Skoda Octavia Workshop Manual

5-speed manual gearbox 02c 4 wheel drive.
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Service
Workshop Manual
OCTAVIA
5-Speed Manual Gearbox 02C
4 Wheel Drive
Service Department. Technical Information
S00.5130.50.20 Edition 11.99

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   Summary of Contents for Skoda Octavia

  • Page 1

    Service Workshop Manual OCTAVIA 5-Speed Manual Gearbox 02C 4 Wheel Drive Service Department. Technical Information S00.5130.50.20 Edition 11.99...

  • Page 2

    The Service Manual is intended only for use within the Škoda Organisation; it is not permitted to pass it onto third persons. Printed in CR © 1999 ŠKODA AUTO a. s.

  • Page 3

    Rear final drive S00.5130.53.20 Contents ⇒ next page. The Service Manual is intended only for use within the Skoda Organisation; it is not permitted to pass it on to Printed in CR third persons. S00.5130.53.20 © 2002 ŠKODA AUTO a. s.

  • Page 5: Table Of Contents

    OCTAVIA Service Contents Technical Data Page Identification of gearbox ......................00-1 Code letters, component assignment, transmission ratios, capacities ........00-2 Overview of power flow ......................00-3 Notes on brake and performance test and on towing vehicle ..........00-4 General repair information ......................

  • Page 6

    Service OCTAVIA ¡ ¢ £ ¤ ¥ ¦ § ¨ © ¡ ¤ £    £ ¡    £ ¤ § ¨ ¡ ©  ¤                                                                                                 ¡...

  • Page 7: Identification Of Gearbox

    OCTAVIA Technical Data Identification of gearbox Assignment ⇒ page 00-2. K Location on gearbox Code letters and date of manufacture (arrow 1) Manual gearbox 02C 4WD (arrow 2) K Manual gearbox 02C 4WD (arrow 2) K Code letters and date of manufacture of gear-...

  • Page 8: Code Letters, Component Assignment, Transmission Ratios, Capacities

    OCTAVIA Technical Data Code letter, component assignment, transmission ratios, capacities Manual gearbox 5-speed manual gearbox 02C 4x4 Code letters Manufactured from 05.99 08.00 07.00 Assignment Engine 1.9-ltr./66 kW TDI 1.9-ltr./66 kW TDI Transmission ratios: Final drive 62 : 17 = 3.647 62 : 17 = 3.647...

  • Page 9

    OCTAVIA Technical Data Code letter, component assignment, transmission ratios, capacities Manual gearbox 5-speed manual gearbox 02C 4x4 Code letters Manufactured from 04.00 08.00 07.00 Assignment Engine 2.0-ltr./85 kW 2.0-ltr./85 kW Transmission ratios: Final drive 64 : 15 = 4.267 64 : 15 = 4.267 1st gear 34 : 9 = 3.778...

  • Page 10

     ¢ ¨ ¤ §  & " ( ' &  0 0 1 ¥ 2 OCTAVIA Technical Data ¤ §  & & "  % ' 1   % & &  2 ¤ §  & ) " 1 '   &...

  • Page 11

    " # $  % & ' (   $  #    ) 0  1 2 3  4 $   &  5  6 7 $  4 $  OCTAVIA Technical Data  &...

  • Page 12: Notes On Brake And Performance Test And On Towing Vehicle

    OCTAVIA Technical Data Notes on brake and performance test and on towing vehicle Brake test on roller dynamometer ♦ Use only dynamometers designed for 4WD vehicles. ♦ If a dynamometer for a 2WD vehicle is used, 1 to 2 brake tests can be performed with the ignition switched on and the engine not run- ning.

  • Page 13

    § ¥ ¨ ¤ ¨ £ ©  ¤  ¥  ¨  £ ¤ ¢ OCTAVIA Technical Data        Scrupulous care and cleanliness, as well as proper tools, are an essential requirement for carrying out proper and successful gearbox re- pairs.

  • Page 14

    £ ¤ ¥ ¦ § ¨ ©      ¨   OCTAVIA Technical Data       ¤    ♦ Replace circlips. ♦ Do not over-tension circlips. ♦ Circlips must be installed in the base of the groove.

  • Page 15

    ¡ ¢ £ ¤ ¥ ¡ ¦ § ¨ ¢ ©  § £   © © £ § OCTAVIA  ¥ Technical Data ♦ Re-gauge shims at several points with a mi- crometer. Different tolerances make it pos- sible to exactly gauge the required shim thick-    ©...

  • Page 17: Testing Operation Of Haldex Coupling

    OCTAVIA Self-Diagnosis/Electrical Test Testing operation of Haldex coupling Drive the front wheels of the vehicle onto a roller dynamometer. Warning! Keep area in front of the vehicle clear. Proceed with appropriate care when conducting the test in or- der to avoid any damage.

  • Page 18: Self-diagnosis

    OCTAVIA Self-Diagnosis/Electrical Test Self-diagnosis Function The central component of the four-wheel drive is the electronically-hydraulically controlled Haldex coupling. Advantages: ♦ stepless distribution of force between front and rear wheels ♦ short response time of the Haldex coupling ♦ individual adaptation of the four-wheel drive...

