Page 1 Service Workshop Manual FABIA II 2007 ➤ Automatic 6-speed gearbox 09G Edition 05.07 Service Department. Technical Information...
Page 2 Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 32 - Torque converter 37 - Control, housing 38 - Wheels, Control 39 - Final drive, differential gear...
Page 3: Table Of Contents
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Contents 00 - Technical data ........... .
Page 4 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Removing and installing the gearbox input r.p.m. sender G182 ....
Page 5: Technical Data
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 00 – Technical data Technical Data for the Gearbox Identification of the gearbox The “Automatic 6-speed gearbox 09G” is installed in combination with 4-cylinder engines. Assignment ⇒ page 1...
Page 6 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Automatic gearbox 6-speed gearbox 09G Final drive Drive pinion Crown wheel Ratio 4,067 Automatic gearbox 6-speed gearbox 09G Identification characters Manufac‐ from 07.10 tured through Assignment Engine 1.6 ltr./77 kW Torque con‐...
Page 7: Information And Repair Instructions For The Automatic Gearbox 09G
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Information and repair instructions for the automatic gearbox 09G Information for the automatic gearbox Gearbox The automatic 6 speed gearbox 09G is equipped with 6 hydraul‐ ically controlled forward gears. When the lockup clutch is closed, these forward gears become mechanically driven gears by by‐...
Page 8 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 ♦ Do not run the engine or tow the vehicle when the oil pan of the gearbox has been removed or without ATF filling. ♦ If the automatic gearbox is replaced, check ATF level if nec‐...
Page 9: Explanation Of The Terms Used In This Workshop Manual
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 O-rings, gasket rings, gaskets ♦ Always replace O-rings, gaskets and gasket rings. ♦ After removing gaskets, examine the contact surface in the housing or on shafts for burrs or damage, and correct if nec‐...
Page 10 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Brakes They hold together the rotating components in the gearbox. As opposed to the clutches the brakes are supported on the gearbox housing. Torque converter Transfers the engine torque to the automatic gearbox and serves as a hydraulic starting clutch.
Page 11 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 tribute it via the oil galleries to the gearshift elements (clutches and brakes). Automatic gearbox control unit -J217- Control unit -J217- determines the shifting points. The function of the gearbox is monitored via self-diagnosis. If components or sensors fail, an emergency running programme is activated to continuity of vehicle operation.
Page 12: Torque Converter
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 32 – Torque converter Torque converter Note Repair instructions ⇒ page 3 ♦ Coat gasket rings with ATF. Other types of lubricant will cause ♦ the gearbox hydraulic control system to malfunction.
Page 13: Checking The Torque Converter
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Removing gasket ring for torque converter – Lever out gasket ring with ejection lever -MP3-418 (VW 681)- . Install gasket ring for torque converter – Insert the gasket ring for the torque converter using a pressure plate - T10175- .
Page 14 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Measure the dimension -a- between the screw-on flange of the gearbox housing and the contact surface of the threaded bores of the torque converter using a depth gauge.
Page 15: Control, Housing
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 37 – Control, housing Electric/Electronic components and fitting locations Electric/Electronic components and fitting locations 1 - Automatic gearbox control unit -J217- ❑ Fitting location and re‐ moving and installing ⇒...
Page 16 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 8 - Cover for shift mechanism ❑ removing and installing ⇒ page 26 ❑ the Tiptronic switch -F189- ist integrated in the shift mechanism; Fitting location ⇒ page 14 9 - Relay for starter interlock switch ❑...
Page 17 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Selector lever lock solenoid -N110- Fitting location: Selector lever lock solenoid -N110- -A- is located in the gearshift mechanism Slide valve body Fitting location: The slide valve body is bolted to the bottom of the gearbox housing and covered with the gearbox oil pan.
Page 18 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Multi-function switch -F125- Fitting location: The multi-function switch is located at the top of the gearbox. The plug connection -5- is directly placed onto the multi-function switch. Switch for Tiptronic -F189- Fitting location: The Tiptronic switch -F189- is integrated into the circuit board -A- of the gearshift mechanism.
Page 19 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Gearbox output r.p.m. sender -G195- Fitting location: The gearbox output r.p.m sender - G195- -arrow 2- is fixed to the gearbox housing behind the slide valve body. Gearbox input r.p.m. sender -G182- Fitting location: The gearbox input r.p.m sender -G182-...
Page 20: Removing And Installing Automatic Gearbox Control Unit J217
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Kick-down switch -F8- Brake light switch -F- Fitting location: The brake light switch -F- -arrow- is located in the foot controls. Note The switch may only be installed once to ensure that it has an adequately tight fit.
Page 21: Removing And Installing Selector Lever Lock Solenoid N110
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Press off locking tabs -arrows- from control unit holder. – Remove control unit from the top. Note The adaptation values in the gearbox control unit are reset when the plug connection of the gearbox control unit is separated.
Page 22 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Remove front exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26 with bracket -1-. – Remove underbody cover on right and left -arrows-. – Remove tunnel bridge -arrows-. – Unhook rear silencer in such a way that it does not come in contact with the rear axle.
Page 23 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Unscrew cover for bottom shift mechanism -arrows-. – Carefully slide the cover with boot over the selector lever con‐ trol cable forward. At the same time do not damage the boot.
Page 24 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Remove heat shield -arrows-. – Attach front exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26 with bracket -1-. – Attach underbody cover on right and left -arrows-. – Install tunnel bridge -arrows-.
Page 25 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Mount the plug connection -A-. – Install centre console ⇒ Body Work ⇒ Rep. Gr. 68 . – Installing the cover for the shift mechanism ⇒ page 26...
Page 26: Repairing Shift Mechanism
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Repairing shift mechanism Inspecting the gearshift mechanism WARNING Before working on the engine when the engine is running, in‐ sert the selector lever in position “P” and apply handbrake.
Page 27: Inspecting And Adjusting The Selector Lever Control Cable
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Inspecting and adjusting the selector lever control cable Inspection – Shift selector lever into position “P”. – Remove engine cover. – Disconnect plug from automatic gearbox control unit -J217- .
Page 28: Dismantling And Assembling The Gearshift Mechanism - Summary Of Components
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Release screw -2- at the front ball socket of the selector lever control cable -1-. – Tip selector lever in position “P” slightly to the front and to the rear, however under no circumstances move out of “P”...
Page 29 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 1 - Cover for shift mechanism ❑ removing and installing ⇒ page 26 2 - Intermediate piece 3 - 25 Nm ❑ 4 pieces ❑ for attaching the gear‐...
Page 30: Removing And Installing The Cover For The Shift Mechanism
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 12 - 23 Nm ❑ for cable support to gearbox ❑ 2 pieces 13 - Cable support ❑ for selector lever control cable on gearbox Removing and Installing the cover for...
Page 31: Removing And Installing Shift Mechanism
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Always replace retaining clip -arrow- ⇒ Electronic Catalogue of Original Parts . Note When inserting the plug connection ensure that the contact pins of the circuit board are not bent and that the retaining lugs of the cover do not break off.
Page 32 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Unhook the selector lever control cable -1- from the clip -arrow- at the gearbox. – Remove front exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26 with bracket -1-.
Page 33 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Remove heat shield -arrows-. – Unscrew the nuts -arrows-. – Remove the shift mechanism together with the selector lever control to the bottom, ensuring the selector lever control cable does not get bent and kinked.
Page 34: Removing And Installing The Selector Lever Control Cable
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Hang the selector lever control cable -1- in the clip -arrow- at the gearbox. For the routing of the selector lever control cable to the ATF cooler maintain a distance of at least 5 mm.
Page 35 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Unhook the selector lever control cable -1- from the clip -arrow- at the gearbox. – Shift selector lever to position “Tiptronic”. – Remove front exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26 with bracket -1-.
Page 36 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Remove heat shield -arrows-. – Unscrew cover for bottom shift mechanism -arrows-. – Carefully slide the cover with boot over the selector lever con‐ trol cable forward. At the same time do not damage the boot.
Page 37 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Press the selector lever control cable -2- onto the selector lev‐ er -3-. – Fit new locking clasp -1- for selector lever control cable at the gearshift mechanism.
Page 38: Removing And Installing The Tiptronic Switch F189
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Release screw -2- at the front ball socket of the selector lever control cable -1-. – Insert the selector lever control cable in the cable support/ gearbox and carefully press onto the gearshift lever. Do not bend the gearshift lever, otherwise it will no longer be possible to adjust the gearshift operation exactly.
Page 39: Removing And Installing The Gearbox
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Removing and installing the gearbox Special tools and workshop equipment required ♦ Supporting device -MP9-200 (10-222A)- ♦ Cap -MP9-200/3 (10-222A/3)- ♦ Hook for MP9-200 and T30099 -MP9-200/10 (10-222A/10)- ♦ Engine/gearbox jack -V.A.G 1383 A- ♦...
Page 40 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Unscrew earth strap -3-. – Detach cables -1- and -2- at starter and expose. – Mark hoses of ATF radiator to ATF radiator, in order to prevent interchanging when installing.
Page 41 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Separate plug connections -1- and -2- at automatic gearbox. – Unscrew bracket for electrical cables from the gearbox. – Tie up bracket with the electrical cables to the front.
Page 42 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Disconnect plug connection -2-. Note Unscrew bracket for AC pipe (if present) from the fan shroud. – Screw out screws -arrows- and take out fan shroud down‐ wards.
Page 43: Installing The Gearbox
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Mount engine/gearbox mount -3282- onto engine/gearbox jack -V.A.G 1383 A- . – Position adjusting plate -3282/36 - onto the gearbox mount -3282- (adjusting plate fits in only one position).
Page 44 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 WARNING If the converter is installed wrongly the driver of the torque converter or the ATF pump will be destroyed when the gearbox on the engine is connected at its flange.
Page 45: Transporting An Automatic Gearbox
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Torque converter on the driver plate Component Torque converter to drive plate, 6 nuts -arrow- Replace nuts. All other bolted connections Component Screws/nuts Transporting an automatic gearbox Special tools and workshop equipment required ♦...
Page 46 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Attach gearbox to engine and gearbox mount - MP1-202 (wie VW540, jedoch für Montageständer MP9-101)- -arrows-. – The workshop crane can be used ⇒ “3.3 Transporting an automatic gearbox”, page 41 for in‐...
Page 47: Inspecting Atf Level And If Necessary Topping Up
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Inspecting ATF level and if necessary topping up Inspecting ATF level and if necessary topping up Special tools and workshop equipment required ♦ Vehicle diagnosis, measurement and information system - VAS 5051- ♦...
Page 48 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 4.1.1 Inspection Note The ATF level is checked at the ATF inspection plug. ♦ The ATF level is correct, if a small amount of fluid flows out at ♦...
Page 49 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Always replace gasket ring -arrows- for ATF inspection plug ⇒ Electronic Catalogue of Original Parts . First of all the ATF in the overflow tube -arrow 2- drains off.
Page 50: Change Atf Or Top Up After Repair
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Screw in the adapter for ATF oil filling -VAS 6262/2- in the location of the gearbox inspection plug -arrow 1- and connect adapter for oil filling -VAS 6262- .
Page 51 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Note Pay attention to all the notes and test conditions ⇒ page 43 – Attach the reservoir of the ATF filling system as high as pos‐ sible to the vehicle.
Page 52 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Note Pay attention to all the notes and test conditions ⇒ page 43 – Screw in the adapter for ATF oil filling -VAS 6262/2- in the location of the gearbox inspection plug -arrow 1- and connect adapter for oil filling -VAS 6262- .
Page 53: Removing And Installing Atf Radiator
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Removing and installing ATF radiator ATF radiator - Overview of components 1 - Gearbox housing 2 - O-ring ❑ replace ⇒ Electronic Catalogue of Original Parts 3 - ATF radiator ❑...
Page 54 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Remove battery and battery tray ⇒ Electrical System ⇒ Rep. Gr. 27 . – Mark hoses of ATF radiator to ATF radiator, in order to prevent interchanging when installing.
Page 55: Wheels, Control
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 38 – Wheels, Control Removing and installing oil pan, oil filter, slide valve body and internal wiring looms WARNING Do not run the engine or tow the vehicle when the oil pan has been removed or without filling with ATF.
Page 56: Oil Pan, Oil Filter, Slide Valve Body, Internal Wiring Looms - Overview Of Components
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Oil pan, oil filter, slide valve body, internal wiring looms - Overview of com‐ ponents 1 - ATF inspection plug M10 - 27 Nm ❑ Replace gasket ring - Pos.
Page 57 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 ❑ removing and installing ⇒ page 73 16 - Gearbox housing 17 - ATF bleeder 18 - ATF radiator ❑ removing and installing ⇒ page 49 19 - Multi-function switch -F125- ❑...
Page 58 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 1.1.1 Tightening torques Note 90° correspond to a quarter turn. Rep. Gr.38 - Wheels, Control...
Page 59 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 1.1.2 Components at wiring loom of 14-pin plug 1 - Solenoid valve 1 -N88- 2 - Solenoid valve 2 -N89- 3 - Solenoid valve 4 -N91- 4 - Solenoid valve 6 -N93-...
Page 60: Removing And Installing Oil Pan
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 1.1.3 Components at wiring loom of 8-pin plug 1 - Hydraulic pressure sender 1 -G193- ❑ not available 2 - Plug connection for gearbox input r.p.m sender -G182- 3 - Cables for gearbox input r.p.m sender -G182-...
Page 61 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Unscrew the ATF inspection plug -A-. – Unscrew the overflow tube -C- (5 mm Allen key) and drain the ATF. – Loosen the 8 screws of the oil pan -arrows- crosswise.
Page 62: Removing And Installing The Oil Filter
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Tightening torque Component Overflow in oil pan ⇒ page 54 ATF inspection plug to oil pan ⇒ page 54 ⇒ page 54 Oil pan to gearbox housing Tighten crosswise in stages.
Page 63 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Remove the slide valve body WARNING Observe measures when disconnecting and connecting the battery ⇒ Electrical System ⇒ Rep. Gr. 27 . – Disconnect the battery-earth strap with the ignition off ⇒ Elec‐...
Page 64 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Note This sketch is absolutely necessary, so that the plugs on the ♦ solenoid valves are not inadvertently interchanged when re- installing the slide valve body. Under certain circumstances an interchange of the plugs could ♦...
Page 65 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Note Plug connection -1- and plug connection -4- are not available. – Plug connection -1- at hydraulic pressure sender -G193- – Plug connection -2- for the gearbox input r.p.m. sender - G182- .
Page 66 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Loosen the fixing screws -arrows- of the slide valve body crosswise and carefully remove the slide valve body. – Remove the bracket -1- and -2-. 3 - Designation of slide valve body, here e.g. “A2”...
Page 67 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Route the wiring loom -C- (with 8-pin plug) according to the illustration in the specified recess in the slide valve body. • The wiring loom -C- must not rest against the planetary gear‐...
Page 68 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Note If the cable -3- (for gearbox input rpm sender -G182- ) is too ♦ short, in order to screw the plug connection -2- on the provided point onto the slide valve body, it was wrongly routed or trap‐...
Page 69 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – After this, tighten the screws -arrows- for the slide valve body from the outside to the inside to a final torque ⇒ page 68 – Hang the wiring loom in the bracket -B-.
Page 70 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Connect plug connections -1 … 8- according to the sketches made by hand on the solenoid valves. Absolutely pay attention to the colours of the plug connections and cables.
Page 71 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Mount the plug connection -2-. – Mount the plug connection -6-. Note The counterparts of the plugs must have the same colour as the respective plugs. – Position bracket -7- on the gearbox oil temperature sender - G93- -8-.
Page 72 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Note If the cable -3- (for gearbox input rpm sender -G182- ) is too ♦ short, in order to screw the plug connection -2- on the provided point onto the slide valve body, it was wrongly routed or trap‐...
Page 73: Removing And Installing Wiring Loom With 14-Pin Plug
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 removing and installing wiring loom with 14-pin plug A - 14-pin plug B - Wiring loom for 14-pin plug ❑ Identification of solenoid valves and wiring loom routing ⇒ page 55...
Page 74 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 With gearbox installed: – Unplug the 14 pin plug connection -A- from gearbox plug. All: – Unscrew fixing screw of 14-pin plug outside the gearbox hous‐ ing. – Pull the plug out of the gearbox housing and carefully guide through the wiring loom -D-.
Page 75: Removing And Installing Wiring Loom With 8-Pin Plug And Integrated Gearbox Oil Temperature Sender G93
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Removing and installing wiring loom with 8-pin plug and integrated gearbox oil temperature sender -G93- A - 8-pin plug B - Wiring loom for 8-pin plug ❑ Wiring loom compo‐...
Page 76: Removing And Installing The Gearbox Input R.p.m. Sender G182
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 With gearbox installed: – Unplug the 8 pin plug connection -B- from gearbox plug. All: – Unscrew fixing screw of 8-pin plug outside the gearbox hous‐ ing. – Pull the plug out of the gearbox housing and carefully guide through the wiring loom -C-.
Page 77: Removing And Installing The Gearbox Output R.p.m. Sender G195
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Remove the slide valve body ⇒ page 58 – Release screw -1-. – Pull gearbox input r.p.m. sender -G182- with cable -A- out of the gearbox. Installing gearbox input r.p.m. sender -G182-...
Page 78 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Release screw -2-. – Pull gearbox output r.p.m. sender -G195- with cable -B- out of the gearbox. Installing gearbox output r.p.m. sender -G195- Installation is performed in the reverse order, pay attention to the following points: –...
Page 79: Removing, Installing And Setting Multi-Function Switch F125
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Removing, installing and setting mul‐ ti-function switch -F125- Removing and installing the multi-func‐ tion switch -F125- Removing – Shift selector lever to position “N”. – Switch off ignition. – Remove air filter ⇒ Engine ⇒ Rep. Gr. 24 .
Page 80 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Bend back the hooks of the circlip -2- using a screwdriver. Note If one or several hooks of the circlip break off by bending, the circlip must be replaced ⇒ Electronic Catalogue of Original Parts .
Page 81: Setting Multi-Function Switch F125
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – The plug -5- is placed onto the multi-function switch. – Push selector lever control cable -1- onto the gearshift lever -6-, while ensuring that the selector lever control cable does not get kinked.
Page 82 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Remove gearshift lever -1-. – Loosen both screws -B-. Note Do not release the screws. – Fit the setting gauge -T10173 - onto the gearshift shaft. – Turn the multi-function switch -A- until the peg of the plug -arrow 1- engages in the groove of the setting gauge - T10173- .
Page 83: Final Drive, Differential Gear
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 39 – Final drive, differential gear Replace the flange shaft gasket rings Gasket rings can be replaced with the gearbox installed. Replacing the left flange shaft gasket ring Gasket ring can be replaced with the gearbox installed.
Page 84: Replacing The Right Flange Shaft Seal Ring
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Screw a sheet metal screw with a diameter of approx. 4 mm into the drilled hole of the gasket ring -arrow-. Note The sheet metal screw must not be screwed in too deep, so that the bearing behind the screw is not damaged.
Page 85 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 ♦ Adapter -T10055/2- Work procedure Note General repair information ⇒ page 3 – Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 . – Remove right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
Page 86 FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 – Position pressure plate -T10177- in the middle on the shaft seal -A-. – Drive the new gasket ring up to the stop in the pressure plate; do not tilt the gasket ring.
Page 87: Replacing The Gasket Ring For The Gearshift Shaft
FABIA II 2007 ➤ Automatic 6-speed gearbox 09G - Edition 05.07 Replacing the gasket ring for the gearshift shaft Replacing the gasket ring for the gear‐ shift shaft Special tools and workshop equipment required ♦ Thrust piece -T10174- – Removing multi-function switch -F125- ⇒...
Page 88 Service Workshop Manual FABIA II 2011 ➤ Automatic gearbox 0AM Edition 02.10 Service Department. Technical Information...
Page 89 Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 30 - Clutch 34 - Control, housing 35 - Wheels, shafts 39 - Final drive, differential gear...
Page 90 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Contents 00 - Technical data ........... . Technical Data for the Gearbox .
Page 91 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Replace the flange shaft gasket rings ........Replacing the left flange shaft gasket ring .
Page 92: Technical Data
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 00 – Technical data Technical Data for the Gearbox Identification of the gearbox The “7-speed automatic gearbox DSG - 0AM” is installed in com‐ bination with 4-cylinder engines. Assignment ⇒ page 1 Location of identification code letters on the gearbox Example for a gearbox: The gearbox code letter -arrow- is located at the top and bottom...
Page 93: Filling Capacity
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Automatic gearbox DSG 0AM “front-wheel drive” Gearbox Identification charac‐ ters i tot. in the highest gear 2,430 Drive shaft flange ∅ 100 mm Automatic gearbox DSG 0AM “front-wheel drive” Gearbox Identification charac‐...
Page 94 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Gearbox capacity Area with gearbox oil New filling 1.7 ltr. Top-up no top-up Lubricant Gearbox oil for double clutch gearbox 0AM part number ⇒ Electronic Catalogue of Original Parts Capacity in the mechatronics for Area with hydraulic oil double clutch gearbox -J743- Filling...
Page 95: Transmission System - Overview
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Transmission System - Overview The “7-speed automatic gearbox DSG - 0AM” has 2 drive shafts and 3 output shafts. A1 - 1st drive shaft A2 - 2nd drive shaft B1 - 1st output shaft B2 - 2nd output shaft B3 - 3rd output shaft C - Front final drive...
Page 96: Instructions For Automatic Gearbox Dsg - 0Am
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Instructions for automatic gearbox DSG - 0AM The automatic gearbox DSG°-°0AM is also designated as double clutch gearbox. The gearbox is built like a 7-speed manual gear‐ box. Notes on tow starting and towing Caution When towing the vehicle, the selector lever must be in position “N”...
Page 97 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 The gearbox has an opening in the housing -arrow-. Note This opening is closed with a cap. ♦ When installing pay attention that nothing falls into this open‐ ♦ ing. ♦...
Page 98 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 The “7-speed automatic gearbox DSG - 0AM” has 2 separate, different oil fillings. One for the area with gearbox oil -arrow A- and the other one for the area with hydraulic oil -arrow B-. The oil level cannot be checked.
Page 99: Working With Testing Devices
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 The “targeted fault finding” is performed with the ⇒ Vehicle diag‐ nosis, testing and information system VAS 5051. Rules of cleanliness ♦ Thoroughly clean the connection points and their surroundings before releasing.
Page 100: Explanation Of The Terms Used In This Workshop Manual
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Explanation of the terms used in this workshop manual These explanations are only related to the automatic gearbox DSG - 0AM. They do not claim to be valid in all cases. CAN databus Data transfer.
Page 101 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Parking position When the vehicle is parked, the selector lever mechanically locks the parking gear thereby preventing the vehicle from moving off (unintentionally). Shift mechanism The selector lever position is no longer communicated mechani‐ cally, as for the other automatic gearboxes, via the selector lever control cable and the multi-function switch (sensor for driving po‐...
Page 102: Clutch
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 30 – Clutch Removing and installing the double clutch Short description Detach the clutch “upwards” when the gearbox is removed. The mechatronics remains on the gearbox. If a new clutch is installed, the positions of the engaging bearings for “K 1”...
Page 103 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Remove both ventilation caps -arrows- and close with suitable screw plugs so that no oil can flow out. The gearbox must be installed on the gearbox mount -T30109 (VW 353)- with the clutch pointing upwards. The way in which the gearbox is transported and attached to the assembly support can be seen here ⇒...
Page 104 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Remove the circlip for the clutch -arrow-. Note It is possible that the clutch is resting at the circlip so close that ♦ the circlip “fits very tightly”. In this case it is possible to press the clutch slightly downwards as described in the following work procedure.
Page 105 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Insert the extractor -T10373- in the clutch and remove the clutch. – Remove the clutch together with the extractor -T10373 - . – Remove the small engaging bearing. – Remove the large engaging lever. –...
