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Roomster

General repair information
General repair information
Scrupulous care and cleanliness as well as the proper tools are essential requirements for carrying out proper and successful gearbox repairs. Obviously, the generally valid basic safety rules apply to repair work.
A number of generally valid notes for individual repair operations - which are otherwise listed several times at numerous points in the workshop manual - are summarized here. They apply to this workshop manual.
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, Fabia II → Chapter
t  Filling capacity, Roomster → Chapter
t  Filling capacity, Rapid → Chapter
t  Oil specification → Electronic Catalogue of Original Parts.
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  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  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 shaft seals is turned towards the fluid to be sealed.
t  Press in new shaft seal in such a way that the sealing lip is not located on the same point as the sealing lip of the old seal (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, top up oil if necessary → Chapter.
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 position: Slot -A- longitudinal to power flow -arrow-.
  S00-0262
Screws, nuts
t  Slacken the bolts and nuts against the tightening sequence.
t  Slacken and tighten nuts and bolts for attaching 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  Insert moist all 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  The temperature can be checked with a temperature measuring instrument.
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
  N00-0383
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.
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 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  The temperature can be checked with a temperature measuring instrument.
t  Check fitting position.
Sliding gears
t  Check 1st to 5th gear sliding gears after assembly for low axial play or smooth operation.
Clutch control
t  When removing gearbox, remove slave cylinder, do not detach the tube-hose line.
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 → 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.
Safety precautions for vehicles with start-stop system
  WARNING
On vehicles with start-stop system, there is the risk of injury from automatic engine start.
t  On vehicles with activated start-stop system (recognizable by a message in the dash panel insert), the engine can start automatically if required.
t  It is therefore necessary to ensure that the start-stop system is deactivated when carrying out work on the vehicle (ignition switched off; if required switch ignition on again).
  N35-10107

Clutch, control > < Overview of Transmission System