Page 1 Service Workshop Manual Octavia II 2004 ➤ Octavia II 2010 ➤ Octavia III 2013 ➤ Octavia III 2014 ➤ Gearbox 0AF Edition 09.2013 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 30 - Clutch 34 - Controls, housing 35 - Gears, shafts 39 - Final drive - differential Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and...
Page 3: Table Of Contents
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Contents 00 - Technical data ........... .
Page 4 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Fitting location of shift mechanism ..........
Page 5: Technical Data
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 00 – Technical data Identification of the gearbox (SRL000618; Edition 09.2013) Edition 09.2013; version 2.0 Assignment (Octavia II) ⇒...
Page 6: Identification Characters, Aggregate Assignment, Ratios, Filling Capacities (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Identification of materials for the gearbox housing There is lettering on aluminium gearboxes -arrow- -GD TL 023-, or -AlSi9Cu3- or -AlSi6Cu4-.
Page 7 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Manual gearbox 5 speed 0AF Drive shaft flange ∅ 100 mm 90 mm Manual gearbox 5 speed 0AF...
Page 8: Identification Characters, Aggregate Assignment, Ratios, Filling Capacities (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Identification characters, aggregate assignment, ratios, filling capacities (Octavia III) Manual gearbox 5th gear 0AF Identification characters Manufactured from 11.2012...
Page 9: Overview Of Transmission System
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Overview of Transmission System Designation of components and transmission ratio Note The arrow shows the direction of travel.
Page 10: Safety Instructions
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Safety instructions Safety precautions when working on vehicles with start-stop sys‐ ⇒ page 6 Safety measures for working on vehi‐...
Page 11: Electrical Components
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Electrical components Summary of components: Electrical components ⇒ page 7 Summary of components: Electrical components Summary of components: Electrical components, manual gear‐...
Page 12: General Repair Information
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 General repair information Scrupulous care and cleanliness as well as the proper tools are essential requirements for carrying out proper and successful gearbox repairs.
Page 13 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Before installing Lightly oil the outer diameter. Fill half the space between the seal‐ ing lips -arrow- with sealant - G 052 128 A1- .
Page 14 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Screws, nuts ♦ Slacken and tighten securing bolts and nuts of covers and housings diagonally across in stages.
Page 15 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 ♦ These are not interchangeable. If re-using, allocate synchron‐ izer rings to the same sliding gear. ♦ Inspect for wear, replace if necessary ⇒ Electronic Catalogue of Original Parts .
Page 16: Clutch
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 30 – Clutch Repairing clutch control Summary (Octavia II) ⇒ page 13 Overview of the fitting positions: Clutch control (Octavia III) ⇒...
Page 17: Summary (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Summary (Octavia II) Note ♦ If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System;...
Page 18: Overview Of The Fitting Positions: Clutch Control (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Overview of the fitting positions: Clutch control (Octavia III) I - Summary of components: Foot controls (Octavia III) ⇒...
Page 19: Summary Of Components - Foot Controls (Octavia Ll)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Summary of components - Foot controls (Octavia ll) 1 - Front wall ❑ with mount for bracket 2 - Gasket ❑...
Page 20: Summary Of Components: Foot Controls (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 ❑ for bracket on front wall ❑ always replace ⇒ Electronic Catalogue of Original Parts 16 - 25 Nm ❑...
Page 21 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 ❑ is installed on both sides ❑ mounted only in combination with over-centre helper spring ❑ is not lubricated 10 - Console ❑...
Page 22: Removing And Installing Bearing Bush (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Removing and installing bearing bush (Octavia III) Removing – Disconnect battery earth strap ⇒ Electrical System; Rep. gr.
Page 23 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Unscrew crash strut -1- in front of the clutch pedal -2-. – Unscrew clutch pedal -1- from bracket -3-, to this end release nut -2- and pull out screw -5-.
Page 24: Removing And Installing Retractor Spring (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Screw on crash strut -1- in front of the clutch pedal -2-. – Install lower part of the dash panel insert on the driver's side ⇒...
Page 25 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove data bus diagnostic interface - J533- -1- from bracket ⇒ Electrical System; Rep. gr. 97 and push it to the side.
Page 26: Removing And Installing Over-Centre Helper Spring (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 • On the retractor spring -1- (⇒ previous image) only coat the following areas of the clutch pedal with grease -G 052 567 A2- : •...