Page 106: Adjust The Positions Of The Engaging Bearing For Clutch "K 1 And K 2
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Remove the support for the engaging lever. Before installing the clutch, check if it must be adjusted or not ⇒ page 15 Install double clutch ⇒ page 24 Adjust the positions of the engaging bearing for clutch “K 1 and K 2”...
Page 107 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 “K 1” “K 2” Note Perform the following work steps accurately and “in sequence”. Adjusting: – Install the parts of the clutch up to the large engaging lever ⇒ page 24 Do not insert an adjusting washer.
Page 108 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Install the circlip of the outer drive shaft -arrow-. – Place the ruler -T40100- upright on the flange of the clutch housing. Note The ruler -T40100 - must remain in this position during the fol‐ lowing measurements.
Page 109 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Measure the dimension “B” once more at the opposite-facing point. Note Do not measure on the joint of the ring. The ring could be pressed off from the joint and thus the measuring result will be inaccurate. –...
Page 110 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Measure the distance from the “shaft end” to the gauge block -T10374- . – Position the digital depth gauge twice at opposite-facing points for a precise measurement. In this way, an even more precise value is determined as the in‐ accuracy resulting from the “wobbling”...
Page 111 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Please read off the value of the clutch tolerance -arrow- from the “new” clutch. A value between minus 0.40 and plus 0.40 mm is attributed to the new clutch. –...
Page 112 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Only insert the small bearing. Do not insert an adjusting washer! The small engaging bearing fits in only one position due to the 4 grooves. – While “turning”, check if the small engaging bearing is correctly installed and the grooves are correctly positioned.
Page 113 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Place the digital depth gauge at the “top” on the outer drive shaft. – Reset the depth gauge to “zero”. – Measure the distance from the “shaft end” to the gauge block -T10374- .
Page 114 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Position the digital depth gauge twice at opposite-facing points for a precise measurement. In this way, an even more precise value is determined as the in‐ accuracy resulting from the “wobbling” on the engaging bearing is thus minimised.
Page 115: Install Double Clutch
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Please read off the value of the clutch tolerance -arrow- from the “new” clutch. A value between minus 0.40 and plus 0.40 mm is attributed to the new clutch. –...
Page 116 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Do not oil or grease! Before installing the clutch, the position of the engaging bearings “K 1 and K 2” must be adjusted ⇒ page 15 – Insert the plastic support of the engaging levers and check for correct fit.
Page 117 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 The small engaging bearing fits in only one position due to the 4 grooves. If the clutch was replaced, the adjusting washer also belongs un‐ der the bearing. – While “turning” the bearing, check if it is correctly installed and the grooves are correctly positioned.
Page 118 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Position the supporting bridge -T10323- parallel to the flange of the clutch housing. – Equalise distances, e.g using washers -B- with a total thick‐ ness of 15 mm. – Attach the supporting bridge -T10323- with screws -A-. Note Fasten screws -A- with nuts.
Page 119 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Turn the clutch against the extractor by hand so that the clutch is thus located in its fitting position. • Only turn the clutch by hand, do not use any tool. Only turn by hand.
Page 120 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Insert the circlip for the hub -arrow-. Fitting location: The joint of the ring must point to the “lug” on the clutch. – Turn the clutch by hand and while turning it pay attention to the “small”...
Page 121 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – In this case, remove the clutch again ⇒ page 11 – Have a close look at the adjusting washers -arrows-. • The washers must be correctly positioned. They should not be damaged.
Page 122: Control, Housing
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 34 – Control, housing Electric/electronic components and fitting locations of the automatic gearbox DSG - 0AM 1 - Diagnostic connection ❑ Fitting location: dash panel in the area of the driver's footwell 2 - Selector lever position indi‐...
Page 123 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 ❑ the removal and installation procedure is only possible together with the gearshift mechanism ⇒ page 40 7 - Selector lever -E313- with Tiptronic switch -F189- , selector lever sensor control unit -J587- and selector lever switch locked in P -F319 - ❑...
Page 124 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Brake light switch -F- and brake pedal switch -F47- Fitting location: Brake light switch -F- and brake pedal switch - F47- -Pos. 3- are located on the master brake cylinder. Kick-down switch -F8- An initialised value of the accelerator pedal position sender - G79- / accelerator pedal position sender 2 -G185 - (intergrated in...
Page 125: Shift Mechanism
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Shift mechanism WARNING Before working on the engine when the engine is running, in‐ sert the selector lever in position “P” and apply handbrake. Inspecting the gearshift mechanism ♦ In selector lever positions “S”, “D”, “R” and Tiptronic position it must not be possible to activate the starter.
Page 126: Inspecting And Adjusting The Selector Lever Control Cable
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Selector lever in position “D”, ignition and light switched on • Selector lever in the Tiptronic gear leads to The lighting up of the “D” on the lamp for selector lever scale il‐ lumination -L101- should go out and the “+”...
Page 127 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – If this is not the case, then the gearshift mechanism must be ⇒ page 36 2.2.2 Adjusting selector lever control cable The selector lever control cable must always be set, if: ♦...
Page 128: Check Operation Of The Ignition Key Anti-Removal Lock
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Position gearshift shaft lever at gearbox in “P”. To do so, press the gearshift shaft lever in -direction of arrow- in the direction towards the cable support. The figure shows the gearbox “from the rear”. -P- is in the direction towards the cable support.
Page 129: Summary Of Components - Gearshift Mechanism
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 • The ignition key should only be removable when the selector lever is in “P”. • The selector lever cannot be moved out of position “P” when the lock button is pressed and the brake pedal is actuated. If the ignition key removal lock does not function as described: ♦...
Page 130: Removing And Installing The Handle And Cover For The Shift Mechanism
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 ❑ Remove the shift mechanism from the shift housing ⇒ page 39 6 - Screw, 8 Nm ❑ 4 pieces 7 - Shift housing with gasket ❑ Remove shift housing ⇒...
Page 131: Removing And Installing Gearshift Mechanism With Selector Lever Control Cable
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Pull the cover -B- upwards over the handle. – Disconnect plug -A- for lamp for selector lever scale illumina‐ tion -L101- . – Open the warm-type clamp -arrow- below the handle and pull off handle with cover.
Page 132 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Disconnect the plug connection -A- from the gearshift mech‐ anism. – Unscrew the screws -arrows- from the shift housing. – Raise vehicle. – Unhook the pre-exhaust pipe from the retaining straps on the assembly carrier.
Page 133 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Remove lock washer. Note The lock washer -arrow- of the selector lever control cable must always be replaced ⇒ Electronic Catalogue of Original Parts . – Remove the gearshift mechanism. Note Do not bend or buckle selector lever control cable.
Page 134: Emergency Release Of Gearshift Mechanism Out Of Position "P
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Carefully press the selector lever control cable -2- onto the lever/gearshift shaft of the gearbox and secure in the cable support with a new lock washer -1-. – Check operation of the ignition key anti-removal lock ⇒...
Page 135: Removing And Installing The Tiptronic Switch F189
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Depress the brake pedal or pull on the handbrake. – Press the yellow plastic wedge -A- in -direction of arrow 1-. – Now press the button on the selector lever grip and move the selector lever -B- in -direction of arrow 2- out of the position “P”.
Page 136: Mechatronics For Double Clutch Gearbox J743
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Mechatronics for double clutch gear‐ box -J743 - Safety instruction for° mechatronics for double clutch gearbox -J743- DANGER! Do not remove the pressure tank. The pressure tank is under pressure and should not be opened. 3.
Page 137 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Caution ♦ Do not slacken cover screws for mechatronics for double clutch gearbox -J743- . ♦ Do not let the engine run and do not tow the vehicle if the mechatronics for double clutch gearbox -J743- is removed or without filling with gearbox oil.
Page 138: Summary Of Components - Mechatronics For Double Clutch Gearbox J743
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Summary of components - mechatronics for double clutch gearbox -J743- Note The “new” mechatronics for the gearbox is already precisely filled with oil at the factory, do not drain the oil. ♦...
Page 139 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Note Observe safety instruction for the mechatronics for double ♦ clutch gearbox -J743- ⇒ page 45 Observe instructions for automatic gearbox DSG - 0AM ♦ ⇒ page 5 General repair information ⇒...
Page 140 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Slacken the long screws -B- (4 pieces, M8 x 90) of the me‐ chatronics for double clutch gearbox -J743- “crosswise” and release them. – Slacken the remaining screws -A- (3 pieces, M8 x 35) “cross‐ wise”...
Page 141 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Insert the assembly lever -T10407- between the engaging lev‐ ers for the clutch control and the gearbox housing -direction of arrow-. The assembly lever -T10407- should rest with the complete sur‐ face of the “reverse side”...
Page 142 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Note Exert a little force on the tip of the assembly lever -T10407- ♦ when turning it. This prevents that the assembly lever -T10407 - slips out when ♦ turning it. Do not remove the assembly lever -T10407- .
Page 143: Remove Mechatronics For Double Clutch Gearbox J743 ; Gearbox Installed
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 If the mechatronics for double clutch gearbox -J743- “hooks” and cannot be removed: It can happen that the mechatronics cannot be removed. In this case, the gear actuator “hooks” at the “top left” on the gearbox housing.
Page 144 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Under “7-speed double clutch gearbox”, select bring gear actuator into neutral position – Switch off ignition. – Disconnect the battery-earth strap with the ignition off ⇒ Elec‐ trical System ⇒ Rep. Gr. 27 . –...
Page 145 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Release oil drain plug -arrow- at the gearbox. – Drain off oil. – Install oil drain plug. Vehicles with radiator fan control unit -J293- – Unscrew the nuts -3- from the left frame side rail and tie up the radiator fan control unit -J293- -4-.
Page 146 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Release the fan shroud on the catch hook e.g. using a screw‐ driver and remove ⇒ Engine ⇒ Rep. Gr. 19 . – Place a catch pan for workshop crane -VAS 6208- under the radiator.
Page 147 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Slacken the long screws -B- (4 pieces, M8 x 90) of the me‐ chatronics for double clutch gearbox -J743- “crosswise” and release them. – Slacken the remaining screws -A- (3 pieces, M8 x 35) “cross‐ wise”...
Page 148 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Insert the assembly lever -T10407- between the engaging lev‐ ers for the clutch control and the gearbox housing -direction of arrow-. The assembly lever -T10407- should rest with the complete sur‐ face of the “reverse side”...
Page 149 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Note Exert a little force on the tip of the assembly lever -T10407- ♦ when turning it. This prevents that the assembly lever -T10407 - slips out when ♦ turning it. Do not remove the assembly lever -T10407- .
Page 150 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 If the mechatronics for double clutch gearbox -J743- “hooks” and cannot be removed: It can happen that the mechatronics cannot be removed. In this case, the gear actuator “hooks” at the “top left” on the gearbox housing.
Page 151: Place The Mechatronics For Double Clutch Gearbox J743 By Hand In The "Removal Position
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Place the mechatronics for double clutch gearbox -J743 - by hand in the “removal position” It is possible that the mechatronics cannot be removed. In this case, the gear actuator “hooks” at the “top left” on the gearbox housing -arrow-.
Page 152 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Lever off the selector lever control cable -A- from the gearshift shaft lever with the removal tool for the inner lining of the door panel -MP8-602/1- . – Detach the lock washer -arrow- of the selector lever control cable.
Page 153: Installing Mechatronics For Double Clutch Gearbox J743 ; Gearbox Removed
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Press the shift fork to the side through the opening in -direction of arrow-. By doing so, the “hooking” gear switch is also pressed back and the mechatronics can be removed. Note Do not reinstall the cover yet, as the gear oil is filled up via this opening after installing the mechatronics for double clutch gear‐...
Page 154 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 N - Neutral R - Reverse gear Note When the reverse gear is engag‐ ♦ ed, the extended tappet of the mechatronics is “hooked” on the gearbox housing. Therefore, the mechatronics ♦...
Page 155 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Set the 4 gear switches on the rear side of the mechatronics for double clutch gearbox -J743- into the specified position. Specified position: -a- = 25 mm Note Clean the sealing surface on the gearbox housing on which ♦...
Page 156 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Screw in the screws -A- (3 pieces, M8 x 35) and -B- (2 pieces, M8 x 90) crosswise by hand. – Remove guide bolts -T10406- . – Screw in the remaining screws -B- (2 pieces, M8 x 90) by hand. Make sure that the tappets are correctly positioned in the pans of the engaging levers -arrow-.
Page 157: Install Mechatronics For Double Clutch Gearbox J743 ; Gearbox Installed
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Tighten all the screws for the mechatronics for double clutch gearbox -J743- crosswise to the tightening torque ⇒ page 47 – Carefully turn the assembly lever -T10407- to the right and remove.
Page 158 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – If this is not yet the case: Close the ventilation with a suitable screw plug so that no oil can flow out. Note Make sure that all the shift forks are in the “centre position” before installing the mechatronics for double ♦...
Page 159 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 N - Neutral R - Reverse gear Note When the reverse gear is engag‐ ♦ ed, the extended tappet of the mechatronics is “hooked” on the gearbox housing. Therefore, the mechatronics ♦...
Page 160 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Set the 4 gear switches on the rear side of the mechatronics for double clutch gearbox -J743- into the specified position. Specified position: -a- = 25 mm Note Clean the sealing surface on the gearbox housing on which ♦...
Page 161 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Screw in the screws -A- (3 pieces, M8 x 35) and -B- (2 pieces, M8 x 90) crosswise by hand. – Remove guide bolts -T10406- . – Screw in the remaining screws -B- (2 pieces, M8 x 90) by hand. Make sure that the tappets are correctly positioned in the pans of the engaging levers -arrow-.
Page 162 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Tighten all the screws for the mechatronics for double clutch gearbox -J743- crosswise to the tightening torque ⇒ page 47 – Carefully turn the assembly lever -T10407- to the right and remove.
Page 163 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Attach the bottom coolant hose at the radiator -arrow- and fill up with coolant ⇒ Engine ⇒ Rep. Gr. 19 . – If removed, install the radiator fan control unit -J293- on the left frame side rail.
Page 164: Removing And Installing The Gearbox
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Removing and installing the gearbox Special tools and workshop equipment required ♦ Removal tool for the inner lining of the door panel -MP8-602/1- ♦ Lifting device -MP9-200 (10-222A)- ♦ Adapter -MP9-200/3 (10-222A/3)- ♦...
Page 165 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Remove battery tray, to do so release the screw and the nuts -arrows-. – Lever off the selector lever control cable -A- from the gearshift lever with the removal tool for the inner lining of the door panel -MP8-602/1- .
Page 166 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 One of the screws is located in the opening for the starter -arrow-. – Screw out this screw. Caution ♦ Under no circumstances must the plug contacts in the plug of the gearbox be touched with the hands, because the control unit can be destroyed through static discharge as well as the mechatronics.
Page 167 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Release the fan shroud on the catch hook e.g. using a screw‐ driver and remove ⇒ Engine ⇒ Rep. Gr. 19 . For vehicles 1.2/77 kW – Remove lambda probe -G39- -1-. –...
Page 168 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Open the spacer holder -1- and remove the cables -2- and -3- for the power-assisted steering gear. – Remove the engine pump aggregate for the power-assisted steering with the bracket from the frame side rail and tie up to the side ⇒...
Page 169 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Install supporting device -MP9-200 (10-222A)- . For this pur‐ pose, position the supports -A- next to the screw -arrow 1- and the support of the front flap -arrow 2- as shown. –...
Page 170 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Screw out the remaining fixing screws -arrows- of the console at the gearbox, starting from the left wheelhouse. – Remove console from gearbox. For the removal of the gearbox 0AM the gearbox mount -3282- is aligned with the adjusting plate -3282/59 - and placed on the en‐...
Page 171: Installing The Gearbox
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 If necessary, remove the bracket at the front of the gearbox. Note If a “new” gearbox must be installed, the brackets must be fitted to the “new” gearbox. – Install the right flange shaft again ⇒...
Page 172 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Carefully raise gearbox with the engine/gearbox jack -V.A.G 1383 A- and put in its installation position with the gearbox mount -3282- . Note Observe all lines and coolant hoses when raising the gearbox. –...
Page 173 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 4.2.1 Tightening torques Attachment of gearbox to engine (1.2 ltr./77 kW TFSI) Pos. Screw M12 x 65 M12 x 65 M12 x 50 M12 x 65 M12 x 65 M10 x 25 2) 3) 2) 3) M10 x 25...
Page 174: Transport The Gearbox And Secure To The Assembly Support
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Transport the gearbox and secure to the assembly support Special tools and workshop equipment required ♦ Ring bolt -3368- (2 pieces) ♦ Shackle -10 - 222 A /12- ♦ Retaining plate -T30108- ♦...
Page 175 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Raise the gearbox at the assembly stand -MP9-101 - . The gearbox is raised together with the gearbox mount -T30109 (VW 353)- at the assembly stand . Attach gearbox to assembly stand -MP9-101 - . –...
Page 176: Change Gearbox Oil
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 Change gearbox oil Special tools and workshop equipment required ♦ Removal tool for the inner lining of the door panel -MP8-602/1- ♦ Sealing grease -G 052 128 A1- ♦ Catch pan Note On the “7-speed automatic gearbox DSG - 0AM”...
Page 177 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Lever off the selector lever control cable -A- from the gearshift shaft lever with the removal tool for the inner lining of the door panel -MP8-602/1- . – Remove the lock washer -arrow- of the selector lever control cable, the selector lever control cable must be left in the fitting position.
Page 178 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Top up with 1.7 ltr. oil through the opening -arrow-. – Clean the sealing surface on the gearbox and the cover. Note Grease the shaft seal in the cover with sealing grease -G 052 ♦...
Page 179: Wheels, Shafts
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 35 – Wheels, shafts Pinions and shafts At present no repairs are carried out on the pinions and shafts. Rep. Gr.35 - Wheels, shafts...
Page 180: Final Drive, Differential Gear
FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 39 – Final drive, differential gear Replace the flange shaft gasket rings Replacing the left flange shaft gasket ring Special tools and workshop equipment required ♦ Multi-purpose tool -MP3-419 (VW 771)- ♦...
Page 181 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Unscrew the nut -1- from the coupling rod -3- -arrow- ⇒ Chas‐ sis ⇒ Rep. Gr. 40 . – Remove coupling rod and turn anti-roll bar -2- slightly up‐ wards.
Page 182 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Fill half the space between the sealing lip and dust lip with sealing grease -G 052 128- -arrow-. – Drive in new gasket ring with pressure plate -T30028 (3305)- up to the stop.
Page 183 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 1.2.1 Removing Note Observe the general repair instructions ⇒ page 5 ♦ Do not remove both flange shafts simultaneously from the ♦ gearbox. If the differential bevel gears twist in the differential gear, it will be difficult to reinstall the fixing screw for the flange shaft.
Page 184 FABIA II 2011 ➤ Automatic gearbox 0AM - Edition 02.10 – Drive the new seal ring in up to the stop, do not twist the seal ring. – Insert the flange shaft. – Tighten new conical screw to tightening torque. –...
Page 185 Service Workshop Manual Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , Rapid India 2011 ➤ , Rapid NH 2013 ➤ , Roomster 2006 ➤ Gearbox 02R Edition 08.2014 Service Department. Technical Information...
Page 186 Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 30 - Clutch 34 - Controls, housing 35 - Gears, shafts 39 - Final drive - differential...
Page 187 Clutch control ............Summary of components - foot controls (Fabia II 2007 ►; Roomster 2006 ►) ..
Page 188 Removing and installing the gearbox ......... . Removing gearbox (Fabia II 2007 ►; Roomster 2006 ►) ......
Page 189: Technical Data
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 00 – Technical data Identification of the gearbox (SRL000728; Edition 08.2014) ⇒ “1.1 Identification of the gearbox”, page 1...
Page 190: Technical Data
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Technical data ⇒ “2.1 Identification characters, aggregate assignment (Fabia II)”, page 2 ⇒ “2.2 Identification characters, aggregate assignment (Room‐...
Page 191: Identification Characters, Aggregate Assignment (Roomster)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Identification characters, aggregate assignment (Roomster) Manual gearbox 5 speed 02R Identification characters Manufac‐ from 03.06...
Page 192: Filling Capacity
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Manual gearbox 5 speed 02R Identification characters Manufactured from 07.12 07.12 07.12 through Assignment: Engine 1.6 ltr./77 kW TDI CR...
Page 193: Overview Of Transmission System
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Overview of Transmission System ⇒ “3.1 Designation of components and transmission ratio”, page 5...
Page 194: General Repair Instructions
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 General repair instructions To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential.
Page 195 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 O-rings, gasket rings, gaskets ♦ Replace O-rings, gasket rings and gaskets ⇒ Electronic Cata‐...
Page 196 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Nuts and bolts ♦ Slacken the bolts and nuts against the tightening sequence. ♦ Slacken and tighten nuts and bolts for attaching covers and housings without tightening sequence diagonally across in stages.
Page 197: Clutch Control
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ♦ These are not interchangeable. If re-using, allocate synchron‐ izer rings to the same sliding gear.
Page 198: Summary Of Components - Foot Controls (Fabia Ii 2007 ►; Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 30 – Clutch Clutch control ⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;...
Page 199: Clutch Control
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Note Summary of components - Hydraulics ♦ ⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) ”, page 41 After the battery earth strap is disconnected and re-connected, carry out additional operations ⇒...
Page 200 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 9 - Bushing 10 - Bearing bolt 11 - Clutch pedal ❑ removing and installing ⇒...
Page 201 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Difference between clutch pedal switches - F36- ♦ -A- Clutch pedal switch with angular housing Removing and installing ⇒...
Page 202: Removing And Installing The Crash Strut For The Clutch Pedal (Fabia Ii 2007 ►; Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Unplug connector -1- from the clutch pedal switch - F36- . – Turn clutch pedal switch - F36- -2- in the bracket 45° to the left and remove it from the support.
Page 203: Bia Ii 2007 ►; Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Removing – Remove the storage area on the driver's side ⇒ Body Work; Rep. gr. 70 .
Page 204: Removing And Installing The Clutch Pedal (Fabia Ii 2007 ►; Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Then press the over-centre helper spring onto the centering pin of the clutch pedal -arrow-.
Page 205: Summary Of Components - Foot Controls (Fabia Ii 2011 ►; Roomster 2011 ►; Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – The support -A- must be located on the actuating rod -B- of the master cylinder.
Page 206 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - Front wall ❑ with mount for bearing bracket and master cyl‐ inder 2 - Bushing ❑...
Page 207 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ❑ removing and installing ⇒ “1.11 Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ►;...
Page 208 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Removing and installing tension spring – Insert the vibration damper with the recess -arrows- as of the 2nd spring coil -arrows-.
Page 209 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 • The tappet -A- of the clutch pedal switch must not be pulled out.
Page 210 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Tightening torque Crash strut to steering column (2 screws) 9 Nm...
Page 211 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Version with one fixing screw Removing – Remove the storage area on the driver's side ⇒ Body Work;...
Page 212 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Tightening torque Crash strut to steering column (1 screw) 20 Nm...
Page 213: Summary Of Components - Foot Controls (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Summary of components - Foot controls (Rapid) Note Summary of components - Hydraulics ⇒ “1.15 Summary of components - Hydraulic (Rapid) ”, page 44 ♦...
Page 214 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 9 - Clutch pedal ❑ removing and installing with over-centre helper spring ⇒ “1.12 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) ”,...
Page 215: Removing And Installing The Bracket With The Master Cylinder (Fabia Ii 2011 ►; Roomster 2011 ►; Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Unplug connector from the clutch pedal switch - F36- . – Turn the clutch pedal switch at the bracket 45° in -direction of arrow- and remove it from the support.
Page 216 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – If the master cylinder is not accessible, remove the engine control unit from the front wall ⇒ Engine; Rep. gr. 23 .
Page 217 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove clutch pedal switch - F36- -1- ⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”, page 20 –...
