Gearbox 02Q (Components): Technical Data

Make

Skoda

Model

Octavia Mk2

Section

Technical Data › General repair information › Components

Power transmissionComponents

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.

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

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.

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.

04 Transmission