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Setting drive shaft > < Drive shaft

Octavia Mk2

Disassembling and assembling the drive shaft
Disassembling and assembling the drive shaft
Special tools and workshop equipment required
t  Pressure spindle -MP3-423 (VW 407)-
t  Pressure washer -MP3-455 (VW 447 H)-
t  Pressure spindle -MP3-408 (VW 412)-
t  Pipe section -MP3-451 (VW 422)-
t  Pressure plate -MP3-406 (VW 401)-
t  Pressure plate -MP3-407 (VW 402)-
t  Pressure spindle -MP3-448 (VW 408 A)-
t  Knock-in bushing -T30034(41-501)-
t  Pressure washer -MP3-456 (VW 447 I)-
t  Bushing -MP1-316 (30-100)-
t  Pressure washer -MP3-413 (VW 510)-
t  Separating device 12 - 75 mm -Kukko17/1-
  Note
t  Removing and installing drive shaft → Chapter.
t  When installing new pinions observe the technical data → Chapter and → Electronic Catalogue of Original Parts.
t  If the position of the tapered-roller bearing is influenced when parts are replaced the drive shaft must be reset. Setting overview → Chapter.
   
1 - Clutch housing
2 - Outer ring/tapered-roller bearing
q   pressing off → Fig.
q   pressing on → Fig.
3 - Inner ring/tapered-roller bearing
q   pressing off → Fig.
q   pressing on → Fig.
4 - Drive shaft
q   adjust → Chapter
5 - 3rd gear pinion
q   Collar points to the 4th gear
q   pressing off → Fig.
q   pressing on → Fig.
6 - Circlip
q   always replace → Electronic Catalogue of Original Parts
7 - 4th gear pinion
q   pressing off with outer ring/tapered-roller bearing and bushing → Fig.
q   pressing on → Fig.
q   Collar points to the 3rd gear
8 - Inner ring/tapered-roller bearing
q   pressing off with 4th gear pinion and bushing → Fig.
q   pressing on → Fig.
9 - Thrust washer
10 - Outer ring/tapered-roller bearing
q   pressing off → Fig.
q   pressing on → Fig.
11 - Adjusting washer
q   Determine thickness → Chapter
12 - Gearbox housing
13 - Bushing
q   for needle bearing
q   pressing off with 4th gear pinion and inner ring/tapered-roller bearing → Fig.
q   pressing on → Fig.
q   insert thrust washer Pos. 9 before assembly 9
14 - Needle bearing
q   for 5th gear
15 - 5th gear sliding gear
q   remove together with 5th gear synchronizer body
16 - Corrugated spring ring
q   as of production date 26.05.08
q   assign according to the → Electronic catalogue of original parts.
17 - 5th gear synchronizer ring
q   with integrated arresters Octavia II → Chapter
q   with integrated arresters Superb II → Chapter
q   check for wear Octavia II → Chapter
q   check for wear Superb II → Chapter
18 - Sliding sleeve with 5th and 6th gear synchronizer body
q   Sliding sleeve was modified as of production date 06.06 → Fig.
q   removing and installing Octavia II → Chapter
q   removing and installing (Superb II) → Chapter
q   disassembling and assembling → Fig.
q   Setting 5th/6th gear (Octavia II up to production date 05.06) → Chapter
q   Setting 5th/6th gear (Octavia II as of production date 06.06) → Chapter
q   Setting 5th/6th gear (Superb II) → Chapter
q   Install springs bent at right angles and stops (on certain gearboxes) → Fig.
19 - 6th gear synchronizer ring
q   with integrated arresters Octavia II → Chapter
q   with integrated arresters Superb II → Chapter
q   check for wear Octavia II → Chapter
q   check for wear Superb II → Chapter
20 - Corrugated spring ring
q   as of production date 26.05.08
q   assign according to the → Electronic catalogue of original parts.
21 - 6th gear sliding gear → Chapter
q   Octavia II → Chapter
q   Superb II → Chapter
22 - Needle bearing
q   for 6th gear
q   replace together with bushing
q   Octavia II → Chapter
q   Superb II → Chapter
23 - Bushing
q   for 6th gear needle bearing
q   replace together with needle bushing
q   Octavia II → Chapter
q   Superb II → Chapter
24 - Thrust washer (Octavia II) → Chapter
q   no longer available as of production date 09.06
25 - Inner ring for cylindrical-roller bearing (Octavia II up to 08.06) → Chapter
q   for drive shaft
q   identify before removing
q   do not interchange with inner ring/cylindrical-roller bearing of output shaft
26 - Inner ring/cylindrical-roller bearing (as of 09.06)
q   for drive shaft
q   Superb II → Chapter
q   Octavia II → Chapter
q   Octavia II - Guide inner ring/cylindrical-roller bearing Pos. 25 together with thrust washer Pos. 24 → Fig.
27 - Screw with internal serrations
q   for drive shaft
q   Octavia II → Chapter
q   Superb II → Chapter
q   up to production date 08.06: 40 Nm + torque a further 180°
q   as of production date 09.06: 80 Nm + torque a further 90°
q   self-locking
q   always replace → Electronic Catalogue of Original Parts