Page 218: Removing And Installing The Bracket With The Master Cylinder (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Vehicles with start-stop system – Insert the clutch position sender - G476- with connected elec‐...
Page 219 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Detach return hose -A- at master cylinder and close with a suitable tool e.g. closing tool - T10249/1- .
Page 220: Removing And Installing The Bracket Without The Master Cylinder
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Note Position self-locking nuts -1- and -2- for bracket -3- on front wall and tighten.
Page 221 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – If present, remove crash strut ⇒ “1.5.2 Removing and installing crash strut”, page 21 –...
Page 222: Removing And Installing The Bracket Without The Master Cylinder (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Note Replace self-locking nuts -1- and -2- for bracket -3- on front wall. – The support -A- must be located on the actuating rod -B- of the master cylinder.
Page 223 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Unlock the actuating rod/master cylinder from the clutch pedal as follows: – Pull clutch pedal slightly into the passenger compartment.
Page 224: Removing And Installing The Clutch Pedal With The Over-Centre Helper Spring (Fabia Ii 2011 ►; Roomster 2011 ►; Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1.11 Removing and installing the clutch pedal with the over-centre helper spring (Fa‐ bia II 2011 ►; Roomster 2011 ►; Rapid Note Install the clutch pedal with a new bearing axle.
Page 225 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Insert the over-centre helper spring laterally from the bottom into the support -A- in the bracket next to the body of the mas‐...
Page 226: Removing And Installing The Clutch Pedal With The Over-Centre Helper Spring (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1.12 Removing and installing the clutch pedal with the over-centre helper spring (Rap‐ Note Install the clutch pedal with a new bearing axle.
Page 227: Removing And Installing The Clutch Pedal With The Tension Spring
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Position the over-centre helper spring on the centering pin of the clutch pedal -arrow-.
Page 228 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Removing – Removing the footwell vent ⇒ Heating and Air Conditioning; Rep. gr. 87 .
Page 229: Summary Of Components - Hydraulic (Fabia Ii ►; Roomster ►; Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – The support -2- must be located on the actuating rod -1- of the master cylinder.
Page 230 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - Brake fluid reservoir 2 - Supply hose ❑ out of rubber ❑ on certain vehicles out of plastic ⇒...
Page 231 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 8 - Gasket ring/O-ring ❑ pull onto line connection ❑ insert with brake fluid ❑...
Page 232: Summary Of Components - Hydraulic (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Install the support -A- at the actuating rod of the master cylinder in -direction of arrow- Gasket rings/O-rings for tube-hose lines Pos.
Page 233 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - Brake fluid reservoir 2 - Spring clamp 3 - Supply hose 4 - Master cylinder ❑...
Page 234 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ❑ for tube-hose line pos. 14 16 - Support ❑ for tube-hose line Pos. 14 on the gearbox ❑...
Page 235: Check Hydraulic Clutch Control
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Gasket rings/O-rings for tube-hose lines Pos. Version of line connection Line connection with round slot -arrow 1-...
Page 236: Removing And Installing The Master Cylinder
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove the slave cylinder from the gearbox last, - do not open the line system - and check the collar for brake fluid leak.
Page 237: Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Detach return hose -A- at master cylinder and close with a suitable tool e.g. closing tool - T10249/1- .
Page 238: Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Unscrew the nuts -arrows 1- and remove the bracket -arrow A- together with the master cylinder.
Page 239: Removing And Installing The Slave Cylinder
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ⇒ “1.7 Removing and installing the bracket with the master cylin‐ der (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”, page 27 Removing bearing bracket with the master cylinder (Rapid 2011 ►)
Page 240 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Removing Note If the battery earth strap is disconnected and connected, carry out certain additional operations ⇒ Electrical System; Rep. gr. 27 .
Page 241: Bleeding The Clutch Control
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Disconnect the Bowden cable support from gearbox -arrows-. – Tie up shift cable and selector cable.
Page 242 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Tightening torque Component Tightening torque Slave cylinder to gearbox Fabia II, Roomster, Rapid NH ⇒...
Page 243 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Insert the bleeder hose on the slave cylinder -arrow- and open the vent valve.
Page 244: Repairing The Clutch Release Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Repairing the clutch release mecha‐ nism Special tools and workshop equipment required ♦ Grease for plug serration of clutch disc - G 000 100- ♦...
Page 245 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ❑ Grease contact point on the clutch release lever with grease for plug serration of clutch disc - G 000 100 9 - Slave cylinder ❑...
Page 246: Repairing Clutch
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Repairing clutch Fault finding of power transmission - problems with the clutch and clutch control ⇒...
Page 247 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - Flywheel ❑ make sure the centering pins are tight ❑ The locating face for the...
Page 248: Fault Finding Power Transmission - Problems With The Clutch And Clutch Control
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Fitting position of clutch disc in connection with two-mass flywheel • Legend “side of gearbox” -arrow- points to the gearbox.
Page 249 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Complaint Fault type Measure ♦ Release bearing on the guide – Replace guide bushing and re‐...
Page 250 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Complaint Fault type Measure ♦ Wrong clutch disc installed. – Assign clutch disc via the ⇒...
Page 251 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Complaint Fault type Measure ♦ Displacement of engine/gear‐ – Insert dowel sleeves before box too large (dowel sleeves gearbox has been fitted.
Page 252 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Complaint Fault type Measure Clutch grabbing, ♦ Air in the system. – Bleed system, check brake fluid unit shaking.
Page 253 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Complaint Fault type Measure Noises in idle. ♦ Torsional damper spring bro‐ – Replace clutch disc.
Page 254: Controls, Housing
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 34 – Controls, housing Shift mechanism ⇒ “1.1 Fitting location of shift mechanism”, page 66 ⇒...
Page 255 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 A - Shift cable B - Selector cable C - Heat shield ❑ take off before removing...
Page 256: Summary Of Components Of The Shift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Summary of components of the shift mechanism Note After the battery earth strap is disconnected and re-connected, carry out additional operations ⇒ Electrical ♦...
Page 257: Summary Of Components - Gearshift Knob And Cover
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Summary of components - gearshift knob and cover 1 - Gearshift knob ❑ with collar ❑...
Page 258: Separating Collar From Gearshift Lever (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Lever off the collar with disassembly wedge - 3409- out of the surround of centre console in -direction of arrow-.
Page 259 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – For this step, press on the frame in -direction of arrow- and at the same time raise the frame.
Page 260: Remove And Install Gearshift Knob And Shift Lever Collar (Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Remove and install gearshift knob and shift lever collar (Rapid NH) Special tools and workshop equipment required ♦...
Page 261 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - Lock washer ❑ removing and installing ⇒ page 74 2 - Spring 3 - Gasket ❑...
Page 262: Summary Of Components - Control Cables
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Removing and installing lock washer – When removing and installing the circlip -A- pull the gearshift...
Page 263 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - Shift cable ❑ slacken from the shift lever guide within the shift mechanism ❑...
Page 264 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are different ⇒...
Page 265: Plastic Relay Lever As Of 06.07 (Fabia Ii, Roomster, Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Assign cable locks The holes in the cable locks have different diameters. Cable lock for Dimension “a”...
Page 266 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1.9.1 Removing and installing plastic relay lever – Pull forward the locking mechanism as far as the stop in -direction of arrow 1-, then lock by turning to the left in -direction of arrow 2-.
Page 267: Remove And Install Shift Mechanism (Fabia Ii, Roomster, Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1.9.2 Remove and install cable lock for selec‐ tor cable from plastic relay lever Remove cable lock for selector cable from plastic relay lever •...
Page 268 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove circlip -3- for shift cable from gearbox shift lever -1-. – Pull off shift cable from the stud -arrow-.
Page 269 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove underbody cover on right and left (if present) -arrows-. – Remove tunnel bridge -arrows-.
Page 270 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1.10.2 Install Installation is carried out in the reverse order. However, pay at‐ tention to the following: The holes in the cable locks have different diameters ⇒...
Page 271 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Tightening torques Components Tightening torque Underbody cover 2 Nm Shift housing to body ⇒ “1.7 Summary of components - Shift lever and shift housing”, page 72 Cable support to gearbox ⇒...
Page 272: Removing And Installing Shift Mechanism (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1.11 Removing and installing shift mecha‐ nism (Rapid) Special tools and workshop equipment required ♦...
Page 273 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove underbody cover on right and left (if present) -arrows-. – Remove tunnel bridge -arrows-.
Page 274: Setting The Shift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 The holes in the cable locks have different diameters ⇒ “1.8 Summary of components - Control cables”, page 74 –...
Page 275 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 • Shift mechanism operates freely. • Operating and transmission elements of the shift mechanism are in perfect condition.
Page 276 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Insert rig pin - T10027A- into the hole -A- and into the hole -B-.
Page 277 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 If a gear catches when engaged again. set the shift mechanism once again ⇒ “1.12 Setting the shift mechanism”, page 86...
Page 278 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Removing and installing the gearbox ⇒ “2.1 Removing gearbox (Fabia II 2007 ►; Roomster 2006 ►)”, page 90 ⇒...
Page 279: Removing And Installing The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove lock washer -arrow 1- for shift cable from gearbox shift lever -A-.
Page 280 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove cable support from the gearbox -arrows- and tie up laterally together with selector cable and shift cable –...
Page 281 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove bracket for engine cover -arrow- (install in this hole one of the 2 spindles of the supporting device).
Page 282 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Mark installation position of bolts -1- from left steering joint. – Unscrew screws -1- for left steering joint ⇒ Chassis; Rep. gr.
Page 283 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove the holding bracket for the exhaust pipe -1-. – Separate the exhaust system behind the pre-exhaust pipe at the clamping sleeve and secure with wire to the body ⇒...
Page 284 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Lower engine/gearbox unit sufficiently at the two spindles until the fixing screws attaching the gearbox mounting bracket -A- are accessible from the left wheelhouse.
Page 285: Removing Gearbox (Fabia Ii 2007 ►; Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Note When removing the gearbox -1- ensure the gearbox does not ♦ touch the frame side rail -2-, -arrows-.
Page 286 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove the vacuum hose -A- from the brake servo unit -B- -arrow 1-, in order to avoid damage ⇒ Chassis; Rep. gr. 47 .
Page 287 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove the slave cylinder -arrows-, lay aside and secure it; do not open the line system.
Page 288 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Install supporting device - MP9-200 (10-222A)- . For this pur‐ pose, position the supports -C- next to the screw -arrow 1- and the support for the front flap -arrow 2- as shown.
Page 289 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Unplug connector -arrow-. – Release the fan shroud on the catch hook e.g. using a screw‐...
Page 290 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove pendulum support -arrows A- and -arrow B-. Note When installing the pendulum support position the screws -arrows 1- in the elongated holes in such a way that there is max‐...
Page 291 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – If present, remove small cover plate -A- for flywheel -arrows-. – Remove earth strap -1- from engine mount.
Page 292 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 The vacuum hose -arrows- must not be jammed. Caution The lifting eye of the engine must not touch the brake fluid res‐...
Page 293 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Position the engine and gearbox jack below the vehicle, the arrow -symbol B- (in the previous figure) on the adjusting plate points in the direction of travel/vehicle.
Page 294: Removing Gearbox (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 The gearbox must not touch the engine pump aggregate -A- for the power-assisted steering.
Page 295 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove the vacuum lines with the bracket -1- from the air filter and disconnect the plug -3- -direction of arrow-.
Page 296 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove the slave cylinder -arrows-, lay aside and secure it; do not open the line system.
Page 297 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Hook the rear left shackle - 10-222 A/12- into the engine lifting eye.
Page 298 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Release the nut -arrow- and remove the bracket for the elec‐ trical cables.
Page 299 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – If present, remove small cover plate -A- for flywheel -arrows-. – Remove the screws -arrows- of the left assembly carrier from the gearbox mount.
Page 300 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 • The fixing screws -arrows- for the gearbox console -A- must be accessible. – Remove gearbox console -A- -arrows-.
Page 301: Removing Gearbox (Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Press the gearbox out of the dowel sleeves and carefully swing towards the assembly carrier.
Page 302 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ♦ Shackle - (10-222A/12)- ♦ Grease for plug serration of clutch disc - G 000 100- Note All cable straps which are detached or cut open when remov‐...
Page 303 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove the clip -arrow 1- from the opening in the relay lever. – Pull the relay lever out of its bearing point in the gearshift cover together with the cable lock.
Page 304 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Release the nut -arrow- and remove the bracket for the elec‐ trical cables.
Page 305 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Hook the shackle - 10-222 A/12- into the rear engine lifting eye. – Then hook the shackle - 10-222 A/12- into the shortened spin‐...
Page 306 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Unscrew nuts -arrows- for left and right steering joint ⇒ Chas‐ sis; Rep. gr. 40 .
Page 307 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 The vacuum hose -arrows- must not be jammed. Caution The engine lifting eye must not touch the brake fluid reservoir nor the brake lines.
Page 308: Installing The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Position the engine and gearbox jack below the vehicle, the arrow -symbol B- (in the previous figure) on the adjusting plate points in the direction of travel/vehicle.
Page 309 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Before installing the gearbox press the clutch release lever towards the gearbox housing and secure with mounting bolt or screw M 8 x 35.
Page 310 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 2.5.1 Tightening torques (Fabia II, Roomster) Attach the gearbox to the 3 cylinder engine without particle filter (flange fig.
Page 311 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Attach the gearbox to the 4 cylinder engine with particle filter (flange fig. gearbox) Pos.
Page 312 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Components Tightening torque Fixing screws of engine mount ⇒ Engine; Rep. gr. 10 Pendulum support ⇒...
Page 313: Tightening Torques (Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Components Tightening torque Flange shaft on gearbox (conical screw) ⇒ “2.1 Disassembling and assembling differential gear”, page 196...
Page 314: Transporting The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Components Tightening torque Fixing screws of engine mount ⇒ Engine; Rep. gr. 10 Pendulum support ⇒...
Page 315: Check Gear Oil Level
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Check gear oil level Gearbox oil specification ⇒ Electronic Catalogue of Original Parts .
Page 316 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Disassembling and assembling the gearbox ⇒ “4.1 Gearbox overview”, page 128 ⇒ “4.2 Summary of components”, page 129 ⇒...
Page 317: Disassembling And Assembling The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 12 - Clutch housing ❑ repairing ⇒ “5 Repairing gearbox housing and clutch housing”, page 151...
Page 318: Removing And Installing Gearbox Housing Cover And 5Th Gear
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Removing and installing gearbox housing cover and 5th gear 1 - 18 Nm ❑ for cover to gearbox...
Page 319: Removing And Installing Gearbox Housing And Shift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 12 - Synchronizer body with sliding gear and synchronizer ring for 5th gear ❑ remove separately ⇒...
Page 320 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - 25 Nm 2 - Flange shaft with pressure spring ❑ removing and installing ⇒...
Page 321: Removing And Installing The Drive Shaft, Output Shaft, Differential Gear And Shift Forks
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Removing and installing the drive shaft, output shaft, differential gear and shift forks 1 - Differential gear ❑...
Page 322: Mounting Sequence - Removing And Installing Gearbox Housing Cover And 5Th Gear
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 13 - 25 Nm Mounting sequence - Removing and in‐ stalling gearbox housing cover and 5th...
Page 323 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 4.6.1 Removing gearbox housing cover and 5th gear – Secure the gearbox to the gearbox mount - T30109 (VW 353)- with screws -arrows-.
Page 324 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Unscrew the gearbox housing cover -arrow-. – Check whether the extraction hooks - T10040/2A- can be cor‐...
Page 325 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Remove 5th gear separately Remove 5th gear shift fork as follows: – Cover the openings with a cloth.
Page 326 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Insert the threaded insert - T10309/3- into the shell . – Now insert the other half of the bushing - T10309/1- and place the pipe - T10309/2- on the assembly device.
Page 327: Mounting Sequence - Completely Disassembling And Assembling The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Mounting sequence - completely disas‐ sembling and assembling the gearbox Removing and installing cover for gearbox housing, clutch hous‐...
Page 328 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Secure the gearbox to the gearbox mount - T30109 (VW 353)- with screws -arrows-.
Page 329 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Remove 5th gear shift fork as follows: – Put shift fork -1- in Neutral position.
Page 330 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Gearboxes for vehicles with start/stop system: Remove trans‐ mission neutral sender - G701- -arrow-.
Page 331 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Release screws -A-, that serve to secure the gearbox housing from the clutch housing.
Page 332 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Position the pressure pieces - T10408/2- onto the shafts. – 2 Mount the extractor -A-, e.g. -Kukko 18/1- .
Page 333 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 4.7.2 Assembling gearbox – Insert differential gear. – Always replace O-rings -arrows- for bearing support/output shaft ⇒...
Page 334 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Tighten screw -B- for shift mechanism/reverse gear to the specified tightening torque ⇒ “4.5 Removing and installing the drive shaft, output shaft, differential gear and shift forks”, page 133...
Page 335 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Install the gearshift shaft as follows: – Put the shift rails in neutral position.
Page 336 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Fitting position of the 5th gear pinion The round slot -arrow- points to the gearbox housing.
Page 337 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 5th gear synchronizer ring with integrated arresters -arrows- – Cover all openings in the gearbox housing with a cloth so that no foreign bodies can get into the gearbox.
Page 338 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Screw in new screws -A- for the synchronizer body and the 5th gear pinion and tighten to tightening torque ⇒...
Page 339: Repairing Gearbox Housing And Clutch Housing
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Repairing gearbox housing and clutch housing Special tools and workshop equipment required ♦ Drift - MP3-403 (VW 295)- ♦...
Page 340 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 7 - Adjusting washer ❑ for output shaft ❑ Setting overview ⇒ “3 Setting overview”, page 205 8 - Outer ring/tapered-roller bearing ❑...
Page 341 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 23 - Sealing ring ❑ for left flange shaft ❑ Renew. ⇒ “1 Replacing the flange shaft gasket rings (gearbox assembled)”, page 191...
Page 342 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Remove bushing with gasket ring A leg is located in the inner diameter of the bushing.
Page 343: Repairing The Gearshift Mechanism On The Gearbox Side
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Repairing the gearshift mechanism on the gearbox side ⇒ “6.1 Disassembling and assembling the gearshift mechanism on the gearbox side (gearshift shaft can be removed from gear‐...
Page 344 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - Gearshift shaft ❑ when shifting from the 5th gear to the 4th gear, the screw Pos.
Page 345 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ❑ may be replaced with the gearshift mechanism mounted ❑ Fitting position ⇒ “1.8 Summary of components - Control cables”, page 74 ❑...
Page 346: Disassembling And Assembling The Gearshift Mechanism On The Gearbox Side (Gearshift Shaft Cannot Be Removed From Gearshift Cover)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Disassembling and assembling the gearshift mechanism on the gearbox side (gearshift shaft cannot be removed from gearshift cover) Note Grease bearing points and friction surfaces.
Page 347 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ❑ Fitting position ⇒ “1.8 Summary of components - Control cables”, page 74 ❑ after installing set shift mechanism ⇒...
Page 348: Disassembling And Assembling The Gearshift Forks
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Disassembling and assembling the gearshift forks Special tools and workshop equipment required ♦ Driver - MP1-304 (10-206)- ♦...
Page 349 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 clip has been fitted 9 - 3rd/4th gear shift segment ❑ Identification ⇒ page 161 ❑...
Page 350 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Removing the angular ball bearing Note Do not bend the shift forks when removing and installing the an‐...
Page 351: Gears, Shafts
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 35 – Gears, shafts Drive shaft ⇒ “1.1 Disassembling and assembling the drive shaft”, page 163 ⇒...
Page 352 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - Clutch housing 2 - Outer ring/tapered-roller bearing ❑ pressing out ⇒ page 165 ❑...
Page 353 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 14 - Needle bearing ❑ for 5th gear 15 - 5th gear sliding gear 16 - 5th gear synchronizer ring ❑...
Page 354 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Pressing off inner ring/tapered-roller bearing -A- - separating device 12…75 mm e.g. -Kukko17/1- Press on inner ring/tapered-roller bearing Pressing off 4th gearwheel with tapered-roller bearing and bush‐...
Page 355 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Pressing on 3rd gear pinion Pressing on 4th gear pinion Collar points to the 3rd gear.
Page 356 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Pressing out outer ring/tapered-roller bearing Pressing on outer ring/tapered-roller bearing – After setting the drive shaft insert with adjusting washer.
Page 357: Setting Drive Shaft
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Assembling sliding sleeve/5th gear synchronizer body – Slide the sliding sleeve over the synchronizer body.
Page 358 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ♦ Dial gauge The drive shaft must be re-set when the following components are replaced: ♦...
Page 359 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Press drive shaft towards the dial gauge -direction of arrow-. – Read off play on dial gauge and note (in the example = 1.21 mm).
Page 360 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove drive shaft and press out outer ring/tapered-roller bearing from the gearbox housing with thrust washer - MP3-456 (VW 447 I)- .
Page 361 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Press outer ring/tapered-roller bearing with thrust washer - MP3-413 (VW 510)- into the gearbox housing together with the adjusting washer (in the example 1.175 mm).
Page 362: Output Shaft
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Output shaft ⇒ “2.1 Disassembling and assembling the output shaft”, page 174 ⇒ “2.2 Setting output shaft”, page 184 Disassembling and assembling the out‐...
Page 363 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove circlip Pos. 17. – Press off sliding sleeve with 1st and 2nd gear synchronizer body as shown in ⇒...
Page 364 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ❑ Check pegs for traces of wear 14 - Outer ring for 1st gear ❑...
Page 365 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ❑ pressing on ⇒ page 184 29 - Bushing ❑ for 4th gear needle bearing ❑...
Page 366 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Pressing on small outer ring/tapered-roller bearing Extracting small inner ring/tapered-roller bearing -A- vice with protective jaws –...
Page 367 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Press off sliding sleeve with synchronizer body and bearing sup‐ port – Undo the circlip ⇒...
Page 368 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Check 1st and 2nd gear inner ring for wear – Press the inner ring -2- on the cone of the sliding gear and measure clearance -a- with a feeler gauge -1-.
Page 369 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Assembly of sliding sleeve/1st and 2nd gear synchronizer body together with arresters, which are hollow inside •...
Page 370 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Fitting position of the 2nd gear outer ring The pegs -arrows- point towards the 1st gear sliding gear -A-.
Page 371 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Check 3rd and 4th gear snychronizer ring for wear – Press the synchronizer ring on the cone of the sliding gear and measure clearance -a- with a feeler gauge.
Page 372: Setting Output Shaft
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Fitting position of the sliding sleeve/3rd and 4th gear synchronizer body Chamfer -arrow- points towards the 4th gear.
Page 373 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 ♦ Pressure washer - MP3-460 (VW 512)- ♦ Bolts M8 and M10 - 3114/2- ♦...
Page 374 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 inserted washer 0.65 mm + measured value 0.20 mm + compression (constant value) 0.15 mm Thickness of the adjusting washer 1.00 mm...
Page 375 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Press in small outer ring/tapered-roller bearing with the deter‐ mined adjusting washer (in the example 1.00 mm).
Page 376: Reverse Shaft
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Reverse shaft ⇒ “3.1 Disassembling and assembling the reverse shaft”, page 188 Disassembling and assembling the re‐...
Page 377 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - Clutch housing 2 - Needle bushing ❑ removing ⇒ page 189 ❑ installing ⇒...
Page 378 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Pressing in needle bushing -A- in the clutch housing Pressing out needle bushing from the reverse shaft support Pressing the needle bushing in the reverse shaft support Rep.
Page 379: Final Drive - Differential
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 39 – Final drive - differential Replacing the flange shaft gasket rings (gearbox assembled) ⇒...
Page 380 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Unscrew nuts -arrows- for left steering joint ⇒ Chassis; Rep. gr. 40 .