  • Page 19

    OCTAVIA Self-Diagnosis/Electrical Test Function of 4x4 control unit In view of the interlinked control units with two databus lines, always first of all interrogate the contents of all the fault memories of the control units fitted to the vehicle when beginning fault finding.

  • Page 20

    ¤ ¥ ¦ § § ¨ © ¨ § ¥   ¨ ¦ § ¨ OCTAVIA Self-Diagnosis/Electrical Test Fault finding system tester V.A.G 1552 at ”Haldex coupling” (guide) Connect vehicle system tester V.A.G 1552 ↓ Select address word 22 - 4WD electronics ↓...

  • Page 21: Electrical/electronic Components And Fitting Locations

    ¡ ¢ £ ¤ ¢ ¥ ¦ ¥ § ¨ OCTAVIA Self-Diagnosis/Electrical Test Electrical/electronic and fitting locations 3 - ABS control unit -J104- ♦ Fitting location: in left of engine com- partment at hydraulic unit ♦ The following signals are transmitted over the data BUS to the 4WD control  ©...

  • Page 22

    # 1 0 # B C  D ¥   E F G E   E H I G    E F P G F  Q R ¨ S T OCTAVIA Self-Diagnosis/Electrical Test K Fig. 1...

  • Page 23

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  • Page 24

    ¤ ¥ ¦ § ¨ © ©  ¥  OCTAVIA Self-Diagnosis/Electrical Test         ! " #  $ %  & ' "    ( ) 0 ) 1 2 3 4 5  ¨ ©...

  • Page 25

        ©   ! " # $ % & & ' " ( )  0 ¤  £ £  ¤  ©  ¡ ¢ £ £ ¤ ¥ ¦ § ¢ ¨ § © ¢ ¤     ¦  ¤  ©  © OCTAVIA Self-Diagnosis/Electrical Test ©   ¦  ¡   0      ¦...

  • Page 26: Performing Self-diagnosis

    OCTAVIA Self-Diagnosis/Electrical Test Performing self-diagnosis Note: The description which follows relates only to models fitted with the new control unit genera- tion (from 10.99) ⇒ page 01-2. Connecting vehicle system tester V.A.G 1552 and selecting functions Test requirements l Haldex coupling operating properly; testing ⇒...

  • Page 27: Interrogating Fault Memory

    → OCTAVIA Self-Diagnosis/Electrical Test Select the 4WD control unit with the address word 22 and confirm the entry with the key 02D900554B HALDEX LSC ECC 0006 K The following readout then appears in the dis- play (example): What is displayed is: ♦...

  • Page 28

    "     " 8  "  "   9  @   6 OCTAVIA Self-Diagnosis/Electrical Test #          '  # E  "  "    9 @ @ '  $ $...

  • Page 29: Fault Table

    £ ¤ ¥ ¦ § ¨ ¦ ©                 !  " § ¤ OCTAVIA Self-Diagnosis/Electrical Test ⇒ ♦ In view of the fact that the control units are interlinked ♦...

  • Page 30

     ¨   ! " ¥ # ¦ ©  ¥ $ ¦ © "  ¤ ¥ #  $ % & ' $ ¦ © "  ⇒ ⇒ OCTAVIA Self-Diagnosis/Electrical Test ⇒ ⇒ 00532 ⇒ Supply voltage ♦...

  • Page 31: Erasing Fault Memory

    $  % & # ¥ ¨ ! © ⇒ ⇒ ⇒ OCTAVIA ⇒ Self-Diagnosis/Electrical Test ( ) 0 1 2 3 4 3 5 6 7 8 9 @ A B C 9 D 9 E F G H...

  • Page 32: Final Control Diagnosis

    %  )    # )    ) "  " !   #  !    !   & % #  ! %   &  !  # )  !  ! ©        0   " # %  #    ! ) 6 7 8  9  3 OCTAVIA Self-Diagnosis/Electrical Test   0 #        # 1             1   )   !  ! ) &...

  • Page 33

    OCTAVIA Self-Diagnosis/Electrical Test ⇒ Final control diagnosis - → K Readout in display: 4WD coupling separated Apply handbrake. Depress the clutch pedal and engage 1st gear. Drive off slowly; only the front wheels should rotate when this is done. If a variation exists:...

  • Page 34: Reading Measured Value Block

    OCTAVIA Self-Diagnosis/Electrical Test Reading measured value block The control unit is able to transmit a wide range of measured values. These measured values supply information regarding the operating state of the system or of the sensors connected. In many cases, the measured values transmitted can be used as an aid in fault finding and in rectifying faults.

  • Page 35

    OCTAVIA Self-Diagnosis/Electrical Test Measured value block 001 Read measured value block 1 → not op. not op. K Readout in display: not assigned not assigned Handbrake indicator switch ♦ not op. → handbrake not applied ♦ oper. → handbrake applied If a variation exists: perform electrical test ⇒...

  • Page 36

        &  '  ¨ ¨  '   ¨ ¨   (  ! ) OCTAVIA Self-Diagnosis/Electrical Test     &  '  ¨ ¨  '   ¨  (  ! ! )     &...