Page 27 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove the footwell vent -1- on the driver's side ⇒ Heating, Air Conditioning; Rep. gr. 87 .
Page 28: Removing And Installing Clutch Pedal (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – If present, unhook the tension spring -1- and remove, while doing so pull the clutch pedal in -direction of arrow A-.
Page 29 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Removing – Push the driver seat as far as possible towards the rear and position the steering wheel in the highest position.
Page 30: Removing And Installing Clutch Pedal (Octavia Ili)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Attach support -2- to the actuator rod -1- of the master cylinder. – Press support into the clutch pedal until it audibly clicks into place.
Page 31 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Push steering wheel as far as possible towards the top, while doing so use the entire adjustment range of the steering col‐...
Page 32: Removing And Installing Bearing Bracket (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – If present, install the mount -arrow- with the parking aid control unit - J446- ⇒ Electrical System; Rep. gr. 94 .
Page 33 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Detach inlet hose -3- at master cylinder (detach plastic return hose -3- at master cylinder and close in a suitable manner).
Page 34: Removing And Installing Bearing Bracket For Clutch Pedal (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Screw on crash strut -1- in front of the clutch pedal -2-. – Install lower part of the dash panel insert on the driver's side ⇒...
Page 35 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Vehicles with knee airbag – Install knee airbag -1- driver's side ⇒ Body Work on Body Interior; Rep. gr. 69 .
Page 36 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Right-hand drive A heat-protection matting is installed in combination with certain engines. The appearance may differ from the figure.
Page 37 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Note When working in the footwell, protect the underbody cover with cloths from escaping brake fluid. – Disconnect the plug connection -2- at the clutch position send‐...
Page 38: Removing And Installing Master Cylinder (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Right-hand drive – If present, coil the heat-protection matting in the sequence -1, 2 and 3- around the cable.
Page 39: Removing And Installing Master Cylinder (Octavia Iil)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Attach support -2- to the actuator rod -1- of the master cylinder. – Place a spacer -A- between clutch pedal and stop and press clutch pedal into operating position.
Page 40: Removing And Installing Clutch Position Sender G476 (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove clutch position sender - G476- ⇒ page 38 – Unlock catches -arrows- and push out carrier bolt -2-.
Page 41 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Pinch off return hose 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 42: Removing And Installing Clutch Position Sender G476 (Octavia Iil)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1.16 Removing and installing clutch position sender - G476- (Octavia IIl) Removing – Push the driver seat as far as possible towards the rear.
Page 43 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1 - Brake fluid reservoir ❑ test tightness ⇒ page 43 2 - Spring strap clamp ❑ is not installed on all ve‐...
Page 44 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 12 - O-ring ❑ always replace ⇒ Electronic Catalogue of Original Parts ❑ pull onto line connection ❑...
Page 45: Summary Of Components: Clutch Hydraulics (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1.18 Summary of components: Clutch hydraulics (Octavia III) 1 - Screw, 20 Nm ❑ 2 pieces 2 - Bleeder valve, 4,5 Nm ❑...
Page 46 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 14 - Slave cylinder ❑ removing and installing ⇒ page 46 Disconnect the cables for the clutch control and connect Disconnecting: –...
Page 47: Checking The Hydraulic Clutch Control (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1.19 Checking the hydraulic clutch control (Octavia II) Note If the master cylinder and/or slave cylinder must be replaced ♦...
Page 48: Checking The Master And Slave Cylinder (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1.20 Checking the master and slave cylinder (Octavia III) Before the master cylinder must be replaced due to a fault, first of all carry out the test in the ⇒...
Page 49 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove circlip -arrow 1- for shift cable from gearbox shift lever -A-. Vehicles up to 05.2007 (metal relay lever) –...
Page 50: Removing And Installing Master Cylinder (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Install slave cylinder and tighten screws -arrows- to the given tightening torque. – Insert tube-hose line -B- into the slave cylinder up to the stop.
Page 51: Removing And Installing Cables For Clutch Control (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Place a non-fluffing cloth under the slave cylinder. – Unlock the clip -A- with a screwdriver and disconnect the tube- hose line -B- from the connection.
Page 52 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Right-hand drive A heat-protection matting is installed in combination with certain engines. The appearance may differ from the figure.
Page 53: Bleeding The Clutch Control (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Install The installation is performed in the reverse order, pay attention to the following points: – Connect the tube-hose line -1- with connectors at the master cylinder and at the slave cylinder.
