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Skoda Workshop Service and Repair Manuals

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Self diagnosis, V.A.G Inspection Service > < Notes for brake and performance inspection and towing

Octavia Mk1

General repair information
General repair information
To carry out gearbox repairs successfully and correctly, scrupulous care and cleanliness, as well as the proper tools, are essential requirements. Obviously, the generally valid basic safety rules apply to repair work.
A number of generally valid notes for individual repair operations - which are otherwise listed several times at numerous points in the workshop manual - are summarized here.
Gearbox
t  When installing, ensure the dowel sleeves are correctly located between the engine and gearbox.
t  When installing mounts as well as waxed components, the contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.
t  When replacing the manual gearbox, angle gearbox or the rear final drive pour in gear oil up to lower edge of filler hole.
t  Capacity and specification of manual and angle gearbox, final drive, Haldex coupling → Chapter.
Gaskets, seals
t  Thoroughly clean contact surfaces and apply sealant -AMV 188 200 03- evenly, and not too thickly.
t  Apply sealant evenly - not too thickly.
t  Replace O-rings.
t  Radial shaft seals:
Before installing
   
Lightly oil the outer diameter and pack the space between the seal lips -arrow- with sealing grease.
After installing
t  Inspecting gear oil level in the manual and angle gearbox → Chapter.
t  Checking the gear oil level in the rear final drive → Chapter.
t  Check oil level in the Haldex coupling → Chapter
Locking elements
t  Replace circlips.
t  Do not over-tension the circlips.
t  Circlips must be positioned in the base of the groove.
  N32-0001
t  Replace roll pins. Fitting location: slot longitudinally to power flow.
Screws, nuts
t  Slacken and tighten nuts and bolts for attaching covers and housings diagonally across.
t  Do not twist particularly sensitive parts - e.g. clutch pressure plates - and slacken and tighten diagonally across in stages.
t  Tightening torques apply for non-oiled nuts and bolts.
t  Always replace the self-locking nuts and screws.
t  It is important to ensure at all bolted connections that the contact surfaces as well as the nuts and bolts are waxed only after being installed, should this be necessary.
Bearings
t  Do not oil new taper roller bearings. The bearings are already factory-pretreated with a special oil.
t  Fit all bearings to the gearbox with some gearbox fluid.
t  Replace all taper roller bearings belonging to one shaft at the same time. If possible use bearings of the same manufacturer.
t  Heat inner races to about 100 °C for installing.
t  Do not mix up the outer and inner races of bearings of the same size! Bearings are paired.
t  Position needle bearing with the lettered side (thicker end) towards the drift pin.
Shims
t  Gauge shims at several points with a micrometer. Different tolerances allow to measure the required thickness for each washer very precisely.
t  Inspect for burrs and damage.
t  Install only shims which are in perfect condition.
Synchronizer rings
t  These are not interchangeable. If re-using, allocate synchronizer rings to the same gear.
t  Inspect for wear, and replace if necessary.
t  Insert with some gearbox fluid.
Pinions
t  Clean and heat with induction heater unit -VAS 6414- to approx. 100°C before pressing on.
  V34-1515

Self diagnosis, V.A.G Inspection Service > < Notes for brake and performance inspection and towing