  • Page 37: Electrical Test

     ¥   §  ¥    ¥  ¥     ¥ ¤  ⇒ !   " ¤ ¨ # ¥ $ % & ' ( ¨ ¤ ¤ © )   0 OCTAVIA Self-Diagnosis/Electrical Test...

  • Page 38

    ¤ ¥ ¦ § ¨ ¦ ©    OCTAVIA Self-Diagnosis/Electrical Test electrical test Switch ignition off for all the test steps. Raise vehicle.        ! "   # $ Separate the plug connection at the rear fi- &...

  • Page 39

    OCTAVIA Self-Diagnosis/Electrical Test Test step 1 What is tested is the supply voltage of the con- trol unit -J492-. Set a measuring range of 20 V. Switch ignition on. Measure between contact 1 and contact 2 (earth) at the unplugged connector.

  • Page 40

    '  ¦ ( ¨ § ©  § ¨   ©  OCTAVIA Self-Diagnosis/Electrical Test  ©    ¨ ©  § $ % ¦ §      ©   ¥  7 6 §     ©  0 $ 9 ¦...

  • Page 41

    OCTAVIA Self-Diagnosis/Electrical Test If the readouts are less than 300 Ω or ∞ Ω: Repair wiring according to current flow dia- gram. ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder Notes: ♦ If readout is < 300 Ω there is a short circuit to earth.

  • Page 42

    5 6 $ $ $ 2 ' ¥ ¦ § ¨ ©  © ¨   ©   © ¥     ¨  © §  §   OCTAVIA Self-Diagnosis/Electrical Test § ¦ "  ¨ §...

  • Page 43

     ¨   ¨   ¤ ¥ ¦ ¦    ¦   ¨ ¨ § © ¤  © ¤ OCTAVIA Self-Diagnosis/Electrical Test Depress the clutch pedal and engage 1st gear. ⇒ Drive off slowly; the rear wheels must be felt to start off when this is done against the force of the handbrake.

  • Page 45: Servicing Shift Mechanism

    OCTAVIA Shift Mechanism/Housing Servicing shift mechanism Fitting location of shift mechanism A - Shift cable for shift movement B - Selector cable for selector movement C - Heat shield ♦ Take off before removing the shift mechanism. Arrow -A- Shift movement...

  • Page 46

    OCTAVIA Shift Mechanism/Housing I - Assembly overview - gearshift knob Removing and installing shift mechanism and cover ⇒ page 34-3 ⇒ from page 34-10. ¡ ¢ £ II - Assembly overview - gearshift lever Setting shift mechanism ⇒ page 34-13.

  • Page 47

    ¤   £      © ¦ £ £ ¤ ¥ ! ©  ¤  ¡ OCTAVIA Shift Mechanism/Housing " # $ % & ' ( ) 0 1 2 3 " 7 9 1 ) 4 % &...

  • Page 48

    ¡ ¢ £ ¤ £ ¥ ¦ § ¨ ©   ¡ ¤  ¤   ¨ ¡ £ ¤   ¦  ¥  §    §  ¥ £   ¦ § ¨ OCTAVIA Shift Mechanism/Housing Turn the inside of the cover out.

  • Page 49

    ¡ ¡ ¢ £ ¤ ¤ ¥ ¦ § ¨ ©   ¥    ¥  ¢ ¤    ¨ ¥  ¥    ¤       ! ¤   " OCTAVIA Shift Mechanism/Housing...

  • Page 50

    OCTAVIA Shift Mechanism/Housing ¤ ¥ ¦ § ¨ ©    §        ¦    ! "    ©   ¥ ¦ # $  %  &   ¥...

  • Page 51

    ( # ¨ £ ¢ £  ¦  " ! ¦  ¡ % £ ¨ ! ¨ " #   " ( © ! ¨ OCTAVIA Shift Mechanism/Housing ⇒ Shift ♦ Press onto the shift cable guide ♦...

  • Page 52: Iii - Assembly Overview - Shift Mechanism Cables

    OCTAVIA Shift Mechanism/Housing III - Assembly overview - shift mechanism cables ¦ § ¨ ©  §  ¦ § ¨ ©  §  ⇒      ¨   ¨  ©   ! ¥...

  • Page 53

    OCTAVIA Shift Mechanism/Housing 8 - Spacer bush 14 - Relay lever ♦ Fitting location page 34-9 9 - 20 Nm 15 - Sliding shoe 10 - Cable lock ♦ For selector cable at relay lever 16 - Gearbox shift lever ♦...

  • Page 54

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  • Page 55

    © ¦  ¤ ¢  " © #  § § ¡ $ # OCTAVIA Shift Mechanism/Housing   ¦  § ¡    ¨   #  § § ¡ $  #     ¤       ¦       ¡ ¨     %   ¤...

  • Page 56

    OCTAVIA Shift Mechanism/Housing Take off bracket -1- above the exhaust sys- tem -arrows-. Separate exhaust system at the double clamp -2- and remove together with catalytic converter (2nd person required). ⇒ Repair Group 26; Removing and installing parts of the exhaust system.