Page 54: Bleeding The Clutch Control (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Fit the bleeder hose onto the vent valve -arrow-. – Activate system with a pressure of 0.2 MPa.
Page 55 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Put the clutch pedal in home position. – Remove cap from vent valve -arrow-. – Connect the brake filling and bleeding device - VAS 5234- or -V.A.G 1869- .
Page 56: Repairing Clutch Control
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Repairing clutch control Repairing the clutch control (Octavia II) ⇒ page 52 Summary of components: Clutch control (Octavia III) ⇒...
Page 57 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 7 - Ball stud, 20 Nm ❑ Original grease must be removed from the contact surface of the clutch release lever ❑...
Page 58: Summary Of Components: Clutch Control (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Summary of components: Clutch control (Octavia III) 1 - Clutch release lever ❑ Remove and install to‐...
Page 59 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 • Gearbox is removed. Removing and installing clutch release lever -A- with release bearing and guide sleeve Removing –...
Page 60: Repairing Clutch
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Repairing clutch Repairing the clutch (Octavia II) ⇒ page 56 Summary of components: Clutch (Octavia III) ⇒ page 58 Removing and installing clutch (Octavia IlI) ⇒...
Page 61 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1 - Flywheel ❑ make sure the centering pins are correctly fitted ❑ The locating face for the...
Page 62: Summary Of Components: Clutch (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Centring the clutch disc and removing and installing the pressure plate (vehicles with 1.4 l ltr engine) –...
Page 63: Removing And Installing Clutch (Octavia Ili)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1 - Flywheel ❑ Removing and Installing ⇒ Engine; Rep. gr. 13 ❑ make sure the centering pins are tight ❑...
Page 64 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Insert counterholder - MP1-223 (3067)- when slackening the bolts. Note In order to avoid a deformation of the pressure plate when re‐...
Page 65 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Check the extremities of the membrane spring • Wear is allowed up to half the thickness of the membrane springs -arrows-.
Page 66: Fault Finding Power Transmission - Problems With The Clutch And Clutch Control (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Check metal plate ring – Check metal plate ring -arrow- in the clutch plate for damage. •...
Page 67 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Complaint Fault description Measure ♦ Clutch release force increased – Inform customer (higher release due to wear of clutch linings.
Page 68 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Complaint Fault description Measure ♦ Master/slave cylinder, line is – Replace defective component, leaking. top up with brake fluid, bleed system.
Page 69 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Complaint Fault description Measure ♦ Linings spalled off because of – Replace clutch disc. Inform cus‐ too high revs (shift back during tomer.
Page 70 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Complaint Fault description Measure Clutch grabbing, ♦ Air in the system. – Bleed system, check brake fluid unit shaking.
Page 71 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Complaint Fault description Measure Noise when gearbox in neutral po‐ ♦ Torsional damper spring bro‐ – Replace clutch disc.
Page 72: Controls, Housing
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 34 – Controls, housing Shift mechanism Fitting location of shift mechanism ⇒ page 68 Summary of components shift mechanism (Octavia ll) ⇒...
Page 73 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 A - Shift cable B - Selector cable C - Heat shield ❑ take off before removing...
Page 74: Summary Of Components Shift Mechanism (Octavia Ll)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Summary of components shift mechanism (Octavia ll) Note ♦ After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System;...
Page 75: Summary Of Components - Gearshift Knob With Shift Lever Collar (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Summary of components - gearshift knob with shift lever collar (Octavia II) 1 - Gearshift knob ❑ with collar ❑...
Page 76: Summary Of Components: Gear Shift Knob And Shift Lever Collar (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Summary of components: Gear shift knob and shift lever collar (Octavia III) 1 - Transmission cover with...
Page 77: Removing And Installing Gearshift Knob And Shift Lever Collar (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Removing and installing gearshift knob and shift lever collar (Octavia II) – Lever the collar upwards and out of centre console surround -arrows-.
Page 78: Summary Of Components - Shift Mechanism Up To 10.2006 (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Open clamp -arrow- and pull off gearshift knob together with the collar. Install The installation is performed in the reverse order, pay attention to the following points: –...
Page 79 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1 - Lock washer ❑ removing and installing ⇒ page 76 2 - Bushing 3 - Pressure spring...