Page 381: Replace Gasket Ring For Right Flange Shaft (Gasket Ring And Bushing Are One Component)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Drive the new seal ring in up to the stop, do not twist the seal ring.
Page 382 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Unscrew the drive shaft -1- from the flange shaft ⇒ Chassis; Rep. gr. 40 .
Page 383 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – If the oil return line for exhaust turbocharger was unscrewed at the engine, install it again -arrow- ⇒ Engine; Rep. gr. 21 .
Page 384: Differential Gear
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Differential gear ⇒ “2.1 Disassembling and assembling differential gear”, page 196 ⇒ “2.2 Adjusting the differential gear”, page 202 Disassembling and assembling differen‐...
Page 385 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 1 - Gearbox housing 2 - Adjusting washer ❑ for the differential gear ❑ Determine thickness ⇒...
Page 386 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 13 - Pressure spring for flange shaft ❑ fitted behind flange shaft 14 - Thrust washer ❑...
Page 387 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Press outer ring/tapered-roller bearing into the clutch housing No adjusting washer is fitted at the side of the clutch housing.
Page 388 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Press in outer ring/tapered-roller bearing in the gearbox housing – Position adjusting washer under outside ring.
Page 389 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Remove tensioning sleeve without round slot (long tensioning sleeve); press out differential bevel gear shaft When pressing out the tensioning sleeve, it is sheared off during this procedure.
Page 390: Adjusting The Differential Gear
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Fitting position of thrust washer for the conical ring -1- The collar -arrow- points towards the pressure spring -B-.
Page 391 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Press the outer ring/tapered-roller bearing with thrust plate - MP3-464 (30-205) - into the clutch housing.
Page 392 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 – Remove the gearbox housing and pull the outer ring/tapered- roller bearing out of the gearbox housing.
Page 393: Setting Overview
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02R - Edition 08.2014 Setting overview Note When working on the gearbox it is only necessary to re-set the ♦...
Page 394 Service Workshop Manual FABIA II 2007 ➤ Gearbox 02R Edition 12.06 Service Department. Technical Information...
Page 395 Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 30 - Clutch 34 - Control, housing 35 - Wheels, shafts 39 - Final drive, differential gear...
Page 396 Clutch control ............Summary of components - foot controls; Fabia II 2007 ? ......
Page 397 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing and installing gearbox housing cover and 5th gear ..... .
Page 398: Technical Data
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 00 – Technical data Identification of the gearbox Assignment Fabia II 2007 ? ⇒ page 1 Assignment Fabia II 2011 ? ⇒ page 2 Location on the gearbox Identification characters and production date -arrow 1-.
Page 399 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Manual gearbox 5 speed 02R 3rd gear 34 : 26 = 1,308 31 : 23 = 1,348 30 : 24 = 1,250 4th gear 34 : 35 = 0,971 29 : 30 = 0,967...
Page 400 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Manual gearbox 5 speed 02R Identification characters KFK, MZL Assignment: Engine 1.6 ltr./55 kW TDI CR 1.2 ltr./55 kW TDI CR 1.6 ltr./66 kW TDI CR 1.6 ltr./77 kW TDI CR...
Page 401 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Only on vehicles without ABS. Note Vehicles with ABS do not have the sender for speedometer - G22- . Manual gearbox 5 speed 02R Manufactured from 11.10 11.10 through Identification characters...
Page 402: Overview Of Transmission System
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Overview of Transmission System Designation of components and transmission ratio Note The -arrows- show the direction of travel. 1 - Engine 2 - Clutch 3 - Manual gearbox 4 - Drive shaft...
Page 403: General Repair Information
♦ When replacing the gearbox, inspect the gearbox oil level and top up with oil if necessary ⇒ page 85 ♦ Filling capacity, Fabia II 2007 ? ⇒ page 1 ♦ Filling capacity, Fabia II 2011 ? ⇒ page 2 ♦...
Page 404 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 ♦ Do not over-tension the circlips. ♦ Always replace damaged or over-tensioned circlips ⇒ Elec‐ tronic Catalogue of Original Parts . ♦ Circlips must be positioned in the base of the groove.
Page 405 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 ♦ Gauge shims at several points with a micrometer. Different tolerances allow to measure the required thickness for each washer very precisely. ♦ Inspect for burrs and damage. ♦ Install only adjusting washers which are in perfect condition.
Page 406: Clutch
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 30 – Clutch Clutch control Summary of components - foot controls; Fabia II 2007 ? Special tools and workshop equipment required ♦ Polycarbamide grease -G 052 142 A2- Note Summary of components - Hydraulics ⇒...
Page 407 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 8 - Over-centre helper spring ❑ removing and installing ⇒ page 12 9 - Bushing 10 - Bushing 11 - Clutch pedal ❑ removing and installing ⇒ page 14 12 - Support ❑...
Page 408 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Difference between clutch pedal switches -F36- ♦ -A- Clutch pedal switch with angular housing Removing and installing ⇒ page 11 ♦ -B- Clutch pedal switch with cylindrical housing Removing and installing ⇒...
Page 409: Removing And Installing The Crash Strut For The Clutch Pedal; Fabia Ii 2007
– Install the storage area on the driver's side ⇒ Body Work ⇒ Rep. Gr. 70 . Removing and installing the crash strut for the clutch pedal; Fabia II 2007 ? Removing – Remove the storage area on the driver's side ⇒ Body Work ⇒...
Page 410 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing – Remove the storage area on the driver's side ⇒ Body Work ⇒ Rep. Gr. 70 . – Remove crash strut (if present) ⇒ page 12 – Remove clutch pedal switch -F36- , if present ⇒...
Page 411: Removing And Installing The Clutch Pedal; Fabia Ii
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing and installing the clutch ped‐ al; Fabia II 2007 ? Special tools and workshop equipment required ♦ Pliers -T10005- ♦ Polycarbamide grease -G 052 142 A2- Removing – Remove the storage area on the driver's side ⇒ Body Work ⇒...
Page 412: Summary Of Components - Foot Controls; Fabia Ii
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Summary of components - foot controls; Fabia II 2011 ? Note Summary of components - Hydraulics ⇒ page 28 ♦ After the battery earth strap is disconnected and reconnected, carry out additional operations ⇒ Electrical ♦...
Page 413 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 11 - Clutch pedal ❑ removing and installing with over-centre helper spring ⇒ page 23 ❑ removing and installing with tension spring ⇒ page 25 12 - Bushing 13 - Tension spring with vibration damper ❑...
Page 414 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 1.5.1 Removing and installing clutch pedal switch -F36- Note The clutch pedal switch -F36- may only be installed once to en‐ sure that it has an adequately tight fit in the bracket for clutch pedal.
Page 415: Removing And Installing The Bracket With The Master Cylinder; Fabia Ii 2011
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing and installing the bracket with the master cylinder; Fabia II 2011 ? Special tools and workshop equipment required ♦ Closing tool -T10249- 1.6.1 Removing Note After the battery earth strap is disconnected and reconnected, carry out additional operations ⇒...
Page 416 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Vehicles with start-stop system: – Unclip clutch position sender -G476- at master cylinder -arrow A- and -arrow B-. – Remove the clutch position sender with connected electrical plug connection from the master cylinder.
Page 417 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Note Replace self-locking nuts -1- and -2- for bracket -3- on front wall. – Install the clutch pedal switch -F36- ⇒ page 17 – If present, install crash strut -A-. To do so, tighten fixing screws -arrows- to tightening torque ⇒...
Page 418: Removing And Installing The Bracket Without The Master Cylinder; Fabia Ii 2011
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing and installing the bracket without the master cylinder; Fabia II 2011 ? Special tools and workshop equipment required ♦ Pliers -T10005- Removing – Remove the footwell vent ⇒ Heating, Air Conditioning ⇒ Rep.
Page 419 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Unscrew the two lower fixing nuts -arrows-. – Remove the bracket -A- from the front wall -B-. • The master cylinder is locked into position with the bracket. • The assistance of a 2nd mechanic is required to counterhold it when removing the bracket from the engine compartment.
Page 420: Removing And Installing The Clutch Pedal With The Over-Centre Helper Spring; Fabia
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing and installing the clutch pedal with the over-centre helper spring; Fabia II 2011 ? Note Install the clutch pedal with a new bearing axle. ♦ If only the over-centre helper spring should be removed, the ♦...
Page 421 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove the bearing axle for the clutch pedal. – Turn the bearing axle for the clutch pedal to the left in -direction of arrow-. -1- = Allan key, wrench size 8 mm.
Page 422 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Press on clutch pedal slightly and slide through new bearing axle. – Position the studs -A- horizontally. – Turn the bearing axle to the right in -direction of arrow-. -1- = Allan key, wrench size 8 mm.
Page 423 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Unhook the tension spring e.g with hook -3438- . Note Only observe the right part of the fig. -arrows- when installing. – Unlock the actuating rod/master cylinder from the clutch pedal as follows: –...
Page 424 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Position the studs -A- horizontally. – Turn the bearing axle to the right in -direction of arrow-. -1- = Allan key, wrench size 8 mm. • The catches -B- must click audibly into place.
Page 425: Summary Of Components - Hydraulics
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 1.10 Summary of components - Hydraulics 1 - Brake fluid reservoir 2 - Tubing 3 - Master cylinder ❑ removing and installing; Fabia II 2007 ? ⇒ page 30 ❑ removing and installing;...
Page 426: Check Hydraulic Clutch Control
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 14 - Dust cap 15 - Clamp ❑ to remove the tube-hose line Pos. 9 pull out of the slave cylinder up to the stop 16 - Gearbox 17 - Slave cylinder ❑...
Page 427: Removing And Installing The Master Cylinder; Fabia Ii
– To do so, take off the collar from the tappet -arrow-. 1.12 Removing and installing the master cyl‐ inder; Fabia II 2007 ? Special tools and workshop equipment required ♦ Pliers -T10005- ♦ Polycarbamide grease -G 052 142 A2-...
Page 428 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing Note After the battery earth strap is disconnected and reconnected, carry out additional operations ⇒ Electrical System ⇒ Rep. Gr. 27 . – Remove engine cover ⇒ engine ⇒ Rep. Gr. 10 .
Page 429: Removing And Installing The Master Cylinder; Fabia Ii
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Unscrew the nuts -arrows 1- and remove the bracket -arrow A- together with the master cylinder. – Unscrew pedal stop ⇒ Item 19 (page 10) – Remove the master cylinder.
Page 430: Removing And Installing The Slave Cylinder
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Unlock the clutch pedal from the master cylinder with the pliers -T10005- . – Remove the master cylinder from the bracket. Install – Insert the master cylinder in the bracket.
Page 431 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove lock washer -arrow 1- for shift cable from gearbox shift lever -A-. Vehicles up to 05.07 (metal relay lever) – Remove circlip -arrow 2- for selector cable from relay lever -B-.
Page 432: Bleed The Clutch Control
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Screw the slave cylinder at the gearbox with the screws -5-. – Insert the tube-hose line -3- into the slave cylinder up to the stop. – Press in retaining clip -2- up to the stop.
Page 433 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Fit the bleeder hose -A- on the slave cylinder -arrow- and open the bleeder valve. – Activate system with a pressure of 0.2 MPa (2 bar). – Allow approx. 100 cm of brake fluid to flow out until no more air bubbles are visible.
Page 434: Repairing Clutch Control
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Repairing clutch control Special tools and workshop equipment required ♦ Grease for the plug serration of the clutch disc -G 000 100- ♦ Sealing grease -G 052 128 A1- 1 - Gearbox 2 - Ball stud, 25 Nm ❑...
Page 435 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 10 - 20 Nm 11 - Mounting bolt ❑ secures the clutch release lever when installing the gearbox ⇒ page 80 ❑ unscrew after the gearbox has been fitted ⇒ page 80...
Page 436: Repairing Clutch
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Repairing clutch Special tools and workshop equipment required ♦ Counterholder -MP1-223 (3067)- ♦ Centering mandrel -MP3-475A (3190A)- ♦ Grease for the plug serration of the clutch disc -G 000 100- (Gearbox removed)
Page 437 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 1 - Flywheel ❑ make sure the centering pins are tight ❑ The locating face for the clutch lining must be free from grooves, oil and grease ❑ removing and installing ⇒...
Page 438: Fault Finding Power Transmission - Problems With The Clutch And Clutch Control
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Fitting position of clutch disc in connection with two-mass flywheel • Legend “side of gearbox” -arrow- points to the gearbox. Check the extremities of the membrane spring • Wear is allowed up to half the membrane spring thickness.
Page 439 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Complaint Fault type Measure ♦ Membrane spring of the pres‐ – Replace pressure plate. sure plate broken. Complaint Fault type Measure Actuating force on the clutch pedal ♦ Over-centre helper spring de‐...
Page 440 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Complaint Fault type Measure Rattling, scratching occurs when ♦ Air in the system, clutch does – Bleed system; check system, the forward or reverse gear is en‐ not separate fully. top up with brake fluid.
Page 441 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Complaint Fault type Measure ♦ The lining is spalled off because – Replace clutch disc. Inform cus‐ of too high revs (shift back into tomer. lower gears during high speeds). ♦ When starting, linings are spal‐...
Page 442 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Complaint Fault type Measure Clutch grabbing, ♦ Air in the system. – Bleed system, check brake fluid unit shaking level, check system for tight‐ ness. – Replace defective part. ♦ Engine does not run clean.
Page 443 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Complaint Fault type Measure Noises in idle ♦ Torsional damper spring bro‐ – Replace clutch disc. ken. ♦ Clutch disc without predamper – Assign clutch disc via the ⇒ installed (idle rattling).
Page 444: Control, Housing
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 34 – Control, housing Shift mechanism Fitting location of shift mechanism -Arrow A- Shift movement -Arrow B- Selector movement A - Shift cable B - Selector cable C - Heat shield ❑...
Page 445: Summary Of Components Of The Shift Mechanism
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Summary of components of the shift mechanism Note After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical ♦ System ⇒ Rep. Gr. 27 . Remove shift mechanism for replacing control cables ⇒...
Page 446: Summary Of Components - Gearshift Knob And Cover
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Summary of components - gearshift knob and cover 1 - Gearshift knob ❑ with collar ❑ the gearshift knob and collar cannot be separa‐ ❑ always replace together ⇒ Electronic Catalogue of Original Parts ❑...
Page 447 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Vehicles up to 09.08 – Lever off the collar with disassembly wedge -3409- out of the surround of centre console in -direction of arrow-. Vehicles as of 09.08 – Raise the silver frame for the collar using a disassembly wedge -3409- and remove it from the shift lever.
Page 448: Summary Of Components - Shift Lever And Shift Housing
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Summary of components - Shift lever and shift housing Note Grease bearing and friction surfaces with grease -G 000 450 02- . 1 - Circlip ❑ removing and installing ⇒ page 52...
Page 449 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing and installing lock washer – When removing and installing the circlip -A- pull the gearshift lever in the -direction of the arrow A- while simultaneously pressing the spring down with a screwdriver up to the stop in the -direction of the arrow B-.
Page 450: Summary Of Components - Control Cables
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Summary of components - Control cables Note Grease bearing and friction surfaces with grease -G 000 450 02- . 1 - Shift cable ❑ slacken from the shift lever guide within the shift mechanism ❑...
Page 451 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 10 - Cable lock ❑ for selector cable at relay lever ❑ after installing set shift mechanism ⇒ page 61 ❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are different ⇒...
Page 452: Plastic Relay Lever As Of
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Assign cable locks The holes in the cable locks have different diameters. Cable lock Dimension “a” Shift cable at gearbox shift lever 10 mm Selector cable at metal relay lever 8 mm...
Page 453 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 1.7.1 Removing and installing plastic relay lever – Pull forward the locking mechanism as far as the stop in -direction of arrow 1-, then lock by turning to the left in -direction of arrow 2-.
Page 454: Removing And Installing Shift Mechanism
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 1.7.2 Remove and install cable lock for selec‐ tor cable from plastic relay lever Remove cable lock for selector cable from plastic relay lever • Relay lever removed. – Insert cross-head screwdriver -A- between bushing -B- and relay lever.
Page 455 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove lock washer -3- for shift cable from gearbox shift lever -1-. – Pull off the shift cable from the stud -arrow-. Metal relay lever – Remove circlip -4- for the selector cable from relay lever -2-.
Page 456 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Turn securing mechanism -arrow A- in -direction of arrow B- and pull off gearshift knob together with the collar. – Remove centre console ⇒ Body Work ⇒ Rep. Gr. 68 .
Page 457 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove tunnel bridge -A- -arrows-. – Unhook rear silencer in such a way that it does not come in contact with the rear axle. – Remove heat shield -arrows-. – Swivel shift housing down and remove with control cables.
Page 458: Setting The Shift Mechanism
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Apply a small quantity of grease -G 000 450 02- onto the studs -arrows- of the gearbox shift lever -1- and of the relay lever -2-. – Always replace lock washers -3- and -4- after each removal ⇒...
Page 459 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Note The following are required for correct setting of the shift mech‐ ♦ anism: Control elements and transmission elements of the shift mech‐ ♦ anism are in perfect condition. Shift mechanism operates freely.
Page 460 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Lever off the collar with disassembly wedge -3409- out of the surround of centre console in -direction of arrow-. Vehicles as of 09.08 – Raise the silver frame for the collar using a disassembly wedge -3409- and remove it from the shift lever.
Page 461 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Pull rig pin -T10027A- out of hole -A- and -B-. – Perform a functional test of the shift mechanism ⇒ page 64 – Fit collar into the surround for centre console.
Page 462: Removing And Installing The Gearbox
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing and installing the gearbox Removing the gearbox; Fabia II 2007 ? Special tools and workshop equipment required ♦ Supporting device -MP9-200 (10-222A)- ♦ Adapter -MP9-200/3 (10-222A/3)- ♦ Retaining plate -3282- ♦...
Page 463 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Plastic relay lever • Before removal, the cable lock must be separated from the selector cable in order to avoid damage to the selector cable. – Pull forward the locking mechanism as far as the stop in -direction of arrow 1-, then lock by turning to the left in -direction of arrow 2-.
Page 464 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Disconnect plug -arrow 1- from reversing light switch -F4- . – Remove connector -arrow 2- and cable -arrow 3- from the starter. – Expose cables. – Remove engine/gearbox connecting screws at the top.
Page 465 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – If present, remove heat shield for drive shaft from the engine -arrows-. – Unscrew bracket from starter -arrow- and lay aside together with lines. – Remove the starter ⇒ Electrical System ⇒ Rep. Gr. 27 .
Page 466 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove pendulum support -arrows 1- and -arrow 2-. Note When installing the pendulum support position the screws -arrows 1- in the elongated holes in such a way that there is max‐...
Page 467 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Unscrew the fixing screws -arrows- from the gearbox mount. – Lower engine/gearbox unit sufficiently at the two spindles until the fixing screws attaching the gearbox mounting bracket -A- are accessible from the left wheelhouse.
Page 468: Removing The Gearbox; Fabia Ii
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Position the engine and gearbox jack below the vehicle, the arrow -symbol B- (in the previous figure) on the adjusting plate points in the direction of travel/vehicle. – Align adjusting plate parallel to the gearbox and lock securing mounts at gearbox.
Page 469 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove the vacuum lines with the bracket -1- from the air filter and disconnect the plug -3- -direction of arrow-. – Unscrew the charge pressure control solenoid valve -N75- with the bracket -2- -arrow- and lay with the vacuum line on the engine.
Page 470 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove cable support from the gearbox -arrows- and tie up laterally together with selector cable and shift cable – If present, remove the bracket -B- from the gearbox and pull off from the tube-hose line -A-.
Page 471 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Shorten the original spindle -I- of the supporting device -MP9-200 (10-222A)- by 100 mm: I - Original spindle ♦ Dimension -a- = 442 mm ♦ Dimension -x- = 100 mm II - shortened spindle MP9-200/10 (10-222A/10) ♦...
Page 472 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove the charge air hose “hot” side, to do so slacken the hose clamps -1- ⇒ Engine ⇒ Rep. Gr. 21 . – Remove charge air pipe “cold” side from engine ⇒ Engine ⇒...
Page 473 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Release the nut -arrow- and remove the bracket for the elec‐ trical cables. – Remove the starter ⇒ Electrical System ⇒ Rep. Gr. 27 . – Remove the front left wheelhouse liner ⇒ Body Work ⇒ Rep.
Page 474 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Unscrew the nut -1- from the coupling rod -3- -arrow- ⇒ Chas‐ sis ⇒ Rep. Gr. 40 . – Remove coupling rod and turn anti-roll bar -2- slightly up‐ wards.
Page 475 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Lower the gearbox to the dimension -a- approx. 55 mm. – In addition, slightly lower the engine. The vacuum hose -arrows- must not be jammed. Caution The lifting eye of the engine must not touch the brake fluid res‐...
Page 476 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Screw in the mounting elements -A- and -C- as shown on ad‐ justing plate . – Screw in the bolt -3282/29- , as indicated on the adjusting plate. – Position the engine and gearbox jack below the vehicle, the arrow -symbol B- (in the previous figure) on the adjusting plate points in the direction of travel/vehicle.
Page 477: Installing The Gearbox
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Swivel out the gearbox further and carefully lower it. – Screw down the gearbox in the area of the 5th gear (sheet metal cover) via the spindles of the gearbox mount -3282- .
Page 478 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Before installing the gearbox press the clutch release lever towards the gearbox housing and secure with mounting bolt or screw M 8 x 35. – After installing the gearbox release screw again. The hole is then closed with the 3rd fixing screw for the cable support/ control cables.
Page 479 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 2.3.1 Tightening torques Attach the gearbox to the 3 cylinder engine without particle filter (flange fig. gearbox) Pos. Screw Pieces M12 x 50 M12 x 150 M12 x 150 M10 x 58...
Page 480 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Attach the gearbox to the 4 cylinder engine with particle filter (flange fig. gearbox) Pos. Screw Pieces M12 x 50 M12 x 55 M12 x 150 M10 x 50 M10 x 50...
Page 481: Transporting The Gearbox
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Components Tightening torque Pre-exhaust pipe with catalytic converter and clamping ⇒ Engine ⇒ Rep. Gr. 26 sleeve Drive shaft to flange shaft ⇒ Chassis ⇒ Rep. Gr. 40 Coupling rod to anti-roll bar ⇒...
Page 482: Check Gear Oil Level
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Check gear oil level Gearbox oil specification ⇒ Electronic Catalogue of Original Parts . – Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 . – Unscrew plug for inspecting gear oil -arrow-.
Page 483: Disassembling And Assembling The Gearbox
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Disassembling and assembling the gearbox Gearbox overview 1 - 1st gear 2 - 2nd gear 3 - 3rd gear 4 - 4th gear 5 - 5th gear 6 - Gearbox housing ❑...
Page 484: Summary Of Components
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Summary of components Mounting sequence - Removing and installing gearbox housing cover and 5th gear ⇒ page 91 Mounting sequence - completely disassembling and assembling the gearbox ⇒ page 96 I - Removing and installing...
Page 485: Removing And Installing Gearbox Housing Cover And 5Th Gear
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing and installing gearbox housing cover and 5th gear 1 - 18 Nm ❑ for cover to gearbox housing 2 - Cover for gearbox housing Note 3 - Gasket 4 - 80 Nm and torque a further 90°...
Page 486: Removing And Installing Gearbox Housing And Shift Mechanism
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 ❑ remove together with gearbox housing ⇒ page 96 ❑ Fitting position ⇒ page 104 Removing and installing gearbox hous‐ ing and shift mechanism Special tools and workshop equipment required ♦ Sealant -AMV 188 200 03-...
Page 487: Removing And Installing The Drive Shaft, Output Shaft, Differential Gear And Shift Forks
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 ❑ Repairing ⇒ page 112 16 - 25 Nm Removing and installing the drive shaft, output shaft, differential gear and shift forks 1 - Differential gear ❑ disassembling and as‐ sembling ⇒...