  • Page 57: Setting Shift Mechanism

    ¡ ¢ £ ¤ ¥ ¦ § § ¦ ¨ ©   ¤  ¢   ¢  ¨ ¢ ¨  ¢ OCTAVIA Shift Mechanism/Housing Setting shift mechanism and aids ♦ Locking pin T10027 Notes: It is essential to observe the following points to ensure that the shift mechanism is correctly set: ♦...

  • Page 58

        ¦ ¨ ¡ ¤ ¡  ¦ £ ¡ ¤ ¥   ¥  ¡  ¥  ¦ ¥ OCTAVIA Shift Mechanism/Housing  ¥ ¤ " ¦ ¨ ¡  ¨   ¦  ¡ ¢ ¡ £    ¥   ¥ ©  ¥...

  • Page 59

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  • Page 60

       ¨ ! " # $ % & ' ( ) ) ' 0 1  ¦  ( # 0 ( # 3 4 % 2 # 5 OCTAVIA Shift Mechanism/Housing 6 # 7 ) 8 % 9 @ and aids ♦...

  • Page 61

    ) ¦ ' (  ¨  ¥   ©  $ ¦  ¥ ! ¥  & OCTAVIA Shift Mechanism/Housing '  ¥ % )   ¥     ¦  % )    ¥ §     2  ©  $ ¦  ¥ ! ¥   $ $ ¦ © ¥  ©  $ ¦  © § $ ¦ &...

  • Page 62

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  • Page 63

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  • Page 64

    (  #      # ) ¦   #    !     OCTAVIA Shift Mechanism/Housing Note: 2  © 3 "  § )  )  ¦  '  #  " ©  " § #  '   )  # '   0 )    The splash guard is located behind the bevel 4  ) ¦...

  • Page 65

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  • Page 66

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  • Page 67

     ¥     ¥ ! $  % !  ¥    ¨ (    '  2 2  ¨ ¨ OCTAVIA Shift Mechanism/Housing      © ¨ § 2    (   $  ¥ ¦           ¥  3 ¥...

  • Page 68

    ¡ ¢ £ ¤ ¥ ¦ ¡ § ¨ £ ©  ¢ ¡  ¦  © OCTAVIA Shift Mechanism/Housing K - Bolt gearbox supporting device MP 3-478 to clutch housing. Adjust supporting arm at slide with detent pin (arrows).

  • Page 69

    ⇒ OCTAVIA Shift Mechanism/Housing ⇒ K ♦ If the gearbox has been replaced, always fit ⇒ the existing speedometer sender. ⇒ ♦ If the gearbox has been replaced, ensure that the intermediate plate is correctly located. ♦ Check whether dowel sleeves for centering engine/gearbox are present in the cylinder block;...

  • Page 70

    ¡ ¢ £ ¡ ¤ ¥ ¤ ¦ § OCTAVIA Shift Mechanism/Housing Drive shaft to flange shaft ⇒ Running Gear; Repair Group 40 Tightening torque Gearbox mounting bracket to 50 Nm + 90° gearbox Gearbox mounting bracket to 60 Nm + 90°...

  • Page 71

    % % $ & ' ( ) & 0 1 " ) 2 & 3 4 % 5 " 6 7 OCTAVIA Shift Mechanism/Housing and aids ♦ 6 mm wrench socket, at least 190 mm long, e.g. V.A.G 1669 ♦ Drip tray ♦...

  • Page 72

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  • Page 73

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  • Page 74

    ¥ ¦ §  ¢    ¤ ¢ ¢ ¨  ¤ ¢ ¨ ¨ OCTAVIA Shift Mechanism/Housing ♦ Fit front exhaust pipe onto catalytic converter. Repair Group 26 of the particular engine ♦ Inspect gear oil in manual gearbox with bevel page 34-31.

  • Page 75

    ©  § ¦   ¤  ¨ ¤ ©  ¤ OCTAVIA Shift Mechanism/Housing oil in manual Note: Gearbox and bevel box are filled together through the oil filler hole of the manual gearbox. Gear oil specification ⇒ page 00-2   ! "...

  • Page 76

    ¤ ¥ ¦ § ¦ ¦ ¨ ©   ¥   § ¦ ¦ ¨ ©   ¥    ¨ §     OCTAVIA Shift Mechanism/Housing     ! " # ( ) 0  1 2 3 1 4 5 5 5 $ %  &...

  • Page 77

    £ ¤ ¥ © ©  ¥ © £   ¥ OCTAVIA Shift Mechanism/Housing # $ % & housing and 0 1 2 3 ) 1 5 2 6 @ A B ♦ For cover at gearbox housing ⇒...

  • Page 78

     3  #  ! !  ( !  #  ( 5 ⇒ ⇒ 9 !  @   )   " A B 2 3 OCTAVIA Shift Mechanism/Housing II - and installing housing and shift mechanism...

  • Page 79

    $  ! ! § % §         ©      ! © % OCTAVIA Shift Mechanism/Housing shaft and shift ( ) 0 1 1 2 3 2 4 5 0 6 7...