Page 80 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 ❑ Tightening torques: ♦ M8: 25 Nm ♦ M6: 8 Nm 27 - Bushing ❑ fits in one position only 28 - Lock washer ❑...
Page 81: Summary Of Components - Shift Mechanism As Of 11.2006 (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Summary of components - Shift mech‐ anism as of 11.2006 (Octavia II) Note Grease all bearing and contact surfaces with grease -G 000 450 02- .
Page 82: Disassembling And Assembling Shift Mechanism As Of 11.2006 (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 11 - Bushing 12 - Lock washer ❑ removing and installing ⇒ page 76 13 - Pressure spring ❑...
Page 83 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove shift lever. Note Hold the gearshift lever -2-. ♦ Press spacer sleeve -3- in direction of arrow.
Page 84 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Then turn the shift lever guide in -direction of arrow 1-. • The stud -arrow 2- must be located in the recess of the shift housing.
Page 85 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Position shift housing with shift lever guide into the larger re‐ cess -arrow- of the Insert base - T10083- .
Page 86: Summary Of Components - Control Cables Up To 10.2006 (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 • The shift lever guide must protrude out of the shift housing as far as the stop.
Page 87 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1 - Shift cable ❑ connect with cable lock Pos. 11 ❑ Fitting position ⇒ page 68 ❑...
Page 88 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 11 - Cable lock ❑ for shift cable at gearbox shift lever ❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are different, assignment ⇒...
Page 89: Summary Of Components - Control Cables As Of 11.2006 (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 As of 06.2006 the diameter of the fixing bolts is smaller Fixing bolts Dimension “a” until 05.2006 - Shift cable at gearbox shift lever 10 mm as of 06.2006 - Shift cable at gearbox shift lever...
Page 90 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1 - Shift cable ❑ connect with cable lock Pos. 11 ❑ Fitting position ⇒ page 68 ❑...
Page 91: Plastic Relay Lever (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 ❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are different, assignment ⇒...
Page 92 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 The relay lever is secured with a catch -arrow 1- on the gearshift cover – Carefully press the catch -arrow 1- up to the stop towards the bottom.
Page 93: Summary Of Components: Gearshift Mechanism (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Lever off cable lock for selector cable from plastic relay lever • Relay lever removed. – Position a cross-head screwdriver -A- between bushing -B- and relay lever.
Page 94 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1 - Gearshift shaft with cover 2 - Sealing ring ❑ for gearshift shaft ❑ replace ⇒ page 146...
Page 95 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 ❑ replace after removing the shift housing ❑ self-adhesive ❑ stuck onto the shift housing 13 - Shift housing 14 - Safety mechanism ❑...
Page 96 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 • During installation, the following areas in particular must be greased thoroughly: • Shaft -A- of the relay lever -arrows-.
Page 97 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Removing and installing relay lever – Press the safety mechanism on the cable lock for the selector...
Page 98: Removing And Installing Shift Mechanism (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Press cable end-piece for gate selector cable onto relay lever • The relay lever is removed. •...
Page 99 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Unscrew nuts -arrows- attaching the shift housing. – Remove circlip -3- for shift cable from gearbox shift lever -1-.
Page 100 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove underbody cover on right and left -arrows-. – Detach tunnel bridges below the exhaust system ⇒ Engine;...
Page 101: Removing And Installing Shift Mechanism And Selector Cable (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1.14.2 Install Installation is performed in the reverse order, pay attention to the following points: The holes in the cable locks have different diameters ⇒...
Page 102 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Bend up tabs -arrows- of cover for the shift mechanism using a screwdriver and remove cover.
Page 103 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove circlips -1- and -2-. – Remove the cable support from the cables. 1.15.2 Install Installation is performed in the reverse order, pay attention to the following points: Vehicles up to 10.2006...
Page 104: Remove And Install Shift Mechanism (Octavia Ili)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1.16 Remove and install shift mechanism (Octavia IlI) Removing – Disconnect battery earth strap ⇒ Electrical System; Rep. gr.
Page 105 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Lay the shift cable and selector cable from the selector hous‐ ing -2-to the gearbox. •...
Page 106: Setting Shift Mechanism (Octavia Ii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Note Replace clamp -arrow-. – Installing collar with gear shift knob ⇒ page 73 – Setting the shift mechanism ⇒...
Page 107 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Fix the gearshift shaft as follows: – Press down the gearshift shaft in -direction of arrow 1-.
