e damaged or o2ertensioned 4ir4lips > "le4troni4 Catalogue o= Original Parts
9 T3rust was3er
&ear pinion =or 5t3 gear
: $itting position groo2e to t3e top
; .o4 was3er
: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
1 5t3 gear s3i=t =or
: adRust > An43or
11 M19 x 1? 15 #m
: sel=lo4ing
: alwaEs repla4e > "le4troni4 Catalogue o= Original Parts
: new s4rew is mi4ro en4apsulated 7t3read wit3 lo4ing agent8
: to release or tig3ten t3e s4rew obser2e mounting se:uen4e > C3apter
SummarE o= 4omponents remo2ing and installing gearbox 3ousing and s3i=t me43anism
!
http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39760http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41920http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43504http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45008http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp47056http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48080http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49600http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50656http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp39760http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp41920http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp43504http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp45008http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp47056http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp48080http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:ext-dok=idp49600http://var/www/apps/conversion/tmp/scratch_1/http:%2F%2Fctrl:IDREF=idp50656
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