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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 check the gear oil level → Chapter.
t  Filling capacity and specification (Octavia II) → Chapter.
t  Filling capacity and specification (Superb II) → Chapter.
t  Filling capacity and specification (Yeti) → Chapter.
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.
Locking elements
t  Do not over-tension the circlips, replace if necessary → 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 and tighten screws or fixing nuts of covers and housings diagonally across in stages.
t  Do not twist particularly sensitive parts - e.g. clutch pressure plates - and slacken and tighten diagonally across.
t  Tightening torques apply for non-oiled nuts and bolts.
t  Always replace the self-locking screws and nuts → Electronic Catalogue of Original Parts.
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 bearing on a heating plate or with the induction heater unit -VAS 6414- to approx. 100°C, when installing press in 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.
  N30-10156
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 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 on a heating plate or with the induction heater unit -VAS 6414- to approx. 100°C before pressing on.
t  Check fitting position.
Sliding gears
t  Check 1st to 6th gear sliding gears after assembly for low axial play or for smooth operation.
Clutch control
t  When removing gearbox, remove slave cylinder without opening the line system.
t  If the slave cylinder with connected hydraulic line is removed, do not depress the clutch pedal. Otherwise the piston 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 → 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 > < General repair information