Page 488: Mounting Sequence - Removing And Installing Gearbox Housing Cover And 5Th Gear
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Mounting sequence - Removing and in‐ stalling gearbox housing cover and 5th gear Note If it is intended to only remove the 5th gear, keep to the fol‐ ♦ lowing work sequence.
Page 489 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 4.6.1 Removing gearbox housing cover and 5th gear – Secure gearbox to gearbox mount -T30109 (VW 353)- with screws -arrows-. – Remove clutch release lever with release bearing ⇒ page 37 •...
Page 490 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Unscrew the gearbox housing cover -arrow-. – Check whether the pull-off hooks -T10040/2A- can be correct‐ ly positioned under the 5th gear pinion. The pull-off hooks -T10040/2A- cannot be correctly positioned.
Page 491 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Remove 5th gear separately Remove 5th gear shift fork as follows: – Cover the openings with a cloth. – Put shift fork -1- in Neutral position. – Release screws -2- for bearing pins.
Page 492 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Insert the threaded insert -T10309/3- into the shell . – Now insert the second shell -T10309/1- and position the pipe -T10309/2- onto the device. – Check the synchronizer body for damage after removing.
Page 493: Mounting Sequence - Completely Disassembling And Assembling The Gearbox
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Mounting sequence - completely disas‐ sembling and assembling the gearbox Removing and installing cover for gearbox housing, gearbox housing, gearshift shaft with gearshift cover, drive shaft, output shaft, differential gear and gearshift mechanism.
Page 494 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Secure gearbox to gearbox mount -T30109 (VW 353)- with screws -arrows-. – Removing the clutch release lever, clutch release bearing and guide bushing ⇒ page 37 • The bearing of the input shaft and of the output shaft must not be damaged when removing and installing the 5th gear.
Page 495 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Remove 5th gear shift fork as follows: – Put shift fork -1- in Neutral position. – Release screws -2- for bearing pins. – Pull out bearing pins -direction of arrow A-.
Page 496 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Gearbox for vehicles with start-stop system: remove the trans‐ mission neutral sender -G701- -arrow-. – Remove gearshift shaft with cover Put the gearshift shaft into Neutral. Subsequently unscrew screws -arrows- and remove the gearshift shaft from the gearbox housing.
Page 497 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Release screws -A-, that serve to secure the gearbox housing from the clutch housing. Note Do not release nuts -B- for the output shaft bearing support. – Remove bearing pins -A- on the top side of the gearbox and fixing screws -B- for the gearbox housing on the clutch housing near the differential gear.
Page 498 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove shift forks -A- together with shift rails. – Unscrew shift mechanism/reverse gear -B-. – Release nuts -B- for the bearing support/output shaft. – Successively remove the reverse gear -A-, drive shaft -B- and output shaft -C- from the clutch housing.
Page 499 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Insert together the drive shaft -1- and the drive shaft -2-. – Tighten nuts for the bearing support/output shaft to tightening torque ⇒ page 131 – Position the reverse pinion -3- on the needle bearing in the clutch housing.
Page 500 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Screw the pin screw -A- M8 x 100 mm in the reverse shaft support, to ensure it is aligned once the gearbox housing has been fitted. – Align shift rails.
Page 501 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Gearbox for vehicles with start-stop system: insert the trans‐ mission neutral sender -G701- -arrow- and tighten the fixing screw to the tightening torque ⇒ Item 11 (page 89) – Install both flange shafts with pressure springs, stop discs and conical rings.
Page 502 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Drive in 5th gear pinion Checking 5th gear synchronizer ring for wear – Press the synchronizer ring on the cone of the sliding gear and measure the clearance -a- with a feeler gauge before installing the sliding gear and the 5th gear snychronizer ring.
Page 503 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Drive in 5th gear synchronizer body/sliding sleeve. Note Pay attention to the free travel of the synchronizer ring during the driving in operation. – Remove supporting bridge -MP3-425 (30-211 A)- and sup‐...
Page 504 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Set 5th gear as follows: – Engage 5th gear. – Release screw -1-. Press the sliding sleeve and the gear shift gate in the -direction of the arrow-. – Tighten screw -1- to tightening torque ⇒...
Page 505: Repairing Gearbox Housing And Clutch Housing
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Repairing gearbox housing and clutch housing Special tools and workshop equipment required ♦ Drift -MP3-403 (VW 295)- ♦ Adapter -MP3-403/1 (VW 295 A)- ♦ Thrust piece -MP3-411 (VW 454)- ♦ Multi-purpose tool -MP3-419 (VW 771)- ♦...
Page 506 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 8 - Outer ring/tapered-roller bearing ❑ for drive shaft ❑ removing and installing ⇒ page 120 ❑ when replacing: set the drive shaft ⇒ page 126 9 - Needle bushing ❑ removing and installing ⇒...
Page 507 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Driving out needle bearing Drive in needle bearing up to stop – Using a drift secure needle bearing in 3 points in the gearbox housing with 120° offset. Driving out the guide bushing Driving the gasket ring into the guide bushing up to the stop Rep.
Page 508 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Pull out bushing with gasket ring A leg is located in the inner diameter of the bushing. – Position the extraction hook -MP3-419/37 (VW 771/37) - of the multi-purpose tool -MP3-419 (VW 771)- directly behind the leg in the bushing.
Page 509: Repairing The Gearshift Mechanism On The Gearbox Side
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Repairing the gearshift mechanism on the gearbox side Disassembling and assembling the gearshift mechanism on the gearbox side (gearshift shaft can be removed from gearshift cover) Special tools and workshop equipment required ♦...
Page 510 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 1 - Gearshift shaft ❑ when shifting from the 5th gear to the 4th gear, the screw Pos. 5 guides the gearshift shaft into the 4th gear shift gate via the leg -arrow- ❑...
Page 511 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 ❑ Fitting position ⇒ page 53 ❑ after installing set shift mechanism ⇒ page 61 13 - Lock washer ❑ replace after each disassembly ⇒ electronic catalogue of original parts ❑ is not required, if the relay lever is made of plastic...
Page 512: Disassembling And Assembling The Gearshift Mechanism On The Gearbox Side (Gearshift Shaft Cannot Be Removed From Gearshift Cover)
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Disassembling and assembling the gearshift mechanism on the gearbox side (gearshift shaft cannot be removed from gearshift cover) Note Grease bearing points and friction surfaces. ♦ Assign the grease via the ⇒ Electronic Catalogue of Original Parts .
Page 513 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 10 - Screw cap 11 - Spring ❑ if present, insert in the screw cap Remove locking angle -A- from gearshift cover – Remove the outer part of the locking angle.
Page 514: Disassembling And Assembling The Gearshift Forks
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Disassembling and assembling the gearshift forks Special tools and workshop equipment required ♦ Driver -MP1-304 (10-206)- ♦ Pressure plate -MP3-407 (VW 402)- ♦ Thrust piece -MP3-453 (VW 431)- ♦ Distance sleeve -MP3-458 (VW 472)- ♦...
Page 515 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 9 - 3rd/4th gear shift segment ❑ Identification ⇒ page 118 ❑ It must still be possible to rotate the shift segment freely once the circlip has been fitted 10 - Sliding block ❑...
Page 516 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Removing the angular ball bearing Note Do not bend the shift forks when removing and installing the an‐ gular ball bearings. Insert the angular ball bearing up to the stop into the gearshift fork The recess in the pressure plate -T30100/1- points towards the ball bearing.
Page 517: Wheels, Shafts
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 35 – Wheels, shafts Drive shaft Disassembling and assembling the drive shaft Special tools and workshop equipment required ♦ Pressure plate -MP3-406 (VW 401)- ♦ Pressure plate -MP3-407 (VW 402)- ♦ Pressure spindle -MP3-408 (VW 412)- ♦...
Page 518 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 1 - Clutch housing 2 - Outer ring/tapered-roller bearing ❑ pressing out ⇒ page 122 ❑ installing ⇒ page 122 3 - Inner ring/tapered-roller bearing ❑ pressing off ⇒ page 123 ❑...
Page 519 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 15 - 5th gear sliding gear 16 - 5th gear synchronizer ring ❑ with integrated arresters ⇒ page 104 ❑ check for wear ⇒ page 104 17 - Spring ❑ Fitting position ⇒...
Page 520 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Pressing off inner ring/tapered-roller bearing -A- - separating device 12...75 mm e.g. -Kukko17/1- Press on inner ring/tapered-roller bearing Pressing off 4th gearwheel with tapered-roller bearing and bush‐ Pressing off 3rd gear pinion –...
Page 521 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Pressing on 3rd gear pinion Pressing on 4th gear pinion Collar points to the 3rd gear. Press on inner ring/tapered-roller bearing Press on bushing for 5th gear needle bearing Rep. Gr.35 - Wheels, shafts...
Page 522 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Pressing out outer ring/tapered-roller bearing Pressing on outer ring/tapered-roller bearing – After setting the drive shaft insert with adjusting washer. 5th gear synchronization Springs for arresters Sliding sleeve with 3 recesses -arrows A- for the arresters...
Page 523: Setting Drive Shaft
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Assembling sliding sleeve/5th gear synchronizer body – Slide the sliding sleeve over the synchronizer body. The sharp teeth -A- of the sliding sleeve and the collar -B- of the synchronizer body point in the same direction.
Page 524 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 ♦ Dial gauge The drive shaft must be re-set when the following components are replaced: ♦ Gearbox housing ♦ Clutch housing ♦ Drive shaft ♦ Gear pinion for 4th gear Or the ♦...
Page 525 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Press drive shaft towards the dial gauge -direction of arrow-. – Read off play on dial gauge and note (in the example = 1.21 mm). Note Dial gauge does not return to initial position.
Page 526 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove drive shaft and press out outer ring/tapered-roller bearing from the gearbox housing with thrust washer - MP3-456 (VW 447 I)- . – Determine the adjusting washer thickness from the table ⇒...
Page 527 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Press outer ring/tapered-roller bearing with thrust washer - MP3-413 (VW 510)- into the gearbox housing together with the adjusting washer (in the example 1.175 mm). – Position the gearbox housing and tighten screws to the given tightening torque ⇒...
Page 528: Output Shaft
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Output shaft Disassembling and assembling the out‐ put shaft Special tools and workshop equipment required ♦ Pressure plate -MP3-407 (VW 402)- ♦ Drive bushing -MP3-408 (VW 412)- ♦ Thrust piece -MP3-411 (VW 454) - ♦...
Page 529 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 1 - 25 Nm and torque a further 90° ❑ 4 nuts for bearing sup‐ port Pos. 9 ❑ always replace ⇒ Elec‐ tronic Catalogue of Original Parts 2 - Clutch housing 3 - Adjusting washer ❑...
Page 530 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 ❑ replace if there are any traces of scoring or friction 15 - 1st gear synchronizer ring ❑ check for wear ⇒ page 137 ❑ Fitting position ⇒ page 136 16 - Sliding sleeve with 1st and 2nd gear synchronizer body ❑...
Page 531 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 30 - Needle bearing ❑ for 4th gear 31 - 4th gear synchronizer ring ❑ check for wear ⇒ page 139 32 - 4th gear sliding gear 33 - Thrust washer 34 - Needle bearing ❑...
Page 532 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Extracting small inner ring/tapered-roller bearing -A- vice with protective jaws – Insert the gripper and tighten behind the rollers of the bearing, then turn bearing and tighten the gripper. Press on small inner ring/tapered-roller bearing...
Page 533 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Pulling off large inner ring/tapered-roller bearing -A- protective jaws – Before fitting the extractor insert screw M10 x 20 in the output shaft bore. Pressing on large inner ring/tapered-roller bearing -A- Thrust washer –...
Page 534 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Check 1st and 2nd gear snychronizer rings for wear – Press the synchronizer ring, outer ring and inner ring on the cone of the sliding gear and measure clearance -a- with a feeler gauge.
Page 535 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Assembly of sliding sleeve/1st and 2nd gear synchronizer body together with arresters, which are not hollow inside • The sliding sleeve is drawn over the synchronizer body. – Insert arresters and mount springs with 120° offset. The an‐...
Page 536 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Fitting position for synchronizer ring (inner ring for 2nd gear) -A- The pegs -arrow 1- lock into the recesses -arrow 2- of the syn‐ chronizer ring -B-. Fitting position 2nd gear sliding gear The higher collar -A- points towards the 1st gear -B-.
Page 537 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Disassembling and assembling the sliding sleeve/3rd and 4th gear synchronizer body 1 - Spring Assign the springs via the ⇒ Electronic Catalogue of Original Parts . Installation together with arresters, which are hollow inside ⇒...
Page 538: Setting Output Shaft
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Press on the synchronizer body with the 3rd and 4th gear sliding sleeve Pressing on bushing for 4th gear needle bearing – Install needle bearing, 4th gear sliding gear and synchronizer ring.
Page 539 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Or the ♦ Tapered-roller bearing Setting overview ⇒ page 161 Note Sealing surfaces of clutch and gearbox housing must be removed of sealant residues. – Press in outer ring/tapered-roller bearing small in the clutch housing with a 0.65 mm thick adjsuting washer up to the stop...
Page 540 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove output shaft and pull out small outer ring/tapered- roller bearing. -A- interior extractor 37...46 mm , e.g. -Kukko 21/6- -B- countersupport , e.g. -Kukko 22/2- The following adjusting washers are available:...
Page 541: Reverse Shaft
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Reverse shaft Disassembling and assembling the re‐ verse shaft Special tools and workshop equipment required ♦ Pressure plate -MP3-406 (VW 401)- ♦ Thrust piece -MP3-411 (VW 454)- ♦ Pressure spindle -MP3-423 (VW407)- ♦...
Page 542 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 1 - Clutch housing 2 - Needle bushing ❑ removing ⇒ page 145 ❑ installing ⇒ page 146 ❑ always replace after re‐ moving ⇒ Electronic Catalogue of Original Parts 3 - Reverse pinion 4 - Circlip ❑...
Page 543 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Pressing in needle bushing -A- in the clutch housing Pressing out needle bushing from the reverse shaft support Pressing the needle bushing in the reverse shaft support Rep. Gr.35 - Wheels, shafts...
Page 544: Final Drive, Differential Gear
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 39 – Final drive, differential gear Replacing the flange shaft gasket rings (gearbox assembled) Replacing the left flange shaft gasket ring Special tools and workshop equipment required ♦ Multi-purpose tool -MP3-419 (VW 771)- ♦...
Page 545 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Unscrew the nut -1- from the coupling rod -3- ⇒ Chassis ⇒ Rep. Gr. 40 . – Remove coupling rod and turn anti-roll bar -2- slightly up‐ wards. Continued for all vehicles –...
Page 546: Replace Gasket Ring For Right Flange Shaft (Gasket Ring And Bushing Are One Component)
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Tightening torque Flange shaft on gearbox (conical screw) ⇒ page 152 Replace gasket ring for right flange shaft (gasket ring and bushing are one com‐ ponent) Special tools and workshop equipment required ♦...
Page 547 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Release the fixing screw for the flange shaft, to this end insert two screws in the flange and using a tyre iron hold the shaft. – Remove the flange shaft together with the pressure spring.
Page 548 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – If present, screw on heat shield for drive shaft -arrows-. – Check gear oil level ⇒ page 85 – Install the noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
Page 549: Differential Gear
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Differential gear Disassembling and assembling differen‐ tial gear Special tools and workshop equipment required ♦ Counterholder -MP1-223 (3067)- ♦ Pressure plate -MP3-406 (VW 401)- ♦ Pressure plate -MP3-407 (VW 402)- ♦ Pressure spindle -MP3-408 (VW 412)- ♦...
Page 550 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 1 - Gearbox housing 2 - Adjusting washer ❑ for the differential gear ❑ Determine thickness ⇒ page 158 3 - Outer ring/tapered-roller bearing ❑ removing ⇒ page 155 ❑ installing ⇒...
Page 551 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 14 - Thrust washer ❑ Fitting position: Collar towards pressure spring ⇒ page 158 15 - Conical ring ❑ with slots for thrust washer catch ❑ Fitting position: Cone towards differential gear housing 16 - Circlip ❑...
Page 552 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Press outer ring/tapered-roller bearing into the clutch housing No adjusting washer is fitted at the side of the clutch housing. Removing inner ring/tapered-roller bearing – Before fitting the extractor, position the thrust plate -MP3-467 (40-105) - on the differential gear housing.
Page 553 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Press in outer ring/tapered-roller bearing in the gearbox housing – Position adjusting washer under outside ring. – Support the gearbox housing with a bushing -MP3-474 (3144) - directly below the bearing support.
Page 554 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Remove tensioning sleeve without round slot (long tensioning sleeve); press out differential bevel gear shaft When pressing out the tensioning sleeve, it is sheared off during this procedure. – Drive the remaining part of the tensioning sleeve out of the differential gear housing and the differential bevel gear shaft.
Page 555: Adjusting The Differential Gear
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Fitting position of thrust washer for the conical ring -1- The collar -arrow- points towards the pressure spring -B-. The lands -A- are available on certain gearboxes. The lands -A- point towards the conical ring -1-.
Page 556 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Press the outer ring/tapered-roller bearing with pressure plate -MP3-464 (30-205) - into the clutch housing. Note The inner and outer ring of the tapered-roller bearing are paired. Do not interchange! –...
Page 557 FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 – Remove the gearbox housing and pull the outer ring/tapered- roller bearing out of the gearbox housing. A - Countersupport , e.g. -Kukko 22/2- B - Interior extractor 46...58 mm , e.g. -Kukko 21/7-...
Page 558: Setting Overview
FABIA II 2007 ➤ Gearbox 02R - Edition 12.06 Setting overview Note When working on the gearbox it is only necessary to re-set the ♦ drive shaft, output shaft or differential gear if parts were re‐ placed that directly affect the setting of the gearbox.
Page 559 Service Workshop Manual Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , Rapid NH 2013 ➤ , Rapid NH 2014 ➤ , Roomster 2006 ➤ Gearbox 02T Edition 05.2014 Service Department. Technical Information...
Page 560 Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 30 - Clutch 34 - Controls, housing 35 - Gears, shafts 39 - Final drive - differential...
Page 561 Clutch control ............Summary of components - foot controls (Fabia II 2007 ►; Roomster 2006 ►) ..
Page 562 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Remove and install gearshift knob and shift lever collar (Rapid) ....
Page 563: Technical Data
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 00 – Technical data Identification of the gearbox (SRL000700; Edition 05.2014) Assignment Fabia II ⇒...
Page 564 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Manual gearbox 5 speed 02T Manufac‐ from 12.06 06.09 01.07 06.09 tured 05.09 03.10 05.09...
Page 565 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Manual gearbox 5 speed 02T Clutch control hydraulic Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts Drive shaft flange ∅...
Page 566 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Manual gearbox 5 speed 02T Manufac‐ from 02.07 06.09 04.07 06.09 tured 05.09 05.09 05.10...
Page 567 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Manual gearbox 5 speed 02T Clutch control hydraulic Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts Drive shaft flange ∅...
Page 568: Identification Characters, Aggregate Assignment, Ratios, Filling Capacities (Roomster)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Manual gearbox 5 speed 02T Manufac‐ from 02.07 06.09 tured 05.09 09.10 Assign‐ Engine 1.4 ltr./51 kW TDI-PD...
Page 569 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Manual gearbox 5 speed 02T Filling capacity 2.0 l Specification ⇒ Electronic Catalogue of Original Parts...
Page 570 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Manual gearbox 5 speed 02T Identification characters Manufac‐ from 05.06 11.06 06.09 tured 11.06 05.09...
Page 571 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Manual gearbox 5 speed 02T Specification ⇒ Electronic Catalogue of Original Parts Gear oil change interval...
Page 572 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Manual gearbox 5 speed 02T Identification characters Manufac‐ from 08.06 11.06 06.09 tured 11.06 05.09...
Page 573: Identification Characters, Aggregate Assignment, Ratios, Filling Capacities (Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Manual gearbox 5 speed 02T Reverse gear 35 : 24 x 24 : 11 = 3.182...
Page 574 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Note Vehicles with ABS do not have the sender for speedometer - ♦ G22- .
Page 575: Overview Of Transmission System
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Overview of Transmission System Designation of components and transmission ratio Note The arrow shows the direction of travel.
Page 576: General Repair Instructions
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 General repair instructions To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential.
Page 577 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Before installing Lightly lubricate the outside diameter of the gasket ring. Fill half the space between the sealing lips -arrow- with grease - G 052 128 A1- .
Page 578 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Nuts and bolts ♦ Slacken and tighten fixing screws and nuts of covers and housings diagonally across in stages.
Page 579 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 ♦ These are not interchangeable. If re-using, allocate synchron‐ izer rings to the same sliding gear.
Page 580: Clutch
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 30 – Clutch Clutch control Summary of components - foot controls (Fabia II 2007 ►; Room‐...
Page 581: Summary Of Components - Foot Controls (Fabia Ii 2007 ►; Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Summary of components - foot controls (Fabia II 2007 ►; Roomster 2006 ►) Note Summary of components - Hydraulics ⇒...
Page 582: Removing And Installing, Setting Angular Clutch Pedal Switch F36 , (Fabia Ii 2007 ►; Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 13 - 28 Nm ❑ always replace ⇒ Electronic Catalogue of Original Parts 14 - Master cylinder ❑...
Page 583 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Removing – Remove the storage area on the driver's side ⇒ Body Work; Rep. gr. 70 .
Page 584: Removing And Installing The Crash Strut For The Clutch Pedal (Fabia Ii 2007 ►; Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Removing and installing the crash strut for the clutch pedal (Fabia II 2007 ►;...
Page 585 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Tightening torque Crash strut to steering column 9 Nm...
Page 586: Removing And Installing The Over-Centre Helper Spring (Fabia Ii 2007 ►; Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Removing and installing the over-centre helper spring (Fabia II 2007 ►; Roomster 2006 ►) Special tools and workshop equipment required ♦...
Page 587 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Press over-centre helper spring against the bearing and posi‐ tion on the support of the clutch pedal -arrow-.
Page 588 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Tightening torque Crash strut to steering column ⇒ page 22...
Page 589: Removing And Installing The Clutch Pedal (Fabia Ii 2007 ►; Roomster 2006 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Removing and installing the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►) Special tools and workshop equipment required ♦...
Page 590 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Tightening torques Crash strut to steering column ⇒ page 22 ⇒ page 19 Clutch pedal to bracket...
Page 591: Summary Of Components - Foot Controls (Fabia Ii 2011 ►; Roomster 2011 ►; Rapid Nh 2013 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Summary of components - foot controls (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)
Page 592 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 8 - Stop ❑ for the clutch pedal 9 - Bearing bolt ❑ always replace ⇒ Electronic Catalogue of Original Parts 10 - Over-centre helper spring ❑...
Page 593 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Removing and installing tension spring – Removing and installing with hook - 3438- .
Page 594 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 The clutch pedal switch is installed from the front wall. – Insert the clutch pedal switch into the support of the bracket and turn it 45°...
Page 595 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Tightening torque Crash strut to steering column (2 screws) 9 Nm...
Page 596 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Version with one fixing screw Removing – Remove the storage area on the driver's side ⇒ Body Work;...
Page 597 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Tightening torque Crash strut to steering column (1 screw) 20 Nm...
Page 598: Summary Of Components - Foot Controls (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Summary of components - Foot controls (Rapid) Note Summary of components - Hydraulics ⇒ page 54 ♦...
Page 599 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 ❑ removing and installing ⇒ page 54 13 - Master cylinder ❑ removing and installing ⇒...
Page 600: Removing And Installing The Bracket With The Master Cylinder (Fabia Ii 2011 ►; Roomster 2011 ►; Rapid Nh 2013 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Turn the clutch pedal switch at the bracket 45° in -direction of arrow- and remove it from the support.