  • Page 80

    OCTAVIA Shift Mechanism/Housing ¤ ¥ ¦ § ¨ ©     © h ( P G Q R Q @ 8 S I      ⇒ ⇒   ( ) 0 0 1 2 3 4 5 3 6 7 0 3 8 9 @ A B C D E F 0 ) 3 G 8 7 8 @ 5 )  H E ! "...

  • Page 81

    7  )  # & " ' ( ' # 9 % 4 " 7 & 7 ) B % C 6  2 " ' ( ( % 3 D 5 " )  9  % &  ) % OCTAVIA Shift Mechanism/Housing housing shift shaft and aids ♦...

  • Page 82

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  • Page 83

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  • Page 84

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  • Page 85

    ¡ ¢ £ ¤ ¥ ¦ ¢ ¤ § ¨ ©       £     ¢ ¤ #  ¢  £ ! ¦ ¢ ¤  '  ( OCTAVIA Shift Mechanism/Housing " 1 ¢  ¤  0  &...

  • Page 86

    '  § § ¨ $ ' (  ¥       § ©   ¥  #  §    "     " ¥ % )   ¥ OCTAVIA Shift Mechanism/Housing 2 ¥...

  • Page 87

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  • Page 88

    ! "  ¦ ¥ ! ¥ " © $ 0 ¦ $ 4  5 @ © ¢  5 ¤ 5   A B OCTAVIA Shift Mechanism/Housing  5 @ © ¢  5 ' 5   A B ) ¥...

  • Page 89

    OCTAVIA Shift Mechanism/Housing K Fitting location of 5th speed gear The groove all round (arrow) points toward the gearbox housing. Knocking on 5th speed gear. Inspecting 5th speed synchronizer ring Before re-installing selector gear and synchronizer ring of 5th speed, press...

  • Page 90

     §    § ¥ !  "    #  © ¥  ¥ § ¨  ¦        ©   OCTAVIA Shift Mechanism/Housing The pointed teeth of the sliding sleeve (arrow 1) and the high shoulder of the synchronizer body  ¦...

  • Page 91

    OCTAVIA Shift Mechanism/Housing K Fitting location of dished washers for secur- ing bolts The outer diameter (concave side -arrows-) points toward 5th gear. Engage 2 gears before tightening the bolts attaching 5th gear synchroniser body and sliding gear (arrows) ⇒ page 34-38, Fig.

  • Page 92

    ! " # $    % ¨ ¥  ¨ © &  ¨    ' ( ) 0 1 2  $ ¨   &    $ 3 ( 1 #     4  ¥  4 ©  § 4 5   ©  ¨ ¦  6  4 5 ¨ " ¥  ¦ 6 7 8 8 9 @ A B C D E F G F H I P Q OCTAVIA Shift Mechanism/Housing R © S ¨ T ¦...

  • Page 93

    „ ` C T 3 D E E 1 C v D C A T G H S 0 1 C v ⇒  1 v „ OCTAVIA Shift Mechanism/Housing …  ! †  ! !  %  ! ' € $ w ‡ x ˆ...

  • Page 94

    OCTAVIA Shift Mechanism/Housing 13 - Guide sleeve with O-ring ♦ O-ring attached to guide sleeve. If da- maged, replace guide sleeve ♦ With seal ♦ Knocking out seal Fig. 3 ♦ Knocking in seal Fig. 4 ♦ Remove guide sleeve in order to re-...

  • Page 95

    ¤ ¥ ¦ § ¨ ©    ¥ © ¦     ¥ © ¦ § OCTAVIA Shift Mechanism/Housing out needle ¤ ¥ ¦ §   ©    ¥ © ¦     ¥ © ¦...

  • Page 96

    ©      ¦  §     ¦    §  ¦          !      "     # ¨ OCTAVIA Shift Mechanism/Housing ¥...

  • Page 97

        ⇒ ⇒  (  0   )  ! ⇒ OCTAVIA Shift Mechanism/Housing 1    2   )  ! shift mechanism ⇒ 3   !  & ' 4 #  (...

  • Page 98

    T E U H 3 & 7 6 3 % & 9 # E 2 E E E E P S E U OCTAVIA Shift Mechanism/Housing ig. 1 V W   ¦  !       ¦        ¦ ¦ © ¦...

  • Page 99

    OCTAVIA Gears/Shafts Disassembling and assembling input shaft ⇒ ⇒ Notes: ♦ Pay attention to technical data when install- ing new gears page 00-2. ♦ Disassembling and assembling input shaft: 5-Speed Manual Gearbox 02J; Repair Group 35; Disassembling and assembling input shaft Edition 11.99...

  • Page 100

    OCTAVIA Gears/Shafts Disassembling and assembling output shaft (drive pinion) ♦ Disassembling and assembling output shaft: Notes: 5-Speed Manual Gearbox 02J; Repair ♦ Pay attention to the technical data when in- Group 35; Disassembling and assembling stalling new gears or a new output shaft output shaft  page 00-2.

  • Page 101

    OCTAVIA Final Drive/Differential Replacing seals for flange shafts (gearbox installed) Pay attention to the general repair informa- tion ⇒ page 00-5. Replacing seal for left flange shaft Special tools, testers and aids required ♦ Assembly device MP 9-501 ♦ Extraction hook MP 3-419/37 ♦...