Page 108: Setting Shift Mechanism (Octavia Ili)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Pull rig pin - T10027A- out of hole -A- and -B-. – If present, install the noise insulation.
Page 109 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Lock gearshift shaft as follows: – Press down the gearshift shaft in -direction of arrow 1-. – Press down gearshift shaft, turn the angle -A- in -direction of arrow 2- and at the same time press it in so that it engages in the gearshift shaft.
Page 110 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove rig pin from the noise insulation -A- and bores -B- and -C-. – Install shift lever collar ⇒...
Page 111: Removing And Installing The Gearbox
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Removing and installing the gearbox Remove gearbox (Octavia II) ⇒ page 107 Removing gearbox (Octavia III) ⇒ page 113 Transport gearbox ⇒...
Page 112 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove circlip -arrow 1- for shift cable from gearbox shift lever -A-. – Pull off the shift cable from the stud.
Page 113 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove Bowden cable support -arrows-. – Tie up shift cable and selector cable. – Disconnect the tube-hose line -A- from bracket -B- on the gearbox.
Page 114 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove fixing screws for gearbox mount -arrows- from above. – Raise vehicle ⇒ Maintenance ; Booklet Octavia II .
Page 115 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Unscrew the engine/gearbox connecting screw -A- in the area of the right flange shaft. Note In combination with several engines, the engine/gearbox con‐...
Page 116 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Position engine/gearbox jack below the vehicle, ⇒ Abb. S34-0340, arrow symbol -B- on adjusting plate points in the direction of travel/vehicle.
Page 117: Removing Gearbox (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – After this, carefully guide gearbox with the right flange shaft -A- past the flywheel/intermediate plate -arrow 2- as shown.
Page 118 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Unscrew the bolts -arrows- and lay the cable support with control cables to the side. – Unscrew the bolts -arrows- and lay the slave cylinder to the side;...
Page 119 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Unscrew the front left vehicle level sensor - G78- , where available, from the transverse arm ⇒ Chassis; Rep. gr. 43 .
Page 120 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove pendulum support. – Unscrew nut -1- from both sides of anti-roll bar bracket -3-. – Pull anti-roll bar bracket -3- on both sides out of the anti-roll bar -2-.
Page 121 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Unscrew the screws -arrows- from the gearbox mount. – Lower the gearbox by adjusting the spindles of the hook - MP9-200/10 (10-222A/10)- by the dimension -a-.
Page 122 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Connecting screws -2, 3- for engine/gearbox and bolts -4, 5- on the starter are unscrewed. – Unscrew the connecting screws -7, 8- for engine/gearbox.
Page 123: Transporting The Gearbox
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Afterwards, carefully pass with the flange shaft right on the flywheel/at the intermediate plate -arrow 2-.
Page 124 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Note Clean splines of drive shaft and apply a thin film of grease - ♦ G 000 100- .
Page 125: Installing Gearbox (Octavia Iii)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Vehicles with 1.6/75 kW Engine Pos. Screw Pieces M12 x 60 M12 x 135 M10 x 50...
Page 126 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Check whether the intermediate plate is suspended from the sealing flange -arrow top- and slid onto the dowel sleeves -arrows below-.
Page 127 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Gearbox console is attached to the side of the gearbox -arrows- – Install the gearbox console with the new bolts -arrows 2- and tighten to 40 Nm and turn 90°...
Page 128 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Install the drive shifts ⇒ Chassis; Rep. gr. 40 . – If present, screw heat shield for drive shaft -arrows- ⇒ Chas‐...
Page 129 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Check that the vacuum hose of the brake system is installed correctly, install a vacuum hose where necessary ⇒ Brake system;...
Page 130 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Install gearshift lever -B- ⇒ page 89 – Screw on hexagon nut -arrow 2- ⇒ page 89 –...
Page 131: Check Gear Oil Level
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Check gear oil level Gear oil specification: ♦ Octavia II ⇒ page 2 ♦ Octavia III ⇒ page 4 –...
Page 132: Disassembling And Assembling The Gearbox
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Disassembling and assembling the gearbox Gearbox - Summary of components ⇒ page 128 Summary of components ⇒ page 129 Attaching and detaching the gearbox housing cover and 5th gear ⇒...
Page 133: Summary Of Components
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Summary of components l - Removing and installing gearbox housing cover and 5th gear ⇒ page 130...
