Gearbox 02S (Components): Technical Data

Make

Skoda

Model

Octavia Mk2

Section

Technical Data › General repair information › Components

Power transmissionComponents

Components Gearbox t  Thoroughly clean the connection points and their surroundings before releasing. t  Bolts and other attachments should have a classification in the → Electronic Catalogue of Original Parts. t  When installing the manual gearbox, 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 gearbox, inspect the gearbox oil level and top up with oil if necessary → Chapter. t  Filling capacity and specification (Octavia II) → Chapter. t  Filling capacity and specification (Superb II) → Chapter. Vehicles Octavia ll with four-wheel drive Angle gearbox (four-wheel drive) t  The angle gearbox is screwed on laterally to the manual gearbox and has its own closed oil circulation system. t  Filling capacity → Chapter. t  Oil specification → Chapter. t  Inspect gear oil level (top up oil if necessary) → Chapter. Rear final drive t  If the rear final drive is replaced, inspect the gear oil level (top up oil if necessary) → Chapter as well as the oil level in the Haldex coupling (top up oil if necessary) → Chapter. t  Filling capacity → Chapter. t  Oil specification → Chapter. t  When installing carriers as well as waxed components, the contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.   Note t  The „Haldex coupling“ is installed 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 „OBR“ is fitted with the „Haldex coupling of the 4th generation“. t  The rear final drives „02D/0AV“ and „OBR“ have different „Haldex couplings“. t  Oil for Haldex coupling, assignment via the → Electronic Catalogue of Original Parts. Targeted fault finding, Vehicle self-diagnosis and Measuring method t  Before repairing the Haldex coupling try to determine the cause of the fault as accurately as possible using → Vehicle diagnostic, testing and information system VAS 5051 in the functions „Targeted fault finding“, „Vehicle self-diagnosis“ and „Measuring method“. Continued for all vehicles 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. O-rings, gasket rings, gaskets t  Always replace O-rings, gasket 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 → Chapter. Circlips t  Do not over-tension the circlips. t  Always replace damaged or tensioned circlips → Electronic Catalogue of Original Parts. t  Circlips must be positioned in the base of the groove.

t  Replace roll pins. Fitting position: Slot -A- longitudinal to power flow -arrow-. 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 all threaded holes into which self-locking screws or screws with locking agent are inserted (using e.g. a thread 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) in the gearbox with gear oil. t  Heat the inner rings/tapered-roller bearings on a heating plate or with the induction heater unit e.g. -VAS 6414- to approx. 100°C for installing. Install 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 measure the required thickness for each washer very precisely. t  Inspect for burrs and damage. Install only adjusting washers which are in perfect condition. Synchronizer rings t  Do not interchange the synchronizer rings, if re-used assign to the same gear. t  Inspect for wear, replace if necessary → Electronic Catalogue of Original Parts.

t  Check grooves -arrow 1- on synchronizer ring -A-, or check the inside of the ring for flattened parts (grooves worn). t  When installing the intermediate ring -B-, check outer contact surface -arrow 2- and inner contact surface -arrow 3- for grooves, blue coloring (caused by overheating) and other damages. t  Insert with some gearbox fluid. Pinions t  Clean and heat with induction heater unit e.g. -VAS 6414- to approx. 100°C before pressing on. t  The temperature can be checked with a temperature measuring instrument. t  Check fitting position. Sliding gears t  Inspect wheels 1st to 6th gear for small axial play or clearance after installation. Damage to sliding gears or sliding sleeves

t  Damage to synchronizer ring or sliding gear A -  Worn tooth pointing of the clutch gearing (engaging gearing) to synchronizer ring or sliding gear.

t  To compare: Synchronizer ring or sliding gear undamaged B -  Undamaged tooth pointing of the clutch gearing (engaging gearing) to synchronizer ring or sliding gear.

t  Damage to the sliding sleeve: C -  Worn tooth pointing of the longitudinal internal serration to the sliding sleeve.

t  To compare: Sliding sleeve undamaged D -  Undamaged tooth pointing of the longitudinal internal serration to the sliding sleeve. Clutch control t  When removing gearbox, remove slave cylinder, do not detach the hoses. t  If the slave cylinder with connected hydraulic line is removed, do not depress the clutch pedal. Otherwise the tappet is pressed out of the slave cylinder. 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 Octavia II → Chapter, Superb II → Chapter). t  In order to reduce unpleasant odours if the clutch is burnt, thoroughly clean the clutch bell as well as the flywheel and the engine on the side of the gearbox.

04 Transmission