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Skoda Workshop Service and Repair Manuals

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Clutch, control > < Contact corrosion!

Octavia Mk2

Components
Components
Gearbox
t  When installing the manual gearbox, ensure the dowel sleeves are correctly located between the engine and gearbox.
t  When assembling mounts as well as waxed components, the contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.
t  Bolts and other attachments should have a classification in the → Electronic Catalogue of Original Parts.
t  When replacing the gearbox, inspect the gear oil level in the manual gearbox (top up with oil if necessary) → Chapter.
t  Filling capacity (Octavia II) → Chapter.
t  Filling capacity (Superb II) → Chapter.
t  Filling capacity (Yeti) → Chapter.
t  Oil specification → Electronic Catalogue of Original Parts.
Angle gearbox (four-wheel drive)
t  The angle gearbox is screwed on laterally to the manual gearbox and equipped with its own closed oil supply.
t  Filling capacity (Octavia II) → Chapter.
t  Filling capacity (Superb II) → Chapter.
t  Filling capacity (Yeti) → Chapter.
t  Oil specification → Electronic Catalogue of Original Parts.
t  Inspect gear oil level (top up oil if necessary) → Chapter.
Rear final drive
t  When replacing the rear final drive, inspect the oil level in the final drive → Chapter and the oil level in the Haldex coupling (top up with oil if necessary) → Chapter.
t  Filling capacity (Octavia II) → Chapter.
t  Filling capacity (Superb II) → Chapter.
t  Filling capacity (Yeti) → Chapter.
t  Oil specification → Electronic Catalogue of Original Parts.
t  When installing waxed carriers and components, the contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.
  Note
t  The „Haldex coupling“ is located in the rear final drive.
t  The final drive and the „Haldex coupling“ have separate oil circulation systems.
t  The final drives „02D/0AV“ are fitted with the „Haldex coupling of the 2nd generation“.
t  The final drive „0BR“ is fitted with the „Haldex coupling of the 4th generation“.
t  The rear final drives „02D/0AV“ and „0BR“ have different „Haldex couplings“.
t  Oil for Haldex coupling, assignment → Electronic Catalogue of Original Parts.
Targeted fault finding, Vehicle self-diagnosis and Measuring method
t  Before repairing the Haldex coupling, try to determine the origin of the damage as accurately as possible using the → Vehicle diagnostic tester in the functions „Targeted fault finding“, „Vehicle self-diagnosis“ and „Measuring method“.
Sealant
t  Thoroughly clean the contact surfaces of the housing before applying the silicone sealant.
t  Apply sealant AMV 188 200 03 evenly and not too thick.
Gasket rings, O-rings, gaskets
t  Always replace gasket rings, O-rings and gaskets → Electronic Catalogue of Original Parts.
t  After removing gaskets, check the contact surface in the housing or shaft for burrs or damage which occured during the assembly.
   
t  Radial shaft seals - before mounting lightly oil at outside diameter and fill half the space between the sealing lips -arrow- with sealing grease -G 052 128 A1-.
t  The open side of the sealing rings is turned towards the fluid to be sealed.
t  Press in new gasket ring in such a way that the sealing lip is not located on the same point as the sealing lip of the old gasket ring (use tolerance for insertion depth).
t  Before inserting lightly oil the O-rings, in order to prevent the rings being squashed during installation.
t  Inspect the oil level after replacing the gaskets and gasket rings.
Locking elements
t  Do not over-tension the circlips.
t  Always replace damaged or over-tensioned circlips → Electronic Catalogue of Original Parts.
t  Circlips must be positioned in the base of the groove.
  S00-0264
t  Replace roll pins. Fitting location: slot longitudinally to power flow.
Screws, nuts
t  Slacken the bolts and nuts against the tightening sequence.
t  Slacken and tighten screws or fixing nuts of covers and housings without tightening sequence diagonally across in stages.
t  Replace the self-locking screws and nuts.
t  Tightening torques apply for non-oiled nuts and bolts.
t  Clean the threaded holes into which self-locking screws or screws with locking agent were screwed in (using e.g. a screw-tap). Otherwise there is a risk that the bolts will shear at the next disassembling.
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  New taper roller bearings are fitted as supplied and do not require any additional lubrication.
t  Insert moist all bearings (except taper roller bearings) into the gearbox with gear oil.
t  Before installing, heat the inner rings of the tapered-roller bearings on a heating plate or with an induction heater unit, e.g. -VAS 6414-, to approx. 100°C. Press on axial and play-free up to the stop.
t  Do not mix up the outer and inner races of bearings of the same size.
t  Always jointly replace tapered-roller bearings on the same shaft and use products of the same manufacturer.
t  Position needle bearing with the lettered side (thicker end) towards the drift pin.
Shims
  S00-0262
t  Gauge shims at several points with a micrometer. Different tolerances allow to select the required thickness for each washer very precisely.
t  Inspect for burrs and damage.
t  Install only adjusting washers which are in perfect condition.
Synchronizer rings
t  These are not interchangeable. If re-using, allocate synchronizer rings to the same sliding gear.
t  Inspect for wear, replace if necessary → Electronic Catalogue of Original Parts.
  N30-10156
t  Check grooves -arrow 1- on synchronizer ring -A- or inner ring for flattened parts (grooves are worn).
t  On the installed intermediate ring -B-, check outer -arrow 2- or inner -arrow 3- contact surface for traces of scoring and friction.
t  Check the cone of the sliding gear for traces of scoring and friction.
t  Oil with gear oil before installing.
Gear pinions and synchronizer body
t  Clean and heat on a heating plate or with the induction heater unit e.g. -VAS 6414- to approx. 100°C before pressing on.
t  Install axial and play-free up to the stop.
t  Check fitting position.
Sliding gears
t  Inspect wheels 1st to 6th gear for small axial play or clearance after installation.
Clutch control
t  Do not tilt the clutch pressure plate; release and tighten crosswise in small stages.
t  If the clutch pedal does not return to its initial position after the coupling procedure - clutch pedal in home position - the clutch control must be bled (further measures → Chapter).
t  In order to reduce unpleasant odours if the clutch is burnt, thoroughly clean the clutch housing as well as the flywheel and the engine on the side of the gearbox.
  N35-10107

Clutch, control > < Contact corrosion!