Page 134: Removing And Installing Gearbox Housing Cover And 5Th Gear
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Removing and installing gearbox housing cover and 5th gear 1 - Gearbox housing ❑ repairing ⇒ page 141 2 - 5th gear pinion ❑...
Page 135: Detaching And Attaching Clutch Housing
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Detaching and attaching clutch housing 1 - Conical screw, 25 Nm 2 - Flange shaft with pressure spring ❑...
Page 136: Removing And Installing The Drive Shaft, Output Shaft, Differential Gear, Shift Mechanism And Gearshift Forks
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Removing and installing the drive shaft, output shaft, differential gear, shift mechanism and gearshift forks 1 - Differential gear ❑...
Page 137: Mounting Sequence
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 13 - 6 Nm 14 - Gearbox neutral position sender - G701- ❑ only for vehicles with start-stop system...
Page 138 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 4.6.1 Removing – Secure gearbox to gearbox jack - T30012- -arrows-. – Position catch pan underneath. – Drain out gear oil.
Page 139 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Release the fixing screws -A- for the bearing support of the drive shaft and output shaft.
Page 140 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Press off the drive shaft and output shaft together with the bearing support, gearshift mechanism (shift forks) and reverse gear.
Page 141 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – 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.
Page 142 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Carefully press on the bearing support with the drive and out‐ put shaft up to the arrester.
Page 143 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Use new screws -A- to secure the bearing support to the drive shaft and output shaft.
Page 144 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Install both flange shafts with pressure springs, stop discs and conical rings. – Install the clutch release lever together with the release bear‐...
Page 145: Repairing Gearbox Housing And Clutch Housing
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Repairing gearbox housing and clutch housing Special tools and workshop equipment required ♦ Pressure spindle - MP3-448 (VW 408 A)- ♦...
Page 146 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 10 - Gasket ring for drive shaft ❑ release with a screwdriver ❑ inserting ⇒ page 143 ❑...
Page 147 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 23 - Seal ring for left flange shaft ❑ replace ⇒ page 168 Different versions of oil filler plug and oil drain plug.
Page 148 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Remove the bushing -A- for the shiftgear shaft Drive in the bushing -A- for the shift rod up to the stop...
Page 149: Repairing Shift Mechanism
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Repairing shift mechanism Special tools and workshop equipment required ♦ Thrust piece - T10203- ♦ Pipe section - MP3-479 (VW 423)- 1 - Bushing ❑...
Page 150: Replacing The Gasket Ring For The Gearshift Shaft
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 10 - Lock washer ❑ always replace ⇒ Electronic Catalogue of Original Parts ❑ is not required, if the relay lever is made of plastic Remove locking bolt -A- from gearshift cover –...
Page 151 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Lightly oil new gasket ring at outer surface. – Fill space between sealing lip and dust lip -arrow- with sealing grease - G 052 128 A1- .
Page 152: Disassembling And Assembling The Gearshift Forks
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Disassembling and assembling the gearshift forks Special tools and workshop equipment required ♦ Driver - MP1-304 (10-206)- ♦...
Page 153 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 7 - Bearing bolt ❑ for 5th gear shift fork Identification of shift segments and 5th gear shift fork with shift...
Page 154 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Fitting the circlip – Press the circlip with a handle wrench into the slot of the shift segment.
Page 155: Gears, Shafts
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 35 – Gears, shafts Drive shaft Disassembling and assembling the drive shaft ⇒ page 151 Disassembling and assembling the...
Page 156 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1 - Lock washer ❑ always replace ⇒ Elec‐ tronic Catalogue of Original Parts ❑ Determine thickness ⇒...
Page 157 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 ❑ disassembling ⇒ page 155 ❑ Fitting position sliding sleeve/synchronizer body ⇒ page 156 ❑ assembling ⇒ page 156 ❑...
Page 158 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 28 - Arresters (3 pieces) 29 - 5th gear synchronizer body 30 - 5th gear sliding sleeve 31 - Supporting ring ❑...
Page 159 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Remove sleeve for cylinder roller bearing with sliding gear 4th gear! – First remove the circlip. – Insert separating device -A- behind the running gearing (not the engaging gearing) of the 4th gear and press off.
Page 160 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Assemble sliding sleeve/synchronizer body, 3rd and 4th gear • The sliding sleeve is drawn over the synchronizer body.