   
Pressing off outer ring/tapered-roller bearing
  S35-0095
Pressing on outer ring/tapered-roller bearing
  S35-0049
Pressing off inner ring/tapered-roller bearing
A - Separating device 12 - 75 mm -Kukko17/1-
  S35-0153
Press on inner ring/tapered-roller bearing
  S35-0050
Pressing off 4th gearwheel with tapered-roller bearing and bushing
  S35-0338
Pressing off 3rd gear pinion
–  Prior to this remove the circlip.
  S35-0052
Pressing on 3rd gear pinion
  S35-0262
Pressing on 4th gear pinion
Collar points to the 3rd gear.
  S35-0054
Press on inner ring/tapered-roller bearing
  S35-0055
Pressing on bushing for needle bearing
  S35-0278
Pressing off outer ring/tapered-roller bearing
  S35-0057
Pressing on outer ring/tapered-roller bearing
–  After setting the drive shaft insert with adjusting washer.
For vehicles Octavia II
  S35-0058
Deeper recesses are present -arrows- on both sides in the 5th/6th gear sliding sleeve on gearboxes as of production date 06.06
  N34-10745
Dimension -a- (side to 6th gear)
»Gearbox up to production date 05.06«»Gearbox as of production date 06.06«
1.5 mm1.8 mm

Assign sliding sleeve and 5th/6th gear synchronizer body via the → Electronic Catalogue of Original Parts.
   
Dimension -b- (side to 5th gear)
»Gearbox up to production date 05.06«»Gearbox as of production date 06.06«
1.5 mm2.0 mm

Assign sliding sleeve and 5th/6th gear synchronizer body via the → Electronic Catalogue of Original Parts.
Because of the deeper recesses, the setting of 5th/6th gear was modified:
–  set up to production date 05.06 → Chapter
–  set as of production date 06.06 Octavia II → Chapter
For all vehicles
   
Disassembling and assembling the sliding sleeve and 5th/6th gear synchronizer body
1 - Spring
2 - Arresters
3 - Synchronizer body
4 - Sliding sleeve
–  Slide the sliding sleeve over the synchronizer body.
The deeper recesses -arrow A- of the arresters in the synchronizer body and the recesses -arrow B- in the sliding sleeve must be positioned above one another.
  S35-0341
Assemble sliding sleeve/5th/6th gear synchronizer body
l  The sliding sleeve is drawn over the synchronizer body.
–  Insert the arresters in the deeper recesses -arrows- and mount the springs with 120° offset. The angled end of the spring must grip into the hollow arrester.
  Note
t  As of production date 26.05.08, the corrugated spring ring is installed below the 5th gear synchronizer ring and above the 6th gear synchronizer ring → Item and → Item.
t  Then only install the springs for the arresters of which the ends are not bent at right angles. (As shown in → Fig. Pos. 1.)
  S35-0331
Springs bent at right angles -A- on certain gearboxes
These springs are installed on both sides.
–  The springs can only be installed on previous gearboxes together with arresters, which are hollow inside.
–  Insert arresters.
  N35-0336
Fitting location of the springs:
–  Mount the springs with 120° offset.
–  The angled end -A- of the spring must grip into the hollow arrester and at the same time be located below the shoulder -B- of the arresters.
The end bent at right angles always points away from the synchronizer body -direction of arrow-.
  N35-0337
Shape modification of inner ring for cylindrical roller bearing
I - Inner ring/cylindrical-roller bearing up to 08.06
II - Inner ring/cylindrical-roller bearing as of 09.06
  S35-0377

Setting drive shaft > < Drive shaft