Fabia Mk2
Note| t | When installing new pinions or a new input shaft observe the technical data Fabia II → Chapter, Roomster → Chapter and Rapid → Chapter. |
| t | Removing and installing output shaft → Chapter. |
| t | Replace both tapered-roller bearings together. |
| The output shaft can be disassembled as follows: |
| – | Insert separating device under 2nd gear sliding gear Pos. 21 and press off as shown → Fig.. |
| – | Remove circlip Pos. 17. |
| – | Press off sliding sleeve with 1st and 2nd gear synchronizer body as shown in → Fig.. |
| 1 - | 25 Nm and torque a further 90° |
| q | 4 nuts for bearing support Pos. 9 |
| q | always replace → Electronic Catalogue of Original Parts |
| 2 - | Clutch housing |
| 3 - | Adjusting washer |
| q | for output shaft |
| q | Determine thickness → Chapter |
| 4 - | Outer ring/tapered-roller bearing small |
| q | removing → Fig. |
| q | pressing on → Fig. |
| 5 - | Inner ring/tapered-roller bearing small |
| q | remove → Fig. |
| q | pressing on → Fig. |
| 6 - | Output shaft |
| q | adjust → Chapter |
| 7 - | Inner ring/tapered-roller bearing large |
| q | remove → Fig. |
| q | pressing on → Fig. |
| 8 - | O-ring |
| q | Position O-rings (4 pieces) on the bearing support screws |
| q | always replace → Electronic Catalogue of Original Parts |
| 9 - | Bearing support |
| q | with outer ring/tapered-roller bearing large and with screws |
| q | Always replace outer ring together with tapered-roller bearing large and bearing support |
| 10 - | Thrust washer |
| q | Shoulder of thrust washer points to the tapered-roller bearing Pos. 7 |
| 11 - | 1st gear sliding gear |
| 12 - | Needle bearing |
| q | for 1st gear |
| 13 - | Synchronizer ring |
| q | (Inner ring for 1st gear) |
| q | Fitting position → Fig. |
| q | check for wear → Fig. |
| q | Check pegs for traces of wear |
| 14 - | Outer ring for 1st gear |
| q | place onto the inner ring Pos. 13 |
| q | Fitting position → Fig. |
| q | check for wear → Fig. |
| q | replace if there are any traces of scoring or friction |
| 15 - | 1st gear synchronizer ring |
| q | check for wear → Fig. |
| q | Fitting position → Fig. |
| 16 - | Sliding sleeve with 1st and 2nd gear synchronizer body |
| q | after removing the circlip Pos. 17 press off with bearing support Pos. 9 → Fig. |
| q | disassembling → Fig. |
| q | Assembling sliding sleeve/synchronizer body → Fig., → Fig. and → Fig. |
| q | Fitting position → Fig. |
| q | pressing on → Fig. |
| 17 - | Circlip |
| 18 - | 2nd gear synchronizer ring |
| q | check for wear → Fig. |
| q | insert in such a way that the recesses lock into the arresters of the sliding sleeve Pos. 16 |
| 19 - | Outer ring for 2nd gear |
| q | insert into synchronizer ring Pos. 18 |
| q | Fitting position → Fig. |
| q | replace if there are any traces of scoring and friction → Electronic Catalogue of Original Parts |
| 20 - | Synchronizer ring |
| q | (Inner ring for 2nd gear) |
| q | check for wear → Fig. |
| q | Check pegs for traces of wear |
| q | Fitting position → Fig. |
| 21 - | 2nd gear sliding gear |
| q | Fitting position → Fig. |
| 22 - | Needle bearing |
| q | for 2nd gear |
| 23 - | Thrust washer |
| 24 - | Bushing |
| q | for 3rd gear needle bearing |
| q | press off with 2nd gear sliding gear → Fig. |
| q | pressing on → Fig. |
| 25 - | Needle bearing |
| q | for 3rd gear |
| 26 - | 3rd gear sliding gear |
| 27 - | 3rd gear synchronizer ring |
| q | check for wear → Fig. |
| 28 - | Sliding sleeve with 3rd and 4th gear synchronizer body |
| q | press off → Fig. together with 2nd gear Pos. 21 and and 3rd gear Pos. 26 sliding gear |
| q | disassembling → Fig. |
| q | Assembling sliding sleeve/synchronizer body → Fig., → Fig. and → Fig. |
| q | Fitting position sliding sleeve/synchronizer body → Fig. |
| q | pressing on → Fig. |
| 29 - | Bushing |
| q | for 4th gear needle bearing |
| q | press off together with sliding sleeve and 3rd and 4th gear synchronizer body Pos. 28 → Fig. |
| q | pressing on → Fig. |
| 30 - | Needle bearing |
| q | for 4th gear |
| 31 - | 4th gear synchronizer ring |
| q | check for wear → Fig. |
| 32 - | 4th gear sliding gear |
| 33 - | Thrust washer |
| 34 - | Needle bearing |
| q | for output shaft |
| q | removing and installing → Chapter |
| 35 - | Gearbox housing |
| 36 - | Bushing |
| q | for needle bearing/output shaft Pos. 34 |
| q | pressing off → Fig. |
| q | pressing on → Fig. |
| 37 - | 5th gear pinion |
| q | remove separately → Chapter |
| q | remove together with gearbox housing → Chapter |
| q | installing → Chapter |
| 38 - | Disc spring |
| q | Fitting position → Chapter |
| 39 - | 80 Nm and torque a further 90° |
| q | holds disc spring in position with sleeve socket on screw head |
| q | always replace → Electronic Catalogue of Original Parts |
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Note
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Note
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| Dimension „a“ | Fitting dimension | Wear limit |
| 1st and 2nd gear | 0.75 … 1.25 mm | 0.3 mm |
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| Dimension „a“ | Fitting dimension | Wear limit |
| 1st and 2nd gear | 1.2 … 1.8 mm | 0.5 mm |
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| Dimension „a“ | Fitting dimension | Wear limit |
| 3rd and 4th gear | 1.0 … 1.7 mm | 0.5 mm |
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