Page 601 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – If the master cylinder is not accessible, remove the engine control unit from the front wall ⇒ Engine; Rep. gr. 23 or ⇒...
Page 602 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Unscrew the two lower fixing nuts -arrows-. – Remove the bracket -A- from the front wall -B-.
Page 603: Removing And Installing The Bracket With The Master Cylinder (Rapid 2011 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Tightening torques ⇒ page 29 -Position 4- Bracket/clutch pedal to front wall ⇒ page 29...
Page 604 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Unscrew the two lower fixing nuts -arrows-. – Remove the bracket -A- from the front wall -B-.
Page 605: Removing And Installing The Bracket Without The Master Cylinder
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 ⇒ page 36 -Position 4- Master cylinder to front wall Replace self-locking nut. 1.11...
Page 606 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Note Position self-locking nuts -1- and -2- for bracket -3- on front wall. – The support -A- must be located on the actuating rod -B- of the master cylinder.
Page 607 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Unlock the actuating rod/master cylinder from the clutch pedal as follows: – Pull clutch pedal slightly into the passenger compartment.
Page 608: Removing And Installing The Clutch Pedal With The Over-Centre Helper Spring (Fabia Ii 2011 ►; Roomster 2011 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1.13 Removing and installing the clutch pedal with the over-centre helper spring (Fa‐ bia II 2011 ►; Roomster 2011 ►) Note Install clutch pedal with new bearing bolt.
Page 609 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – The support -2- must be located on the actuating rod -1- of the master cylinder.
Page 610: Removing And Installing The Clutch Pedal With The Over-Centre Helper Spring (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1.14 Removing and installing the clutch pedal with the over-centre helper spring (Rap‐ Note Install the clutch pedal with a new bearing bolt.
Page 611: Removing And Installing The Clutch Pedal With The Tension Spring
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – The support -2- must be located on the actuating rod -1- of the master cylinder.
Page 612 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Unhook the tension spring e.g with hook - 3438- . Note Only observe the right part of the fig. -arrows- when installing.
Page 613: Summary Of Components - Hydraulic (Fabia Ii ►; Roomster ►; Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Position the bolts -A- horizontally. – Turn the bearing bolt to the right -in direction of arrow-, for this purpose use the hexagon socket wrench -1-, wrench size 8 mm.
Page 614 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1 - Brake fluid reservoir ❑ test tightness ⇒ page 57 2 - Supply hose ❑...
Page 615 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 11 - Support ❑ holds the tube-hose line -Pos. 9- on the gearbox ❑ not fitted to all vehicles...
Page 616: Summary Of Components - Hydraulic (Rapid 2011 ►)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 As of 12.05 on certain vehicles plastic return hose -1-: ♦ Gaskets -2- must be present on the return hose.
Page 617 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 13 - Gasket ring/O-ring ❑ pull onto line connection ❑ insert with brake fluid ❑...
Page 618 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Push the actuator rod/master cylinder in the support -A- in -direction of the arrow-.
Page 619: Check Hydraulic Clutch Control
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1.18 Check hydraulic clutch control Note If the master cylinder and/or slave cylinder must be replaced ♦...
Page 620: Removing And Installing The Master Cylinder
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1.19 Removing and installing the master cyl‐ inder (Fabia II 2007 ►; Roomster 2006 ►)
Page 621 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Unlock the actuating rod/master cylinder from the clutch pedal as follows: – Insert pliers - T10005- in the clutch pedal recesses.
Page 622 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Tightening torques Crash strut to steering column ⇒ page 22 ⇒ page 19 Clutch pedal to bracket...
Page 623: Removing And Installing The Slave Cylinder
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1.20 Removing and installing the master cyl‐ inder (Fabia II 2011 ►; Roomster 2011 ►;...
Page 624 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Note If the slave cylinder must be replaced due to a predetermined ♦ fault, first of all check the hydraulic clutch control ⇒...
Page 625 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Disconnect the Bowden cable support from gearbox -arrows-. – Tie up shift cable and selector cable.
Page 626 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Tightening torques Slave cylinder to gearbox Fabia II, Roomster, Rapid NH ⇒ page 51 Rapid ⇒...
Page 627: Bleeding The Clutch Control
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1.22 Bleeding the clutch control Special tools and workshop equipment required ♦ Brake filling and bleeding device , e. g. -VAS 5234-...
Page 628: Repairing The Clutch Release Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Repairing the clutch release mecha‐ nism Special tools and workshop equipment required ♦ Grease - G 000 100- 1 - Clutch release bearing ❑...
Page 629 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 8 - Gearbox 9 - 20 Nm 10 - Support 11 - Slave cylinder ❑...
Page 630: Repairing Clutch
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Repairing clutch Fault finding power transmission - problems with the clutch and clutch control ⇒...
Page 631 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1 - Flywheel ❑ make sure the centering pins are correctly fitted ❑ The locating face for the...
Page 632: Fault Finding Power Transmission - Problems With The Clutch And Clutch Control
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Centering the clutch disc and removing and installing the pressure plate for vehicles with 1.2 ltr and 1.4 ltr engines –...
Page 633 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Complaint Fault description Measure Clutch pedal does not return to ini‐ ♦ Air in line system.
Page 634 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Complaint Fault description Measure ♦ Centre displacement of engine/ – Check dowel sleeves. gearbox.
Page 635 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Complaint Fault description Measure ♦ Clutch disc on the serration – Check the hub for damage, if sluggish/jams.
Page 636 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Complaint Fault description Measure ♦ Clutch disc worn out, burnt, – Replace clutch disc.
Page 637 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Complaint Fault description Measure ♦ The contact surface of the pres‐ – Check the contact surface of the sure plate lifts off only unilater‐...
Page 638: Controls, Housing
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 34 – Controls, housing Shift mechanism Installation position - selector mechanism ⇒ page 76 Summary of components - Gearshift mechanism ⇒...
Page 639 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 A - Shift cable B - Selector cable C - Heat shield ❑ take off before removing...
Page 640: Summary Of Components - Gearshift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Summary of components - Gearshift mechanism Note If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System;...
Page 641: Summary Of Components - Gearshift Knob With Shift Lever Collar
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Summary of components - Gearshift knob with shift lever collar 1 - Gearshift knob ❑...
Page 642: Remove And Install Gearshift Knob And Shift Lever Collar (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Lever off the collar with two disassembly wedges - 3409- out of the surround of the centre console in -direction of arrow-.
Page 643: Remove And Install Gearshift Knob And Shift Lever Collar (Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Lever off the collar frame with the disassembly wedge - T30098- out of the surround for the centre console in -direction of arrow-.
Page 644: Summary Of Components - Shift Lever And Shift Housing
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Open clamp -arrow- and pull off gearshift knob together with the collar. Install –...
Page 645 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1 - Lock washer ❑ removing and installing ⇒ page 84 2 - Pressure spring 3 - Gasket ❑...
Page 646: Summary Of Components - Control Cables
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Removing and installing lock washer – When removing and installing the circlip -A- pull the gearshift...
Page 647 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1 - Shift cable ❑ slacken from the shift lever guide within the shift mechanism ❑...
Page 648 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 ❑ it is not necessary, if it is a plastic relay lever 13 - Bush ❑...
Page 649: Plastic Relay Lever As Of 06.07 (Fabia Ii, Roomster, Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Fitting location of gearbox shift lever – When inserting the gearbox shift lever, make sure that the tooth opening -arrow A- is located above the interrupted spac‐...
Page 650 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Pull forward the locking mechanism as far as the stop in -direction of arrow 1-, then lock by turning to the left in -direction of arrow 2-.
Page 651: Remove And Install Shift Mechanism (Fabia Ii, Roomster, Rapid Nh)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Relay lever with clip – Remove clip -arrow°1-. – Carefully take the relay lever together with the cable lock out of its bearing point.
Page 652 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 ♦ Disassembly wedge - 3409- (2 pieces) (Fabia II, Roomster) ♦ Release tool - T30098- (Rapid NH) ♦...
Page 653 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Remove underbody cover on right and left (if present) -arrows-. – Remove tunnel bridge -arrows-.
Page 654 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Always replace lock washers -3- and -4- after each disassem‐ bly ⇒ Electronic Catalogue of Original Parts .
Page 655 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Tightening torques Components Tightening torque Underbody cover 2 Nm Shift housing to body ⇒ page 82 Cable support to gearbox ⇒...
Page 656: Removing And Installing Shift Mechanism (Rapid)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1.11 Removing and installing shift mecha‐ nism (Rapid) Special tools and workshop equipment required ♦...
Page 657 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Remove underbody cover on right and left (if present) -arrows-. – Remove tunnel bridge -A- -arrows-.
Page 658: Setting The Shift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Apply a small quantity of grease - G 000 450 02- onto the studs -arrows- of the gearbox shift lever -1- and of the relay lever -2-.
Page 659 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 • Gearbox in Neutral. Note If the battery earth strap is disconnected and connected, carry out additional operations ⇒...
Page 660 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Turn locking mechanism at shift cable and at selector cable to the right up to the stop -direction of arrow-.
Page 661: Removing And Installing The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Removing and installing the gearbox Removing the gearbox ⇒ page 99 Installing the gearbox ⇒...
Page 662 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Remove circlip -arrow 1- for shift cable from gearbox shift lever -A-. – Pull off shift cable from the stud.
Page 663 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Remove Bowden cable support -arrows-. – Tie up shift cable and selector cable.
Page 664 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Remove the earth strap from the engine/gearbox connecting screw -1- (on certain types of engines the earth strap is not connected).
Page 665 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Install supporting device - MP9-200 (10-222A)- . For this pur‐ pose, position the supports -C- next to the screw -arrow 1- and the support for the engine hood -arrow 2- as shown.
Page 666 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Unscrew the fixing screws -arrows- from the gearbox mount. – Remove front left wheel ⇒ Chassis; Rep. gr. 44 and raise vehicle: ♦...
Page 667 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Release the nuts -arrows- for the left steering joint ⇒ Chassis; Rep. gr. 40 (on certain vehicles release the screws, see fig.
Page 668 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Release the screws -arrows- and remove the fan shroud downwards (on newer models, the screws are no longer present and the fan shroud is only clipped in at the radiator, see fig.
Page 669 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Screw in the mounting elements -A- as shown on adjusting plate . – Position engine/gearbox jack below vehicle, ⇒ Abb. S34-0340, arrow symbol -B- on adjusting plate points in the direction of travel/vehicle.
Page 670: Installing The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Adjust supporting arm at slide with locking pin. Number of visible holes -arrow- = 5.
Page 671 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 2.2.1 Tightening torques Gearbox to 1.2/44 kW, 1.2/47 kW, 1.2/51 kW and 1.2/55 kW en‐...
Page 672 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Gearbox to 1.6 ltr./77 kW engine (Fabia II, Roomster) Pos. Screw Piece M12 x 60...
Page 673 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Components Tightening torque 40 Nm + 90° Fixing screws of gearbox mount Cover plate for flywheel...
Page 674: Inspect The Gear Oil Level In The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Inspect the gear oil level in the gear‐ Special tools and workshop equipment required ♦...
Page 675: Disassembling And Assembling The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Disassembling and assembling the gearbox Gearbox - Summary of components ⇒ page 113 Summary of components ⇒...
Page 676: Summary Of Components
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Summary of components I - Removing and installing gearbox housing cover and 5th gear ⇒...
Page 677: Removing And Installing Gearbox Housing Cover And 5Th Gear
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Mounting sequence ⇒ page 118 Removing and installing gearbox housing cover and 5th gear 1 - Gearbox housing ❑...
Page 678: Detaching And Attaching Clutch Housing
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 13 - 5th gear shift fork ❑ disassembling and assembling ⇒ page 132 14 - Bolt ❑...
Page 679: Removing And Installing The Drive Shaft, Output Shaft, Differential Gear, Shift Mechanism And Gearshift Forks
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Removing and installing the drive shaft, output shaft, differential gear, shift mechanism and gearshift forks 1 - Differential gear ❑...
Page 680: Mounting Sequence
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 12 - 5 Nm + 90° further ❑ always replace ⇒ Electronic Catalogue of Original Parts...
Page 681 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 ♦ Thrust piece - T10085- ♦ Sealant - AMV 188 200 03- Change gearbox holder -T30012- Drill a new hole in the gearbox holder - T30012 (3221)- to attach the Gearbox 02T.
Page 682 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Unscrew the cover -arrow- for the gearbox housing. – Pull out the bearing bolt -1- for the 5th gear shift fork -2- and remove gearshift fork.
Page 683 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Remove transmission neutral sender - G701- -arrow-. Continued for all gearboxes – Remove the gearshift shaft with cover -A-; to do this, put the gearshift shaft in idle position.
Page 684 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Pressing the sleeve of the 5th gear sliding gear needle bearing onto the drive shaft ⇒...
Page 685 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Fit the washer - T10083/1- onto the drive shaft and carefully press in the bearing support together with the drive shaft and the output shaft up to the stop.
Page 686 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Remove transmission neutral sender - G701- -arrow-. Continued for all gearboxes – Screw in new screws -A- and tighten the bearing support of the drive shaft and output shaft.
Page 687 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Insert the 5th gear shift fork -2- and push the bearing pin -1- up to the stop.
Page 688: Repairing Gearbox Housing And Clutch Housing
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Repairing gearbox housing and clutch housing Special tools and workshop equipment required ♦ Thrust piece - MP3-420 (3124)- ♦...
Page 689 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Oil filler plug or oil drain plug with hexagon socket head - 32 Nm 7 - O-ring ❑...
Page 690 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 19 - Bushing ❑ for gearshift shaft ❑ extracting ⇒ page 129 ❑ inserting ⇒...
Page 691 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Remove bushing for gasket ring – Position the distance sleeve - MP3-458/2- and thrust piece - MP3-484 (30-555)- on the differential gear.
Page 692: Repairing Shift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Repairing shift mechanism Special tools and workshop equipment required ♦ Thrust piece - T10203- ♦...
Page 693 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Remove locking bolt -A- from gearshift cover – Remove the outer part of the locking bolt.
Page 694: Disassembling And Assembling The Gearshift Forks
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Disassembling and assembling the gearshift forks Special tools and workshop equipment required ♦ Driver - MP1-304 (10-206)- ♦...
Page 695 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 7 - Bearing bolt ❑ for 5th gear shift fork Identification of shift segments and 5th gear shift fork with shift...
Page 696 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Fitting the circlip – Press the circlip with a handle wrench into the slot of the shift segment.
Page 697: Gears, Shafts
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 35 – Gears, shafts Drive shaft Disassembling and assembling the drive shaft ⇒ page 135...
Page 698 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Note Insert all bearings, gears and synchronizer rings in the gear‐ ♦ box with gear oil.
Page 699 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 7 - Gearbox housing 8 - Bearing support for grooved ball bearing ❑ Always replace grooved ball bearing together with the bearing support ❑...
Page 700 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 ❑ removing ⇒ page 138 ❑ pressing on ⇒ page 138 ❑ Fitting position: The circlip in the bearing points towards the drive shaft 22 - Clutch housing ❑...
Page 701 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Press out the bearing support for grooved ball bearing – Move the sliding sleeve for 1st and 2nd gear to 2nd gear.
Page 702 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Disassembling and assembling the sliding sleeve/3rd and 4th gear synchronizer body 1 - Spring (as of production date 06.09 the springs are longer) ⇒...
Page 703 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Press on the synchronizer body with the 3rd and 4th gear sliding sleeve Press on the inner ring -A- for the cylindrical-roller bearing –...
Page 704 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Note The drive shafts of the individual gearboxes have different ♦ lengths due to the different heights of the serration, dimension -a-.
Page 705 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Remove supporting ring – Unclip the hook -A- of the supporting ring from the synchron‐...
Page 706: Output Shaft
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Output shaft Disassembling and assembling the output shaft ⇒ page 144 Disassembling and assembling the out‐...
Page 707 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1 - Clutch housing ❑ repairing ⇒ page 126 2 - Cylindrical-roller bearing ❑ with circlip ❑...
Page 708 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 14 - Sliding sleeve with 1st and 2nd gear synchronizer body ❑ press off together with 2nd gear sliding gear ⇒...
Page 709 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Pull out the cylindrical-roller bearing from the clutch housing – When removing compress circlip of the cylindrical-roller bear‐...
Page 710 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Fitting position 3rd gear pinion and 4th gear pinion. – Place the 4th gear pinion -A- on the output shaft.
Page 711 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Disassembling and assembling the sliding sleeve/1st and 2nd gear synchronizer body 1 - Spring...
Page 712 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Insert the circlip – Rotate the synchronizer ring in such a way that the slots are flush with the arresters.
Page 713: Final Drive - Differential
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 39 – Final drive - differential Replacing the flange shaft gasket rings (gearbox assembled) Removing ⇒...
Page 714: Install
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – If present, remove heat shield for drive shaft -arrows-. – Remove drive shaft from flange shaft ⇒ Chassis; Rep. gr. 40 .
Page 715 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Steering joint to track control arm ⇒ Chassis; Rep. gr. 40 Wheel bolts to wheel hub ⇒...
Page 716: Differential Gear
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Differential gear Disassembling and assembling differential gear ⇒ page 154 Setting the differential gear ⇒...
Page 717 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 1 - Conical screw, 25 Nm ❑ screw into threaded piece -Pos. 8- 2 - Right flange shaft ❑...
Page 718 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 ❑ Assignment ⇒ Electronic Catalogue of Original Parts 15 - Outer ring/tapered-roller bearing ❑ removing ⇒...
Page 719 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Remove outer ring/tapered-roller bearing from gearbox housing A - Countersupport , e.g. -Kukko 22/2- B - Interior extractor 46 up to 58 mm , e.g.
Page 720 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Remove inner ring/tapered-roller bearing on the side of the gear pinion – Before fitting the extractor, position distance sleeve - MP3-458/2- and thrust piece - MP3-431 (3002)- on the differ‐...
Page 721: Adjusting The Differential Gear
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 Press out differential bevel gear shaft The tensioning sleeve is cut during pressing out.
Page 722 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 ♦ Interior extractor , e.g. -Kukko 21/7- ♦ Thrust plate - MP3-464 (30-205)- ♦ Dial gauge The differential gear must be re-set when the following compo‐...
Page 723 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ... Gearbox 02T - Edition 05.2014 – Set the dial gauge to 0 with 1 mm preload on “0”. A - Dial gauge extension 30 mm –...
Page 724 Service Workshop Manual FABIA II 2007 ➤ Gearbox 02T Edition 12.06 Service Department. Technical Information...
Page 725 Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 30 - Clutch 34 - Control, housing 35 - Wheels, shafts 39 - Final drive, differential gear...
Page 726 Clutch control ............Summary of components - foot controls; Fabia II 2007 ? ......
Page 727 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Removing and installing the drive shaft, output shaft, differential, shift mechanism and gearshift forks ............
Page 728: Technical Data
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 00 – Technical data Identification of the gearbox Assignment ⇒ page 1 Location on the gearbox Identification characters and production date -arrow 1-. Identification of materials for the gearbox housing -arrow 2-.
Page 729 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Manual gearbox 5 speed 02T Z 2 : Z 1 1st gear 49 : 13 = 3,769 2nd gear 44 : 21 = 2,095 3rd gear 43 : 31 = 1,387...
Page 730 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Note Vehicles with ABS do not have the sender for speedometer - ♦ G22- . On gearboxes as of production date 06.09, the springs of the ♦ sliding sleeve with synchronizer body for 3rd, 4th and 5th gear...
Page 731 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Manual gearbox 5 speed 02T Ratio: Final drive 66 : 17 = 3,882 59 : 15 = 3,933 Z 2 : Z 1 1st gear 49 : 13 = 3,769 2nd gear...
Page 732 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Note Vehicles with ABS do not have the sender for speedometer - ♦ G22- . On gearboxes as of production date 06.09, the springs of the ♦ sliding sleeve with synchronizer body for 3rd, 4th and 5th gear...
Page 733: Overview Of Transmission System
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Overview of Transmission System Designation of components and transmission ratio Note The arrow shows the direction of travel. 1 - Engine 2 - Clutch 3 - Manual gearbox 4 - Drive shaft...
Page 734: General Repair Information
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 General repair information To carry out gearbox repairs successfully and correctly, scrupu‐ lous care and cleanliness, as well as the proper tools, are essen‐ tial requirements. Obviously, the generally valid basic safety rules apply to repair work.
Page 735 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 ♦ Replace circlips. ♦ Do not over-tension the circlips. ♦ Circlips must be positioned in the base of the groove. ♦ Replace roll pins. Fitting position: Slot longitudinally to power flow -arrow-.
Page 736 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 ♦ Gauge shims at several points with a micrometer. Different tolerances allow to measure the required thickness for each washer very precisely ⇒ electronic catalogue of original parts . ♦ Inspect for burrs and damage.
Page 737: Clutch
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 30 – Clutch Clutch control Summary of components - foot controls; Fabia II 2007 ? Note ♦ Summary of components - Hydraulics ⇒ page 33 If the battery earth strap is disconnected and connected, carry ♦...
Page 738 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 9 - Bushing 10 - Bearing pins 11 - Clutch pedal ❑ removing and installing ⇒ page 18 12 - Support ❑ removing and installing ⇒ page 18 13 - 28 Nm ❑...
Page 739: Removing And Installing, Setting Angular Clutch Pedal Switch F36
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 removing and installing, setting angular clutch pedal switch -F36- Note The clutch pedal switch -F36- may only be installed once to en‐ sure that it has an adequately tight fit in the bracket.
Page 740 – Install the storage area on the driver's side ⇒ Body Work ⇒ Rep. Gr. 70 . Removing and installing the crash strut for the clutch pedal; Fabia II 2007 ? Removing – Remove the storage area on the driver's side ⇒ Body Work ⇒...
Page 741 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Tightening torque Crash strut to steering column 9 Nm...
Page 742: Removing And Installing The Over-Centre Helper Spring; Fabia Ii
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Removing and installing the over-centre helper spring; Fabia II 2007 ? Special tools and workshop equipment required ♦ Pliers -T10005- ♦ Polycarbamide grease -G 052 142 A2- Removing – Remove the storage area on the driver's side ⇒ Body Work ⇒...
Page 743 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Press over-centre helper spring against the bearing and posi‐ tion on the support of the clutch pedal -arrow-. – Position the clutch pedal with the master brake cylinder ⇒ page 18 –...
Page 744 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Tightening torque Crash strut to steering column ⇒ page 13...
Page 745: Removing And Installing The Clutch Pedal; Fabia Ii
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Removing and installing the clutch ped‐ al; Fabia II 2007 ? Special tools and workshop equipment required ♦ Pliers -T10005- ♦ Polycarbamide grease -G 052 142 A2- Removing – Remove crash strut (if present) ⇒...
Page 746 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Tightening torques Crash strut to steering column ⇒ page 13 ⇒ page 10 Clutch pedal to bracket Always replace self-locking nut ⇒ Electronic Catalogue of Original Parts .
Page 747: Summary Of Components - Foot Controls; Fabia Ii
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Summary of components - foot controls; Fabia II 2011 ? Note Summary of components - Hydraulics ⇒ page 33 ♦ After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical ♦...
Page 748 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 11 - Clutch pedal ❑ Removing and installing the over-centre helper spring ⇒ page 28 ❑ removing and installing with tension spring ⇒ page 30 12 - Bushing 13 - Tension spring with vibration damper ❑...
Page 749 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1.7.1 Removing and installing clutch pedal switch -F36- Note The clutch pedal switch -F36- may only be installed once to en‐ sure that it has an adequately tight fit in the bracket.
Page 750 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Removing and installing the bracket with the master cylinder; Fabia II 2011 ? Special tools and workshop equipment required ♦ Closing tool -T10249- 1.8.1 Removing Note After the battery earth strap is disconnected and connected, carry out additional operations ⇒...
Page 751 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Vehicles with the start-stop system: – Unclip clutch position sender -G476- at master cylinder -arrow A- and -arrow B-. – Remove the clutch position sender with fitted plugs from the master cylinder.