  • Page 102

    OCTAVIA Final Drive/Differential Installing Installation is performed in the reverse order; pay attention to the following points: Knock in new seal as far as the stop; do not twist seal during this step. Pack space between sealing lip and dust lip half-full with grease G 052 128 A1.

  • Page 103

    OCTAVIA Final Drive/Differential Place drip tray below. Disconnect oil return-flow line for turbo- charger from engine -arrow-. ⇒ 1.9-ltr./66 kW (TDI) Engine, Mechanical Components; Repair Group 21; Charge air system for turbocharger Use V.A.G 1669 or commercially available 6 mm wrench socket to remove screw for joint flange of right output shaft.

  • Page 104

    ¨ ¡  ¤ ¡ ¦ ¨ ¡ ¢ £ ¤ ¥ ¥ ¨ ¡  ¦ § ¨ ©  ¢  ¤  £ OCTAVIA ¥ £ ¨ ¥ §  £  § ¡ $  ¥...

  • Page 105

    ¡ ¢ £ ¤ ¥ ¦ § ¨ ©   ¢          OCTAVIA Final Drive/Differential seal for   ! "  # $ flange of bevel box (bevel box ⇒...

  • Page 106: Disassembling And Assembling Differential

    OCTAVIA Final Drive/Differential Disassembling and assembling differential ¡ ¢ £ Special tools, testers and aids required ♦ Thrust plunger MP 3-423 ♦ Sealant AMV188 200 03 ♦ Insertion sleeve MP 3-427 ♦ Thrust plate MP 3-406 ♦ Thrust plunger MP 3-448 ♦...

  • Page 107

    ¢ £ ¤ ¥ ¥  §  ¦ ¥  ©   1   ¤   1  ©  ¤ 0 ⇒ ⇒ OCTAVIA $ ¦ 1    ¨ $ " ¤ $ #   2 ¤     $ Final Drive/Differential ¢...

  • Page 108

    OCTAVIA Final Drive/Differential ¤ ¥ ¦ § ¨ ©       ¤ ¥ ⇒ ⇒ ¤ ¤ ¥   ¨    §    ¨ !   " §    ⇒...

  • Page 109

    ¦  §         ¡ ¥ ¢ ¦ ©  ¦  §  ©  §   ¦ ©  ¡ ¥ ¢ OCTAVIA Final Drive/Differential roller ¡ ¢ £     ¡ ¥ ¢ ¦ ©      §           ¡...

  • Page 110

    ! ' 2 % ! 1 1 # 2 "   )   &   " "  3 #  0 1 # 2 "   ) 4  % 1 % # # ' " " OCTAVIA Final Drive/Differential K Fi on inner of taper...

  • Page 111

    7 " ! ! " ' ! ) ' " # 6 ' 8 6 2 7 8 2 9 1 ( ) 4 " 1 ! @ ) 1 5 # ' ( ) 3 1 OCTAVIA Final Drive/Differential £...

  • Page 112

    3 9 D 8 ) C 4 9 F 6 & D 3 9 0 0 9 D A 9 0 ( D E & A & 8 4 OCTAVIA Final Drive/Differential final drive ear to ¥ ¦ § ¨...

  • Page 113

    % F # 4 # $ ! 7 2 " # ( ' 0 0 6 2 7 7 ! " !  # 2 ' 0 ) ! 8 ! 0 3 ! ' " 5 OCTAVIA Final Drive/Differential P 2 # 2  # 4 # $ ! 0 ' "...

  • Page 114: Assembly Overview

    OCTAVIA Final Drive/Differential Disassembling and assembling bevel box Assembly overview Removal and installation sequence ⇒ page 1 - End cap 39-17 ♦ Is destroyed when removed ♦ Always replace If these parts are replaced, it is necessary to carry out setting operations ⇒ page 39-17.

  • Page 115

    OCTAVIA Final Drive/Differential 4 - Conical bolt, 25 Nm 17 - Head bevel gear with input shaft ♦ For output shaft (item 8) or for flange ♦ Is matched with the shaft bevel gear shaft (item 5), respectively, to the dif-...

  • Page 116

    OCTAVIA Final Drive/Differential 29 - Output flange 32 - Spacer ring ♦ Fitting location: chamfer points toward 30 - 350 Nm shaft bevel gear (item 27) ♦ Unscrewing page 39-18 ♦ Fit onto shaft bevel gear (item 27) ¡ ¢ £ ¤ ¥...

  • Page 117

    #   # $  ©   ⇒ ⇒ ⇒ OCTAVIA Final Drive/Differential ) 0 1 2 3 4 5 6 7 8 9 4 5 5 4 9 6 2 7 ♦ Do not twist when installing; tighten...

  • Page 118

    OCTAVIA Final Drive/Differential ♦ Pipe section 3110 ♦ Adapter piece T30015 ♦ Gearbox holder T30012 ♦ Stop plate T30012/1A ♦ (V.A.G 1582) and (V.A.G 1582/1) ♦ Separating device 22...115 mm, ¥ ¦ § e.g. Kukko 17/2 ♦ Internal extractor 13...23 mm, e.g.