Page 161 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Press on the inner ring -A- for the cylindrical-roller bearing Determining the circlip – Insert circlip with a thickness of 2.0 mm in the slot of the drive shaft and push upwards.
Page 162 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Insert washer - T10083/1- Press on the bearing support for grooved ball bearing – Before pressing on the bearing support heat it with the hot-air blower - V.A.G 1416- to approximately 100°C.
Page 163: Replace Gasket Ring For Drive Shaft
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Disassembling and assembling the sliding sleeve/5th gear syn‐ chronizer body Springs (springs are longer as of production date 06.2009) ⇒...
Page 164 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Remove manual gearbox: ♦ Octavia II ⇒ page 107 ♦ Octavia III ⇒ page 113 – Remove the clutch release lever together with the clutch re‐...
Page 165: Output Shaft
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Output shaft Disassembling and assembling the output shaft ⇒ page 161 Disassembling and assembling the out‐ put shaft Special tools and workshop equipment required ♦...
Page 166 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1 - Clutch housing ❑ repairing ⇒ page 141 2 - Cylindrical-roller bearing ❑ with circlip ❑ removing ⇒...
Page 167 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 14 - Sliding sleeve with 1st and 2nd gear synchronizer body ❑ after removing the circlip pos. 15, press off with sliding gear 2nd gear ⇒...
Page 168 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Pull out the cylindrical-roller bearing from the clutch housing – When removing compress circlip -arrow- of the cylindrical-roll‐...
Page 169 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Fitting position of gear pinion of 3rd and gear pinion of 4th – Place the 4th gear pinion -A- on the output shaft.
Page 170 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Disassembling and assembling the sliding sleeve/1st and 2nd gear synchronizer body Spring Sliding sleeve Synchronizer body Arresters –...
Page 171 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Insert the circlip – Insert the 1st gear synchronizer ring in the sliding sleeve/syn‐ chronizer body. Fitting position of the 1st gear outer ring The pegs -arrows- point towards the reversing gear serration -A-.
Page 172: Final Drive - Differential
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 39 – Final drive - differential Gasket rings Overview of the fitting positions: Gasket rings ⇒ page 168 Replacing the left flange shaft gasket ring ⇒...
Page 173 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1.2.1 Removing – Remove front left wheel ⇒ Chassis; Rep. gr. 44 and raise vehicle. – Remove the sound dampening system ⇒ Body Work; Rep.
Page 174: Replacing The Right Flange Shaft Gasket Ring (On An Installed Gearbox)
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1.2.2 Install – Drive the new seal ring in up to the stop, do not twist the seal ring.
Page 175 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Release the fixing screw for the flange shaft, to this end insert two screws in the flange and counterhold the flange shaft using an assembly lever.
Page 176: Differential Gear
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Differential gear Disassembling and assembling differential gear ⇒ page 172 Setting the differential gear ⇒ page 176 Disassembling and assembling differen‐...
Page 177 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 1 - Conical screw, 25 Nm ❑ screw into threaded piece Pos. 8 2 - Right flange shaft...
Page 178 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 17 - Differential gear housing ❑ with gear pinion for final drive 18 - Tensioning sleeve ❑ to secure the differential bevel gear shaft ❑...
Page 179 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Remove inner rings/tapered-roller bearing Note Both inner rings/tapered-roller bearings of the differential gear housing are removed in the same way.
Page 180: Adjusting The Differential Gear
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 Removing inner ring/tapered-roller bearing – Before fitting the extractor, position distance sleeve - MP3-458/2- and thrust piece - MP3-431 (3002)- on the differ‐...
Page 181 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 ♦ Pressure plate - MP3-406 (VW 401)- ♦ Pressure spindle - MP3-408 (VW 412)- ♦ Pressure washer - MP3-413 (VW 510)- ♦...
Page 182 Octavia II 2004 ➤ , Octavia II 2010 ➤ , Octavia III 2013 ➤ , Octavia III ... Gearbox 0AF - Edition 09.2013 – Press the outer ring/tapered-roller bearing (opposite pinion side) without adjusting washer into the clutch housing. – Insert the differential gear in the gearbox housing.

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Octavia ii 2010 Octavia iii 2013 Octavia iii 2014

Skoda Octavia II 2004 Workshop Manual

Technical Data

Clutch

Controls, Housing

Gears, Shafts

Final Drive - Differential

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