Page 752 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Note Position self-locking nuts -1- and -2- for bracket -3- on front wall. – Install the clutch pedal switch -F36- ⇒ page 22 – If present, install the crash strut -A-. To do so, tighten the fixing screws -arrows- ⇒...
Page 753 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Replace self-locking nut. Removing and installing the bracket without the master cylinder; Fabia II 2011 ? Special tools and workshop equipment required ♦ Pliers -T10005- Removing – Remove the footwell vent ⇒ Heating, Air Conditioning ⇒ Rep.
Page 754 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Unscrew the two bottom fixing nuts -arrows-. – Remove the bracket -A- from the front wall -B-. • The master cylinder is secured to the bracket. • When removing the bracket, the master cylinder in the engine compartment must be held by a 2nd mechanic.
Page 755: Removing And Installing The Clutch Pedal With The Over-Centre Helper Spring; Fabia
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1.10 Removing and installing the clutch pedal with the over-centre helper spring; Fabia II 2011 ? Note Install clutch pedal with new bearing bolt. ♦ If only the over-centre helper spring is removed, the clutch ♦...
Page 756 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Remove bearing bolt for clutch pedal. – Turn the bearing bolt for the clutch pedal to the left in -direction of arrow-. -1- = 8 mm Allan key. The catch -A- is destroyed.
Page 757 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Press on clutch pedal slightly and insert a new bearing bolt. – Position the bolt -A- horizontally. – Turn the bearing bolt to the right in -direction of arrow-. -1- = 8 mm Allan key.
Page 758 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Unhook tension spring with e.g hook -3438- . Note Only observe the right part in the fig. -arrows- when installing. – Unlock the actuating rod/master cylinder from the clutch pedal as follows: –...
Page 759 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Position the bolt -A- horizontally. – Turn the bearing bolt to the right in -direction of arrow-. -1- = 8 mm Allan key. • The catch -B- must click audibly into place.
Page 760: Summary Of Components - Hydraulics
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1.12 Summary of components - Hydraulics 1 - Brake fluid reservoir ❑ test tightness ⇒ page 35 2 - Tubing ❑ out of rubber ❑ as of 12.05 on certain vehicles out of plastic ⇒...
Page 761 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 11 - Support ❑ holds the tube-hose line Pos. 9 at the gearbox ❑ not fitted to all vehicles 12 - 20 Nm 13 - Locking clip ❑ to remove the tube-hose line Pos. 9 pull out of the slave cylinder Pos. 16 up to the stop...
Page 762: Check Hydraulic Clutch Control
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 as of 12.05 on certain vehicles plastic return hose -1- ♦ Gaskets -2- must be present on the return hose. ♦ Do not use hose clamp -MP7–602- 1.13 Check hydraulic clutch control Note ♦...
Page 763: Removing And Installing The Master Cylinder; Fabia Ii
⇒ page 35 1.14 Removing and installing the master cyl‐ inder; Fabia II 2007 ? Special tools and workshop equipment required ♦ Pliers -T10005- ♦ Hose clamp -MP7-602 (3094)- 1.14.1...
Page 764 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Pinch off return hose -A- to master cylinder with hose clamp - MP7-602 (3094)- (if the return hose is made out of plastic, do not use the hose clamp -MP7–602 - , otherwise the return hose can get damaged).
Page 765 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1.14.2 Install Installation is performed in the reverse order, pay attention to the following points: – The support -A- must be located on the actuating rod -B- of the master cylinder.
Page 766 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Tightening torques Crash strut to steering column ⇒ page 13 ⇒ page 10 Clutch pedal to bracket Always replace self-locking nut ⇒ Electronic Catalogue of Original Parts .
Page 767: Removing And Installing The Master Cylinder; Fabia Ii
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1.15 Removing and installing the master cyl‐ inder; Fabia II 2011 ? Special tools and workshop equipment required ♦ Pliers -T10005- ♦ Polycarbamide grease -G 052 142 A2- Removing Remove bracket with master cylinder ⇒...
Page 768 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1.16.1 Removing Note If the battery earth strap is disconnected and re-connected, carry out additional operations ⇒ Electrical System ⇒ Rep. Gr. 27 . – Disconnect the battery-earth strap with the ignition off ⇒ Elec‐...
Page 769 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Pull retaining clip -A- for tube-hose line out of the slave cylinder up to the stop. – Pull tube-hose line out of the support -C-. – Pull tube-hose line -B- out of the slave cylinder and close opening in a suitable manner.
Page 770 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Tightening torques Slave cylinder to gearbox ⇒ page 33 Cable support to gearbox ⇒ page 61 Gearbox shift lever to gearbox ⇒ page 61...
Page 771: Bleed The Clutch Control
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1.17 Bleed the clutch control Special tools and workshop equipment required ♦ Brake filling and bleeding device (e.g. -ROMESS S15- or -VAS 5234- ) Note If the battery earth strap is disconnected and connected, carry ♦...
Page 772: Repairing The Clutch Control
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Repairing the clutch control Special tools and workshop equipment required ♦ Grease -G 000 100- 1 - Clutch release bearing ❑ Do not wash the bear‐ ing, just wipe clean ❑ replace noisy bearings ⇒...
Page 773 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 8 - Gearbox 9 - 20 Nm 10 - Support 11 - Slave cylinder ❑ removing and installing ⇒ page 40 ❑ grease tappet end with grease -G 000 100- Remove and install the clutch release lever together with the re‐...
Page 774: Repairing The Clutch
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Repairing the clutch Special tools and workshop equipment required ♦ Counterholder -MP1-223 (3067)- ♦ Centering mandrel -T10086- ♦ Centering mandrel -MP3-475A (3190A) - ♦ Grease -G 000 100- (Gearbox removed) Note Observe the fault finding of the power transmission before replacing the clutch disc and the pressure plate ♦...
Page 775 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1 - Flywheel ❑ make sure the centering pins are correctly fitted ❑ The locating face for the clutch lining must be free from grooves, oil and grease ❑ removing and installing ⇒...
Page 776: Fault Finding Power Transmission - Problems With The Clutch And Clutch Control
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Centering the clutch disc and removing and installing the pressure plate for vehicles with 1.2 ltr and 1.4 ltr engines – Release and tighten screws gradually and crosswise. – When removing inverse the position of the pressure pad - MP1-223 (3067)- .
Page 777 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Complaint Fault description Measure Clutch pedal does not return to ini‐ ♦ Air in line system. – Vent air from the line system; tial position. top up with brake fluid. ♦ Line system, master or slave –...
Page 778 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Complaint Fault description Measure ♦ Centre displacement of engine/ – Check dowel sleeves. gearbox. ♦ Clutch disc installed the wrong – Correct installation. way up. ♦ Wrong clutch disc installed. – Assign clutch disc via the ⇒...
Page 779 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Complaint Fault description Measure ♦ Clutch disc on the serration – Check serration of the hub for sluggish/jams. Corroded hub, damage, if necessary replace damaged during assembly. Hub clutch disc. profile knocked out on one side.
Page 780 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Complaint Fault description Measure ♦ Clutch disc worn out, burnt, – Replace clutch disc. pressure plate overheated, scoring, pressure plate warped – Replace pressure plate. through incorrect assembly, contact pressure of the pressure –...
Page 781 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Complaint Fault description Measure ♦ The contact surface of the pres‐ – Check the contact surface of the sure plate lifts off only unilater‐ clutch lining at the flywheel, ally due to the tilted release check pressure plate and mem‐...
Page 782: Control, Housing
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 34 – Control, housing Shift mechanism Fitting location of shift mechanism Arrow A - Shift movement Arrow B - Selector movement A - Shift cable B - Selector cable C - Heat shield ❑...
Page 783: Summary Of Components
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Summary of components Note If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System ♦ ⇒ Rep. Gr. 27 . Remove shift mechanism for replacing control cables ⇒...
Page 784: Summary Of Components - Gearshift Knob With Gearshift Lever Cover
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Summary of components - Gearshift knob with gearshift lever cover 1 - Gearshift knob ❑ with collar ❑ It is not possible to sep‐ arate the gearshift knob from the collar ❑...
Page 785 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Vehicles up to 09.08 – Lever off the collar with disassembly wedge -3409- out of the surround of centre console in -direction of arrow-. Vehicles as of 09.08 – Lever off the silver cover frame for the collar using a disas‐...
Page 786: Summary Of Components - Gearshift Mechanism
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Summary of components - Gearshift mechanism Note Grease bearing and friction surfaces with grease -G 000 450 02- . 1 - Lock washer ❑ removing and installing ⇒ page 60 2 - Pressure spring 3 - Gasket ❑...
Page 787 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Removing and installing circlip – When removing and installing the circlip -A- pull the gearshift lever in the -direction of the arrow A- while simultaneously pressing the spring down with a screwdriver up to the stop in the -direction of the arrow B-.
Page 788: Summary Of Components - Control Cables
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Summary of components - Control cables Note Grease bearing and friction surfaces with grease -G 000 450 02- . 1 - Shift cable ❑ slacken from the shift lever guide within the shift mechanism ❑...
Page 789 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 ❑ after installing set shift mechanism ⇒ page 71 11 - Cable lock ❑ for shift cable ⇒ page 62 ❑ after installing set shift mechanism ⇒ page 71 12 - Lock washer ❑...
Page 790: Plastic Relay Lever As Of
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Fitting location of gearbox shift lever – When inserting the gearbox shift lever, make sure that the tooth opening -arrow A- is located above the interrupted spac‐ ing of the teeth -arrow B- for the gearshift shaft.
Page 791 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Press the relay lever towards the front in the -direction of arrow 3-. Relay lever with a catch – Carefully press down the pin detent -arrow 1- as far as the stop.
Page 792: Removing And Installing Shift Mechanism
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Lever off cable lock for selector cable from plastic relay lever. • Relay lever removed. – Insert cross-head screwdriver -A- between bushing -B- and relay lever. Press on cable lock •...
Page 793 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Remove circlip -3- for shift cable from gearbox shift lever -1-. Metal relay lever – Remove circlip -4- for selector cable from relay lever -2-. – Remove selector cable and shift cable from the studs.
Page 794 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Turn securing mechanism -arrow A- in -direction of arrow B- and pull off gearshift knob together with the collar. – Removing surround for the centre console ⇒ Body Work ⇒...
Page 795 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Remove tunnel bridge -arrows-. – Unhook rear silencer in such a way that it does not come in contact with the rear axle. – Remove heat shield -arrows-. – Swivel shift housing down and remove with control cables.
Page 796 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Always replace lock washers -3- and -4- after each removal ⇒ Electronic Catalogue of Original Parts . – Secure the shift cable with the lock washer -3- and the selector cable with the lock washer -4- (for metal relay lever).
Page 797 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Tightening torques Components Tightening torque Underbody cover 2 Nm Shift housing to body ⇒ page 59 Cable support to gearbox ⇒ page 61 Tunnel bridge ⇒ Engine ⇒ Rep. Gr. 26...
Page 798: Setting The Shift Mechanism
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Setting the shift mechanism Special tools and workshop equipment required ♦ Rig pin -T10027A- Note The following are required for correct setting of the shift mecha‐ nism: • Gearbox, clutch and clutch control in perfect condition •...
Page 799 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Vehicles up to 09.08 – Lever off the collar with disassembly wedge -3409- out of the surround of centre console in -direction of arrow-. Vehicles as of 09.08 – Lever off the silver cover frame for the collar using a disas‐...
Page 800 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Pull rig pin -T10027A- out of hole -A- and -B-. – Fit collar into the surround for centre console. 1.9.1 Operation • The shift lever must be in Neutral, in the gate of 3rd/4th gear.
Page 801: Removing And Installing The Gearbox
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Removing and installing the gearbox Removing Special tools and workshop equipment required ♦ Gearbox mount -3282- ♦ Adjusting plate -3282/31- ♦ Engine/gearbox jack (e.g. -V.A.G 1383/A- ) ♦ Gearbox attachment device -MP3-478 (3336)- ♦...
Page 802 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Plastic relay lever • In order to avoid damage at the selector cable, the cable locks must be seperated from the selector cable before removal. – Pull forward the locking mechanism as far as the stop in -direction of arrow 1-, then lock by turning to the left in -direction of arrow 2-.
Page 803 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Unplug connector -arrow- from speedometer sender -G22- (if available). Vehicles with diesel engines – Unplug connector -arrow- from speedometer sender -G22- (if available). Continued for all vehicles – Remove the earth strap from the engine/gearbox connecting screw -1- (on certain types of engines the earth strap is not connected).
Page 804 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Shorten the original spindle -I- of the supporting device -MP9-200 (10-222A)- by 100 mm: I - Original spindle ♦ Dimension -a- = 442 mm ♦ Dimension -x- = 100 mm II - Shortened spindle MP9-200/10 (10-222A/10) ♦...
Page 805 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Unscrew the fixing screws -arrows- from the gearbox mount. – Remove front left wheel and raise vehicle. – Remove the sound dampening system ⇒ Body Work ⇒ Rep. Gr. 50 .
Page 806 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Release the nuts -arrows- for the left steering joint ⇒ Chassis ⇒ Rep. Gr. 40 (on certain vehicles release the screws, see fig. S39-0142). – Release screws -1-. – Unbolt coupling rod -2- -arrow-.
Page 807 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Release the screws -arrows- and remove the fan shroud downwards (on newer models, the screws are no longer present and the fan shroud is only clipped in, see fig. N19-10333).
Page 808 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Screw in the mounting elements -A- as shown on adjusting plate . – Position engine/gearbox jack below vehicle, ⇒ Fig. S34-0340 arrow symbol -B- on adjusting plate points in the direction of travel/vehicle.
Page 809: Install
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Adjust supporting arm at slide with locking pin. Number of visible holes (-arrow-) = 5. – Raise gearbox with workshop crane and gearbox suspension device -MP3-478 (3336)- . – Place down gearbox, e.g. in a transport container.
Page 810 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 2.2.1 Tightening torques Gearbox to 1.2/44 kW, 1.2/51 kW and 1.2/55 kW engine Position Screw Pieces Pos. not as‐ M12 x 60 signed M12 x 60 M12 x 135 M12 x 60...
Page 811 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Gearbox on 1.6 ltr./77 kW engine Pos. Screw Pieces M12 x 60 M12 x 135 M12 x 150 M12 x 60 M10 x 50 M12 x 80 Screw with threaded pin M8.
Page 812 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Components Tightening torque Screen cap/drive shaft to engine ⇒ Chassis ⇒ Rep. Gr. 40 Steering joint to track control arm ⇒ Chassis ⇒ Rep. Gr. 40 Wheel bolts ⇒ Chassis ⇒ Rep. Gr. 44 Always replace these screws ⇒...
Page 813: Inspect The Gear Oil Level In The Gearbox
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Inspect the gear oil level in the gear‐ Special tools and workshop equipment required ♦ Socket wrench insert -T30023 (3357)- Gear oil specification ⇒ page 1 – Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Page 814: Disassembling And Assembling The Gearbox
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Disassembling and assembling the gearbox Gearbox overview 1 - 1st gear 2 - 2nd gear 3 - 3rd gear 4 - 4th gear 5 - 5th gear 6 - Cover for gearbox housing ❑...
Page 815: Summary Of Components
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Summary of components I - Removing and installing gearbox housing cover and 5th gear ⇒ page 89 II - Detaching and attaching clutch housing ⇒ page 90 III - Removing and installing...
Page 816: Removing And Installing Gearbox Housing Cover And 5Th Gear
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Removing and installing gearbox housing cover and 5th gear 1 - Gearbox housing ❑ is made out of alumini‐ um or magnesium ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts ❑...
Page 817: Detaching And Attaching Clutch Housing
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 14 - Bolt ❑ for 5th gear shift fork Detaching and attaching clutch housing Special tools and workshop equipment required ♦ Sealant -AMV 188 200 03- 1 - Conical screw, 25 Nm...
Page 818 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Removing and installing the drive shaft, output shaft, differential, shift mech‐ anism and gearshift forks 1 - Differential gear ❑ disassembling and as‐ sembling ⇒ page 127 2 - Gearbox housing ❑...
Page 819: Gearshift Forks
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 12 - 5 Nm + torque a further 90° ❑ always replace ⇒ Electronic Catalogue of Original Parts 13 - Reversing light switch - F4- , 20 Nm 14 - Gasket ring ❑...
Page 820 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Change gearbox holder -T30012- Drill a new hole in the gearbox holder -T30012 (3221)- to attach the Gearbox 02T. Dimensions in mm. – Drill a hole ∅ 11.0 mm -arrow-. 4.6.1 Removing –...
Page 821 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Unscrew the cover -arrow- for the gearbox housing. – Pull out the bearing bolt -1- for the 5th gear shift fork -2- and remove gearshift fork. – Remove circlip -3- for 5th gear synchronizer body.
Page 822 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Unscrew screw -A- for reverse shaft support. – Remove the bearing pins -B- at the bottom of the gearbox. Note Do not remove the cover -arrow- to disassemble the gearbox.
Page 823 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Insert the components together into the gearbox housing, by passing the guide bolt -T10079- through the fixing holes of the gearshift mechanism in the gearbox housing. – Unscrew -T10079- guide bolt.
Page 824 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Screw in new screws -A- and tighten the bearing support of the drive shaft and output shaft. Note Tighten the screws gradually crosswise to the corresponding tightening torque ⇒ page 91 –...
Page 825 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Install both flange shafts with pressure springs, stop discs and conical rings. – Install the clutch release lever together with the release bear‐ ing and guide bushing ⇒ page 45 –...
Page 826: Repairing The Gearbox Housing And Clutch Housing
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Repairing the gearbox housing and clutch housing Special tools and workshop equipment required ♦ Pressure plate - MP3-420 (3124)- ♦ Assembly device -MP3-434 (3066)- ♦ Thrust piece -MP3-448 (VW 408 A)- ♦...
Page 827 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 plug with hexagon socket head - 32 Nm 7 - O-ring ❑ only on vehicles without ABS ❑ always replace ⇒ Electronic Catalogue of Original Parts 8 - Speedometer sender -G22- ❑...
Page 828 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 19 - Bushing ❑ for gearshift shaft ❑ extracting ⇒ page 102 ❑ inserting ⇒ page 102 20 - Magnet ❑ is held in position by the separator surface of the housing 21 - Screw cap ❑...
Page 829 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Remove bushing for gasket ring – Position the distance sleeve -MP 3-458/2 - and pressure plate -MP3-484 (30-555) - on the differential. A - Extractor , e.g. -Kukko 18/1- B - Separating device 12 to 75 mm , e.g. -Kukko 17/1-...
Page 830: Repairing The Gearshift Mechanism
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Repairing the gearshift mechanism Special tools and workshop equipment required ♦ Pressure plate -T10203- ♦ Pipe section -MP3-479 (VW 423)- 1 - Bushing ❑ for gearshift shaft ❑ pressing in and pressing ⇒...
Page 831 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Remove locking bolt -A- from gearshift cover – Remove the outer part of the locking bolt. – Then lever out locking bolt carefully with a screwdriver. Insert locking bolt -A- into gearshift cover...
Page 832: Disassembling And Assembling The Gearshift Forks
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Disassembling and assembling the gearshift forks Special tools and workshop equipment required ♦ Driver -MP1-304 (10-206)- ♦ Pressure plate -MP3-407 (VW 402)- ♦ Thrust piece -MP3-448 (VW 408 A)- ♦ Pressure plate -MP3-453 (VW 431) - ♦...
Page 833 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 7 - Bearing bolt ❑ for 5th gear shift fork Identification of shift segments and 5th gear shift fork with shift segments Dimension -a- 1 - Shift segments 1st/2nd gear = 10.2 mm 2 - 3rd/4th gear shift segment = 78.6 mm...
Page 834 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Fitting the circlip – Press the circlip with a handle wrench into the slot of the shift segment. Note It must still be possible to rotate the shift segment freely once the circlip has been fitted.
Page 835: Wheels, Shafts
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 35 – Wheels, shafts Drive shaft Disassembling and assembling the drive shaft Special tools and workshop equipment required ♦ Bushing -MP1-316 (30-100) - ♦ Pressure plate -MP3-406 (VW 401)- ♦ Pressure plate -MP3-407 (VW 402)- ♦...
Page 836 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1 - Circlip ❑ always replace ⇒ Elec‐ tronic Catalogue of Original Parts ❑ Determine thickness ⇒ page 89 2 - Sliding sleeve with 5th gear synchronizer body ❑ removing and installing ⇒...
Page 837 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 ❑ check for wear ⇒ page 113 13 - Sliding sleeve with 3rd and 4th gear synchronizer body ❑ press off with 3rd gear sliding gear ⇒ page 112 ❑ disassembling ⇒...
Page 838 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 27 - Spring ❑ on gearboxes as of manufacturing date 06.09, the springs of the sliding sleeve with synchronizer body for 3rd, 4th and 5th gear are changed (the springs are longer) ❑...
Page 839 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Remove the bushingof the cylindrical-roller bearing with the 4th gear sliding gear – Remove circlip. – Insert separating device -A- behind the running gearing (not the engaging gearing) of the 4th gear and press off.
Page 840 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Assembling the sliding sleeve/3rd, 4th and 5th gear synchronizer body The sliding sleeve is drawn over the synchronizer body. – Insert the arresters in the deeper recesses -arrows- and mount the springs by turning them 120°.
Page 841 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Press on the inner ring -A- for the cylindrical-roller bearing – Insert the circlip. Determining the circlip thickness – Insert circlip with a thickness of 2.0 mm in the slot of the drive shaft and push upwards.
Page 842 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Press on the bushing -A- for the 5th gear needle bearing Remove supporting ring – Unclip the hook -A- of the supporting ring from the synchron‐ izer body with a screwdriver.
Page 843 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Installing the stop ring – Place the supporting ring onto the flywheel type belt pulley fit‐ ting tool -MP 9-400- . – Insert the supporting ring together with the fitting tool in the synchronizer body/5th gear sliding sleeve (Observe fitting po‐...
Page 844: Output Shaft
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Output shaft Disassembling and assembling the out‐ put shaft Special tools and workshop equipment required ♦ Pressure plate -MP3-407 (VW 402)- ♦ Thrust piece -MP3-408 (VW 412)- ♦ Thrust piece -MP3-423 (VW 407)- ♦...
Page 845 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1 - Clutch housing ❑ repairing ⇒ page 99 2 - Cylindrical-roller bearing ❑ with circlip ❑ removing ⇒ page 120 ❑ installing ⇒ page 120 ❑ Fitting position: the cir‐...
Page 846 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 14 - Sliding sleeve with 1st and 2nd gear synchronizer body ❑ press off together with 2nd gear sliding gear ⇒ page 120 ❑ disassembling ⇒ page 122 ❑ Assemble sliding sleeve/synchronizer body ⇒...
Page 847 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Pull out the cylindrical-roller bearing from the clutch housing – When removing compress circlip of the cylindrical-roller bear‐ ing -arrow- with pliers -C-. A - Countersupport , e.g. -Kukko 22/1- B - Interior extractor 30...37 mm , e.g. -Kukko 21/5- Press the cylindrical-roller bearing into the clutch housing –...
Page 848 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Fitting position 3rd gear pinion and 4th gear pinion. – Place the 4th gear pinion -A- on the output shaft. Fitting position: The collar -arrow 1- points towards the 3rd gear pinion -B-.
Page 849 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Disassembling and assembling the sliding sleeve/1st and 2nd gear synchronizer body 1 - Spring 2 - Sliding sleeve 3 - Synchronizer body 4 - Arresters for synchronizer body – Slide the sliding sleeve over the synchronizer body.
Page 850 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Insert the circlip – Rotate the synchronizer ring in such a way that the slots are flush with the arresters. – Insert the 1st gear synchronizer ring in the sliding sleeve and synchronizer body.