  • Page 119

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  • Page 120

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  • Page 122

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  • Page 123

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  • Page 124

     ¥   # #      ( §  ¦ ) 0  §  $ &   ( OCTAVIA Final Drive/Differential Place Note: §         "   #   $        # #   %    0 §  $     ¥ ¦  "  %    # $    &...

  • Page 125

    1  ¥   $  ¦ 0 OCTAVIA Final Drive/Differential ) § ¦ ¥   ¦ ¥ ¥   ¦  ¨ ¥ § &       ¦ ¥ ¥ ¨   ¦ ¥  ¦  ¥     ¨ ¥ § #     ¦ " ¦   ¦  ¥ $ 2 ¥...

  • Page 126

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  • Page 127

    " # $ % & ' ( ) ) ( 0 1 2 $ 3 0 ' & 5 6 & 3 $ 4 OCTAVIA Final Drive/Differential needle 7 $ 8 ) 9 & @ A ♦ Thrust plate MP 3-406 ♦...

  • Page 128

    OCTAVIA Final Drive/Differential K Now, install the assembly device T10047 as fol- lows: Position the two parts of the device so that the markings ”A” are pointing toward each other. The shoulders (arrows) must be positioned below the bearing. Now, bolt together the two halves as far as the stop.

  • Page 129

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  • Page 130

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  • Page 131

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  • Page 132

    OCTAVIA Final Drive/Differential Recommended sequence for re- setting drive pinion set If it is necessary to set the shaft bevel gear and head bevel gear, observe the following sequence to ensure a rational workflow: 1. Setting shaft bevel gear (S and S Determine thickness of shim ”S...

  • Page 133

    OCTAVIA Final Drive/Differential Re-determining shim “S ” when re- placing output flange This setting is only necessary if the output flange is replaced. The purpose of the setting is to cre- ate the preload of the taper roller bearings for the shaft bevel gear.

  • Page 134

    OCTAVIA Final Drive/Differential Setting shaft bevel gear Special tools, testers and aids required ♦ Universal measuring device VW 385 ♦ Thrust piece MP 3-420 ♦ Pipe section MP 3-450 ♦ Thrust piece MP 6-418 ♦ Gearbox holder T30012 ♦ Stop plate T30012/1A ♦...

  • Page 135

    OCTAVIA Final Drive/Differential Insert shaft bevel gear. Insert inner race of small taper roller bear- ing and output flange and fit on hexagon nut. A - Screw in M 10 hexagon bolt as a counter- support. B - Wrench socket Tighten hexagon nut to 20 Nm, turn back hexagon bolt -A- or turn out fully.

  • Page 136

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  • Page 137

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  • Page 138

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  • Page 139

    OCTAVIA Final Drive/Differential Remove drive pinion housing together with shaft bevel gear. Install calculated size of shim S Performing inspection measurement - in- specting dimension “R” Insert universal gauge and measure dimension “R”. If the correct sized of shims have been selected, the dial gauge must indicate the figure of the variation “r”...

  • Page 140

    OCTAVIA Final Drive/Differential Setting preload of taper roller bearings for head bevel gear (friction torque) The shaft bevel gear is removed. Insert an 1.2 mm shim (Part No. 113 517 211 A) into the seat of the outer race for the small taper roller bearing (S side).

  • Page 141

    OCTAVIA Final Drive/Differential Determining thickness of shim S (setting torsional backlash) Drive pinion housing together with shaft bevel gear and S installed. Head bevel gear of input shaft installed on the side with S (example: 1.85 mm). Friction tot. torques for bearings of head bevel gear of input shaft and shaft bevel gear must be correct.

  • Page 142

    OCTAVIA Final Drive/Differential Determining thickness of shim S = Shim inserted (S tot. – Average torsional backlash + Lift (constant figure) Lift = 0.20 mm Example: Shim inserted (S 1.85 mm tot. – Average torsional backlash 1.25 mm 0.60 mm + Lift (constant figure) 0.20 mm...

  • Page 143

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  • Page 144

       ©    ! " # $ % % # & ' $  & $  " ! ) & 0 1 ! (  ) ( & OCTAVIA Final Drive/Differential 2  3 % 4 ! 5 6 ♦ M 8 x 80 mm bolt and nut Notes: ⇒...

  • Page 145

    OCTAVIA Final Drive/Differential Take pendulum support off the subframe (arrows - A -). Carefully push engine/gearbox forward and at the same time move the pendulum sup- port up in front of the subframe -arrow-. Secure the pendulum support to the sub- frame with bolt -1- (M8x80 mm) and nut -2-.

  • Page 146

      © ©    ' ¨      (  ¦    ! ¦     % OCTAVIA Final Drive/Differential ¥ ¦ § ¨ ©  ' ! % % ©  §    ! ¦  ¨    ¨         ¨ ' &  #  ! ( ©...

  • Page 147

    @ $ ) A B 4 5 1 $ ) ) 0 C 1 D $ ) ' $ 3 B 5 4 ' 7 OCTAVIA Final Drive/Differential F      ¨   G   ©  H   © H...