Page 851: Final Drive, Differential Gear
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 39 – Final drive, differential gear Replacing the flange shaft gasket rings (gearbox assembled) Special tools and workshop equipment required ♦ Inertia extractor -MP9-501- ♦ Gasket ring extractor -MP 3-419/37- ♦ Pressure plate -T10082- ♦...
Page 852: Install
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Release screws -1-. – Unbolt coupling rod -2- -arrow-. For right gasket ring – Turn steering to full right lock. – If present, remove the sound dampening system ⇒ Body work ⇒...
Page 853 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Drive the new gasket ring into the bushing up to the stop, do not twist the gasket ring. Proceed as follows for both gasket rings – Fill half the space between the sealing and dust lip with sealing grease -G 052 128 A1- .
Page 854: Differential Gear
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Differential gear Disassembling and assembling the dif‐ ferential gear Special tools and workshop equipment required ♦ Pressure plate -MP3-406 (VW 401)- ♦ Pressure plate -MP3-407 (VW 402)- ♦ Thrust piece -MP3-408 (VW 412)- ♦...
Page 855 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 1 - Conical screw, 25 Nm ❑ screw into threaded piece Pos. 8 2 - Right flange shaft ❑ do not interchange, the left and right flange shafts are different 3 - Pressure spring for flange shaft ❑...
Page 856 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 ❑ Assignment ⇒ Electronic Catalogue of Original Parts 15 - Outer ring/tapered-roller bearing ❑ removing ⇒ page 130 ❑ installing ⇒ page 130 16 - Inner ring/tapered-roller bearing ❑ remove ⇒ page 131 ❑...
Page 857 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Remove outer ring/tapered-roller bearing from gearbox housing A - Countersupport , e.g. -Kukko 22/2- B - Interior extractor 46 up to 58 mm , e.g. -Kukko 21/7- Press in outer ring/tapered-roller bearing in the gearbox housing –...
Page 858 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Remove inner ring/tapered-roller bearing on the side of the gear pinion – Before fitting the extractor position distance sleeve -MP 3-458/2- and pressure plate -MP3-431 (3002)- on the differ‐ ential housing.
Page 859: Adjusting The Differential Gear
FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 Press out the differential bevel gear shaft The tensioning sleeve is cut during pressing out. – Remove the remaining parts of the tensioning sleeve out of the differential housing and the differential bevel gear shaft.
Page 860 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 ♦ Interior extractor , e.g. -Kukko 21/7- ♦ Thrust plate -MP3-464 (30-205)- ♦ Dial gauge The differential gear must be re-set when the following compo‐ nents are replaced: ♦ Gearbox housing ♦...
Page 861 FABIA II 2007 ➤ Gearbox 02T - Edition 12.06 – Set the dial gauge to 0 with 1 mm preload on “0”. A - Dial gauge extension 30 mm – Set the dial gauge to “0” with 1 mm bias.
Page 862 Service Workshop Manual Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid 2011 ➤ , Rapid India 2011 ➤...
Page 863 Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 32 - Torque converter 37 - Controls, housing 38 - Gears, control 39 - Final drive - differential...
Page 864 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Contents 00 - Technical data ........... .
Page 865 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 General Instructions ............165 Summary of components - oil pan, oil strainer, slide valve body, internal wiring looms .
Page 866: Technical Data
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 00 – Technical data Identification of the gearbox (SRL000705; Edition 07.2014) ⇒ “1.1 Location on the gearbox”, page 1 ⇒...
Page 867: Identification Characters, Aggregate Assignment, Ratios
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Identification characters, aggregate as‐ signment, ratios ⇒ “1.2.1 Identification characters, aggregate assignment, ratios (Octavia II)”, page 2 ⇒...
Page 868 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Automatic gearbox 6-speed gearbox 09G 2. gear 2.370 3. gear 1.556 4. gear 1.155 5. gear 0.859...
Page 869 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Automatic gearbox 6-speed gearbox 09G 6. gear 0.686 Reverse gear 3.394 Intermediate Drive wheel gear...
Page 870 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Automatic gearbox 6-speed gearbox 09G Ratio 1.061 Final drive Output shaft Crown wheel Ratio 4.067...
Page 871 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Automatic gearbox 6-speed gearbox 09G Ratio 4.067 1.2.2 Identification characters, aggregate assignment, ratios (Fabia II)
Page 872 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 1.2.3 Identification characters, aggregate assignment, ratios (Roomster) Automatic gearbox 6-speed gearbox 09G Identification characters Manufac‐...
Page 873 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 1.2.4 Identification characters, aggregate assignment, ratios (Rapid India) Automatic gearbox 6-speed gearbox 09G Identification characters Manufac‐...
Page 874 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Automatic gearbox 6-speed gearbox 09G Manufac‐ from 05.2014 tured through Assignment Engine 1.6 l/81 kW MPI Torque con‐...
Page 875 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Automatic gearbox 6-speed gearbox 09G Manufac‐ from 01.2014 03.2014 tured Assignment Engine 1.6 l/81 kW MPI Torque con‐...
Page 876 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Contents Automatic gearbox 09G Top-up approx. 3 l Lubricant ⇒ Electronic Catalogue of Original Parts Filled for life: change the oil following repairs only.
Page 877: Information And Repair Instructions For The Automatic Gearbox 09G
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Information and repair instructions for the automatic gearbox 09G ⇒ “2.1 Information for the automatic gearbox 09G”, page 12 ⇒...
Page 878: Repair Instructions
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Repair instructions Scrupulous care and cleanliness as well as the proper tools are essential requirements for carrying out proper and successful gearbox repairs.
Page 879 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 ♦ Always replace O-rings, gaskets and gasket rings. ♦ After removing gaskets, examine the contact surface in the housing or on shafts for burrs or damage, and correct if nec‐...
Page 880: Explanation Of The Terms Used In This Workshop Manual
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Explanation of the terms used in this workshop manual These explanations relate solely to this assembly: automatic gearbox 09G.
Page 881 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Parking position When the vehicle is parked, the selector lever locks the parking gear in position “P” thereby preventing the vehicle from moving off (unintentionally).
Page 882: Torque Converter
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 32 – Torque converter Torque converter ⇒ “1.1 Draining the torque converter”, page 17 ⇒ “1.2 Removing and installing gasket ring for torque converter”, page 17 ⇒...
Page 883: Checking The Torque Converter
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Drive in new gasket ring for torque converter with thrust piece - T10175- up to the stop.
Page 884 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Measure the dimension -a- between the screw-on flange of the gearbox housing and the contact surface of the threaded bores of the torque converter using a depth gauge.
Page 885: Controls, Housing
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 37 – Controls, housing Electric and electronic components, fitting locations of the automatic gear‐ ⇒ “1.1 Summary of components - Electric and electronic compo‐...
Page 886 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 1 - Automatic gearbox control unit - J217- ❑ Fitting location ⇒ “1.2 Removing and...
Page 887 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 8 - Cover for shift mechanism ❑ Assignment ⇒ Electronic Catalogue of Original Parts ❑...
Page 888 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Selector lever lock solenoid - N110- Fitting location: Selector lever lock solenoid - N110- -1- is in the gearshift mechanism.
Page 889 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Multi-function switch - F125- Fitting location: The multi-function switch is located at the top of the gearbox.
Page 890 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Gearbox output r.p.m. sender - G195- Fitting location: The gearbox output r.p.m sender - G195- -arrow 2- is fixed to the gearbox housing behind the slide valve body.
Page 891 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Kick-down switch - F8- This switch is not available for vehicles with petrol engine. Instead...
Page 892 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 1 - Automatic gearbox control unit - J217- ❑ Fitting location ⇒ “1.2 Removing and...
Page 893 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 9 - Relay for starter interlock switch ❑ Fitting location ⇒ Electrical System; Rep. gr. 97 10 - Gearbox input r.p.m.
Page 894 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Selector lever lock solenoid - N110- Fitting location: Selector lever lock solenoid - N110- -A- is in the gearshift mechanism.
Page 895 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Multi-function switch - F125- Fitting location: The multi-function switch is located at the top of the gearbox.
Page 896 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Gearbox output r.p.m. sender - G195- Fitting location: The gearbox output r.p.m sender - G195- -arrow 2- is fixed to the gearbox housing behind the slide valve body.
Page 897 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Kick-down switch - F8- Brake light switch - F- up to MY 2011 Fitting location: The brake light switch - F- -arrow- is located in the foot controls.
Page 898 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 1 - Diagnostic connection ❑ Fitting location: Cover in driver's footwell ⇒ Fig. ““Diagnostic con‐...
Page 899 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 ❑ ⇒ “2.1 Removing and installing the multi-function switch F125 ”, page 185 ❑ ⇒ “2.2 Setting multi-function switch F125 ”, page 187 ❑...
Page 900 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Wiring loom with 8-pin plug and integrated gearbox oil tempera‐ ture sender - G93- -Arrow- Fitting location: Wiring harness is fixed to the slide valve body.
Page 901 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Switch for Tiptronic - F189- Fitting location: The Tiptronic switch - F189- is integrated firmly in the gearshift mechanism and cannot be replaced separately.
Page 902 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Selector lever position indicator - Y6- Fitting location: Integrated in the dash panel insert. Note The selector lever position indicator - Y6- can only be replaced together with the dash panel insert.
Page 903: Removing And Installing Automatic Gearbox Control Unit J217
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Removing and installing automatic gear‐ box control unit - J217- ⇒ “1.2.1 Removing and installing automatic gearbox control unit J217 (Octavia II, Octavia III and Superb II)”, page 38...
Page 904 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Removing Caution Observe measures when disconnecting and connecting the battery ⇒ Electrical System; Rep. gr. 27 .
Page 905 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Unlock the plug connection -1- and pull out. – Unscrew screws -arrow-. – Undo the mounting bracket with the automatic gearbox control unit - J217- from the bearing and remove it upwards and out.
Page 906: Repairing Shift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Repairing shift mechanism ⇒ “2.1 Assembly overview - shift mechanism ”, page 41 ⇒ “2.2 Inspecting the gearshift mechanism”, page 54 ⇒...
Page 907 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Ignition key anti-removal lock is not actuated mechanically with the linkage but electrically with a magnet.
Page 908 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 9 - Bearing bolt ❑ for selector lever control cable on gearshift mechanism 10 - Lock washer ❑...
Page 909 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 2.1.2 Summary of components - Gearshift mechanism - Octavia II as of 11.2009 Note The selector lever control cable was replaced as a separate component part up to production date 10.2009.
Page 910 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 ❑ ⇒ “2.3 Inspecting and adjusting the selector lever control cable”, page 55 ❑ ⇒ Fig. ““Remove the shift mechanism together with the selector lever control cable from the shift hous‐...
Page 911 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 2.1.3 Summary of components - Gearshift mechanism -Superb II 1 - Cover with handle up to 10.2012...
Page 912 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 6 - Shift housing with gasket ❑ ⇒ Fig. ““Remove the shift mechanism together with the selector lever control cable from the shift hous‐...
Page 913 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 1 - Cover with handle ❑ ⇒ “2.5 Removing and In‐ stalling the cover for the shift mechanism”,...
Page 914 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 ❑ Do not grease drawbar eye and ball socket. ❑ when installing in the vehicle, clamp on the gearbox side with the fixing part to the heat shield of the...
Page 915 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 needs to be unclipped ⇒ “2.14 Emergency release of gearshift mechanism out of position P ”, page 105 ❑...
Page 916 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Remove the shift mechanism together with the selector lever con‐ trol cable from the shift housing...
Page 917 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 4 - Shift mechanism ❑ with selector lever lock solenoid - N110- ❑ ⇒ “2.14 Emergency release of gearshift mechanism out of position P ”, page 105 ❑...
Page 918 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 2.1.7 Summary of components - Gearshift mechanism (Octavia III, Yeti) 1 - Shift mechanism ❑ with selector lever lock solenoid - N110- ❑...
Page 919: Inspecting The Gearshift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Remove the shift mechanism together with the selector lever con‐ trol cable from the shift housing...
Page 920: Inspecting And Adjusting The Selector Lever Control Cable
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 When the gear selector lever is put into the Tiptronic gate, the selector lever position display in the dash panel insert should change from “PRNDS”...
Page 921 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Press together the catches at the cable support of the selector lever control cable -arrows- and pull out the selector lever control cable from the cable support/gearbox.
Page 922: Check The Function Of The Ignition Key Removal Lock
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Release screw -2- at the front ball socket of the selector lever control cable -1-.
Page 923: Removing And Installing The Cover For The Shift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Removing and Installing the cover for the shift mechanism ⇒ “2.5.1 Removing and Installing the cover for the shift mecha‐...
Page 924 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Pull the cover -B- upwards over the handle. – Disconnect plug -A- for lamp for selector lever scale illumina‐...
Page 925 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove cover using the release tool - T30098- . Pull up rear left and right cover -arrows-.
Page 926 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Removing Note As of 11.2012, the selector lever handle was changed ⇒ “2.1.2 Summary of components - Gearshift mechanism - Oc‐...
Page 927 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 2.5.4 Removing and Installing the cover for the shift mechanism Rapid Special tools and workshop equipment required ♦...
Page 928 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 ♦ Release tool - T30098- – Apply handbrake. – Shift selector lever into position “D/S”.
Page 929 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Using the unlocking tool - T30098- lift up the cover on the left and right -arrow-.
Page 930: Removing And Installing And Installing Selector Lever Handle Up To
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Removing and installing and installing selector lever handle up to 10.2012 ⇒ “2.6.1 Removing and installing retractor spring Octavia II”, page ⇒...
Page 931 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Pull the cover -B- upwards over the handle. – Disconnect plug -A- for lamp for selector lever scale illumina‐...
Page 932 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Removing – Removing the cover for the shift mechanism ⇒ “2.5.2 Removing and Installing the cover for the shift mech‐...
Page 933 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 2.6.3 Removing and installing retractor spring Fabia II, Roomster Special tools and workshop equipment required ♦...
Page 934 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Tighten warm-type clamp -arrow- using the hose binding claw . – Installing the cover for the shift mechanism ⇒...
Page 935: Removing And Installing Selector Lever Handle As Of
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Pull the cover -B- upwards over the handle. – Disconnect plug -A- for lamp for selector lever scale illumina‐...
Page 936 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Open the warm-type clamp -arrow- below the handle. – Detach the selector lever handle -1- together with the selector lever collar from the selector lever towards the top -arrow A- so that the lock button -2- is not pressed in.
Page 937: Installing The Lock Button At The Selector Lever Handle
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Tighten warm-type clamp -arrow- using the hose binding claw . Note The selector lever is only correctly secured when the gripper ♦...
Page 938 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Carefully guide the release tool - T40203- fully into the selector lever handle -1- -arrow-.
Page 939: Removing And Installing Selector Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Removing and installing selector mech‐ anism ⇒ “2.9.1 Removing and installing shift mechanism Fabia II, Room‐...
Page 940 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Lever off the selector lever control cable -1- from the gearshift lever -3-, e.g. using a fixed spanner -2-.
Page 941 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove underbody cover on right and left -arrows-. – Detach tunnel bridge below the exhaust system ⇒ Engine;...
Page 942 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove heat shield -arrows-. For vehicles Fabia II and Roomster up to 10.2011 Note A second mechanic is needed under the vehicle to remove the shift mechanism.
Page 943 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove the shift mechanism with the selector lever control cable to the top -arrow-, ensuring the selector lever control cable does not get bent or kinked.
Page 944 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Insert the selector lever control cable -1- in the cable support/ gearbox and carefully push onto the gearshift lever -3-. Do not bend the gearshift lever, otherwise it will no longer be possible to adjust the gearshift operation exactly.
Page 945 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 2.9.2 Removing and installing slave cylinder Octavia II, Superb II Removing – Shift selector lever into position “P”.
Page 946 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Disconnect plug connection -A- from the shift mechanism to the vehicle wiring harness. Note Ignore pos.
Page 947 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Clip off clips -arrows- and remove heat shield. For Octavia II and Superb II vehicles up to 10.2011...
Page 948 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Insert the shift mechanism and tighten the rear nuts -1- by hand. – Mount the strut for centre console -3- onto the shift mechanism as illustrated in the fig.
Page 949 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Hang the selector lever control cable -1- in the clip -arrow- at the gearbox. When installing the selector lever control cable, respect a minimum distance of at least 5 mm from the ATF cooler.
Page 950 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Removing selector lever handle ⇒ “2.7 Removing and installing selector lever handle as of 11.2012”, page 70...
Page 951 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Unlock the quick-release lock -3- at the mounting bracket -2- and unhook the selector lever control cable -1-.
Page 952 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Unscrew the nuts -arrows- in the vehicle interior. – Remove the shift mechanism together with the selector lever control cable downwards.
Page 953 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Insert the selector lever control cable -1- in the cable support/ gearbox and carefully push onto the gearshift lever -3-. Do not bend the gearshift lever, otherwise it will no longer be possible to adjust the gearshift operation exactly.
Page 954 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove the centre console and air guide ⇒ Body Work; Rep. gr. 68 .
Page 955 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove rear tunnel bridge -1- and the front tunnel bridge -2- from the body.
Page 956 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Unscrew the nuts -arrows- in the vehicle interior. – Remove the shift mechanism together with the selector lever control cable downwards.
Page 957: Removing And Installing The Selector Lever Control Cable
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Insert the selector lever control cable -1- in the cable support/ gearbox and carefully push onto the gearshift lever -3-. Do not bend the gearshift lever, otherwise it will no longer be possible to adjust the gearshift operation exactly.
Page 958 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 For vehicles Fabia II and Roomster (up to production date 10.2011) Note Observe measures when disconnecting and connecting the bat‐...
Page 959 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Disconnect plug connection -1-, remove inserting terminal out of the bracket -2- and expose wiring to lambda probe heater downstream of catalytic converter.
Page 960 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Release screws -arrows-. Caution ♦ Under no circumstances touch the circuit board -B- of the gearshift mechanism with the fingers, because static dis‐...
Page 961 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Detach tunnel bridge below the exhaust system ⇒ Engine; Rep. gr. 26 . – Unhook rear silencer in such a way that it does not come in contact with the rear axle.
Page 962 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Push away selector lever control cable -2- in -direction of arrow- from the selector lever -3-.
Page 963 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Install catch plate -A-. Note The catch plate is clipped to the left and to the right with retaining lugs.
Page 964 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Press the gearshift lever -3- on the gearbox completely to‐ wards the rear to position “P” (in the figure: completely to the right) until the parking lock locks into place.
Page 965: Removing And Installing The Tiptronic Switch F189
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Release screw -2- at the front ball socket of the selector lever control cable -1-.
Page 966 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 tavia III, Superb II, Rapid and Yeti vehi‐ cles The selector lever lock solenoid is integrated firmly in the gearshift mechanism and cannot be replaced separately.
Page 967 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove tunnel bridge -arrows-. – Unhook rear silencer in such a way that it does not come in contact with the rear axle.
Page 968 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Insert selector lever lock solenoid - N110- -A- into the gearshift mechanism. – Insert solenoid control cable into the catch -arrow B-.
Page 969: Checking The Plug Connections At The Gearshift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove the pre-exhaust pipe with mounting bracket -1- ⇒ Engine; Rep. gr. 26 .
Page 970: Emergency Release Of Gearshift Mechanism Out Of Position "P
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 using the ⇒ Vehicle diagnostic tester in the functions “Targeted fault finding”, “Vehicle self-diagnosis” and “Measuring meth‐...
Page 971 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Note Do not remove grip of selector lever. For Octavia II vehicles up to 05.2009 –...
Page 972: Removing And Installing The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Removing and installing the gearbox ⇒ “3.1 Removing the gearbox”, page 107 ⇒ “3.2 Installing the gearbox”, page 132 ⇒...
Page 973 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Lever off the selector lever control cable -3- from gearshift lever, e.g. using an open-end wrench -1-.
Page 974 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove gearbox console -A-, to this end release screws -1- and -2-. – Remove both front wheels.
Page 975 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove the protective cap for right drive shaft from the engine -arrows-. – Disconnect the pre-exhaust pipe from the exhaust manifold ⇒...
Page 976 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove the cap from assembly opening for the converter nuts. – Unscrew the 6 nuts -arrow- from the torque converter. To do so turn the crankshaft each time 60°.
Page 977 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 ♦ Surface - T30099/1- ♦ Alignment rail - MP3-457/2 (VW 457)- ♦ Support device for engine - MP3-470 (3300A)- ♦...
Page 978 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Clamp off the ATF-radiator hoses with hose clamps - MP7-602 (3094)- and remove from ATF-radiator.
Page 979 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove pendulum support -arrows A, B and C-. – Disconnect plug connection -1-. – Release vacuum hose -2-.
Page 980 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Unscrew nut -arrow- on both vehicle sides and remove cou‐ pling rods from the anti-roll bar.
Page 981 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove heat shield for the power-assisted steering control unit -J500- from the assembly carrier -arrows-.
Page 982 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Mount engine/gearbox jack - 3282- onto engine/gearbox mount - V.A.G 1383A- . – Position adjusting plate - 3282/36- onto the gearbox mount - 3282- (adjusting plate fits in only one position).
Page 983 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Note If the battery earth strap is disconnected and connected, carry ♦ out additional operations ⇒ Electrical System; Rep. gr. 27 .
Page 984 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Fit supporting device - MP9-200 (10-222A)- . – Take up the weight of the engine/gearbox unit at the spindles.
Page 985 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Swivel the spring unit outwards- while doing so, press the drive shaft out of the gearbox mounting by hitting on it with a plastic hammer on the wedge - T10161- .
Page 986 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove the cap from the opening for the converter nuts. – Unscrew the 6 nuts -arrow- from the torque converter. To do so turn the crankshaft each time 60°.
Page 987 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 ♦ Hook - MP9-200/10- ♦ Adapter - MP9-200/18- ♦ Surface - T30119- ♦ Engine and gearbox jack - V.A.G 1383A- ♦...
Page 988 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Unscrew earth strap -3-. – Detach electrical cables -1- and -2- at starter and expose.
Page 989 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Remove pendulum support -arrows A, B and C-. – Separate plug connections -1- and -2- at automatic gearbox.
Page 990 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Unscrew nuts -arrows- at left steering joint. – Undo nuts from the holder of the front left vehicle level sender - G78- (when present on vehicle).
Page 991 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Install the gearbox mount - 3282- as follows: • Move the engine/gearbox jack - V.A.G 1383A- with gearbox mount - 3282- underneath the gearbox-1-.
Page 992 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Prevent the torque converter from falling off, e.g. using a wire -A-. Note The depiction of the torque converter and gearbox may vary.
Page 993 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Caution Touch an earthed object before working on the electrical com‐ ponents. Do not grab directly at the plug contacts or electronic components.
Page 994 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Seal the hoses of the ATF radiator with hose clamps - MP7-602 (3094)- .
Page 995 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Separate plug connections -1- and -2- at automatic gearbox. – Unscrew bracket for electrical cables from the lower starter fixing screw/gearbox.
Page 996 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Swivel the spring unit outwards- while doing so, press the drive shaft out of the gearbox mounting by hitting on it with a plastic hammer on the wedge - T10161- .
Page 997: Installing The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 – Screw in the support with bolts - VAS 3282/29- into the rear bore for pendulum support at the gearbox -1-.
Page 998 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Note Replace the self-locking nuts and screws when undertaking ♦ assembly work. Replace screws which have been tightened to a torquing angle ♦...
Page 999: Tightening Torques
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Tightening torques ⇒ “3.3.1 Tightening torques Octavia II”, page 134 ⇒ “3.3.2 Tightening torques Superb II”, page 136 ⇒...
Page 1000 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 09G - Edition 07.2014 Vehicles with 2.0 l/110 kW FSI engine Gearbox to engine Pos. Screw Piece M12 x 55...

Skoda FABIA II 2007 Workshop Manual

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