  • Page 148

    OCTAVIA Final Drive/Differential Notes: If rumbling noises occur when driving, it is then necessary to carry out the following steps: ♦ Unbolt propshaft with flexible joint from flange of Haldex clutch and bolt on again re-posi- tioned by one hole.

  • Page 149

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  • Page 150

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  • Page 151

    ¡ ¢ £ ¤ ¥ ¦ § ¨ ¢ ©  ¢  ¦  ¡ § ¡ ¢ £ ¤ ¥ ¦ OCTAVIA Final Drive/Differential ightening         !  " # ightening $ !  %    &...

  • Page 152

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  • Page 153

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  • Page 154

     ¤ § ¦     ¤ ©   ¦ ¦  ¤ ©  ¡   ¦  ¡ ¤ ¡  ¥    ¥ !  "  ¥ # ¡  ¤ ¦ OCTAVIA Final Drive/Differential Installation is carried out in the reverse order.

  • Page 155

    ¤ ¥ ¦ § ¨ © ¨    ¦   ¥   ¥ ¦ OCTAVIA Final Drive/Differential shaft Notes: ♦ During manufacture, the entire propeller shaft is balanced in order to obtain the maximum possible smooth running. It is not possible ) 0 1 ' ! 2  % 3 "...

  • Page 156

    !    " # $ % & ¥ # ¥  ©  "       ¨ $ ¥ OCTAVIA Final Drive/Differential ⇒ ⇒ 0 0   1   !  ¨ ( ¥ ⇒...

  • Page 157

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  • Page 158

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  • Page 159

    $ % & ' ( & ) $ 0 % & 1 & 0 ' $ 2 3 4 0 ' 5 & 0 3 % 3 % ! OCTAVIA Final Drive/Differential ¡ ¢ £ Edition 11.99 ------------ 3 -------------...

  • Page 160

    !  " ¦ # $ % & ' ( ) 0 1 2 3 3 1 4 5  ¦ 8 9 ) 6 ' 7 2 ' 4 2 ' OCTAVIA Final Drive/Differential at rear final drive drive ♦...

  • Page 161

    ! "        !  %   " # & OCTAVIA Final Drive/Differential 2       2  4 %      " 1  &...

  • Page 162

    ¢ £ ¤ ¥ ¥ ¦ ¡ ¡ § OCTAVIA Final Drive/Differential Lightly oil outer diameter of new seal and between the sealing lips with high-perform- ance oil for the Haldex coupling G 052 175 A1 before installing. Knock in the new seal until flush.

  • Page 163

    3 4 $ 1 " 2 0 " 1 ( " ( 1 " OCTAVIA Final Drive/Differential 5 6 6 7 8 9 @ A 9 5 B C 8 D B E F G @ B H F I 7 @ F P B @...

  • Page 164

       ¦ &     ¨  ' ( ) 0 1 0 2 3 1 ! OCTAVIA Final Drive/Differential Installing 4   5    ¦ $        ¦   ¨...

  • Page 165

    I I H P Q R D S P U V F S D T W X Y ` a b c d e D f I g F h i OCTAVIA Final Drive/Differential in rear final p ` q r s t u v q ` w x u y €...

  • Page 166

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  • Page 167

    W Q F H I T ` Y F W X a S T U P V T E T ` OCTAVIA Final Drive/Differential f g h i p R b F I T P W W Q T W X...

  • Page 168

         ©       ! " # $ $ " % & #  % #  ) 0 '  ( 1  2 $ 3 4 5 OCTAVIA Final Drive/Differential ⇒ rear final drive ♦...

  • Page 169

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  • Page 170

    OCTAVIA Final Drive/Differential ¢ £ ¤ ¥ ¥ ¦ ¡ ¡ § If the final drive is to be replaced or clamped in the repair stand, the cross member -A- must be unscrewed. Installation is carried out in the reverse order.

  • Page 171

    # ¦ ¦ ¤ ¥ £  § £ © ¢  ¨ ¦  § ¡ ¦ % ¨ ¡ § ¨ ¡ ©  ¨ © ¨  ¢ ¥  § OCTAVIA Final Drive/Differential K If 3 £ ¦ © ¨   ©...

  • Page 172

    Q 8 R S T ! " # U V W ) $ $ G # G D # ( ) $ 4 D ' & G # H I P G OCTAVIA Final Drive/Differential W ) $ $ G # G D # ( ) # & ' ! 1 & 0 T ! " # H I P G X ) 7 $ % &...

  • Page 173

    £ ¤ ¥ ¦ § ¨ ©  ¤   §        ! !  " # $ % & '   ( ! ! ( ) 0 OCTAVIA Final Drive/Differential  " $ (  ' oil in final drive Gear oil specification ⇒...

  • Page 174

    # & ' " ! ! (  ) $  & $  ( & & OCTAVIA Final Drive/Differential oil level in 6 7 8 9 3 C D E D 9 3 ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3...

  • Page 175

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  • Page 176

    " ¡ ¥ ¥ ¦ £ ¨ ¤ § " ¡ ¦ & $ £ & ' § ¤ ¤ & ( OCTAVIA § $ $ & ¥ ¦ £ & " $ " ¡ ¥ & § $ ¨ £ 3 # &...

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