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Service
Workshop Manual
OCTAVIA
Service Department. Technical Information
S00.5116.50.20
Edition 08.96

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  • Page 1

    Service Workshop Manual OCTAVIA Automatic Gearbox Service Department. Technical Information S00.5116.50.20 Edition 08.96...

  • Page 2

    The Workshop Manual is intended only for use within the ŠKODA Organisation; it is not permitted to pass it on to third parties. Printed in Czech Republic © 1996 ŠKODA, automobilová a.s.

  • Page 3: Automatic Gearbox

    Service List of Supplements to OCTAVIA Workshop Manual Edition: 06.03 Automatic Gearbox Replaces List of Supplements - Edition: 01.01 Subject Edition Article Number Supple- ment 08.96 Basic Edition of Workshop Manual S00.5116.50.20 03.97 Supplement to Basic Edition S00.5116.51.20 01.98 Supplement of New Gearbox Types S00.5116.52.20...

  • Page 5: Table Of Contents

    OCTAVIA Service Contents Technical Data Page Identification of gearbox ......................00-1 Code letters, component assignment, ratios, equipment ............00-2 Capacities ............................. 00-4 General repair information ......................00-5 Self-Diagnosis/Electrical Test Page Self-diagnosis ..........................01-1 Technical data of self-diagnosis ....................01-3 Conducting self-diagnosis ......................

  • Page 6: Table Of Contents

    Service OCTAVIA Inspecting ATF level or top up ....................37-22 Inspecting ATF level ......................... 37-22 Topping up ATF ........................37-24 Fill with ATF after repair ......................37-25 Gearbox with shift elements ...................... 37-26 Position of shift elements ......................37-26 Disassembling and assembling gearbox ..................

  • Page 7: Identification Of Gearbox

    OCTAVIA Technical Data Identification of gearbox Location on gearbox K Code letters (arrow 1) Automatic gearbox 01M (arrow 2) Example: DTB Code Month Year (1997) letters of manufacture Note: The code letters of the gearbox are also listed on the vehicle data plates.

  • Page 8: Code Letters, Component Assignment, Ratios, Equipment

    OCTAVIA Technical Data Code letters, component assignment, ratios, equipment Automatic gearbox Gearbox Code letters Manufactured from 01.97 01.97 07.98 07.98 Torque converter Code letters QADC QADC Control valve body Code letters /QFB Number of discs Inner Outer Inner Outer Clutch -K1-...

  • Page 9

    OCTAVIA Technical Data Automatic gearbox Code letters Gearbox Manufactured from 0 .9 0 .99 Torque converter Code letters QADC QADC Control valve body Code letters Number of discs Assignment 1.6-ltr./74 kW Ratios .000 .000 Reverse Intermediate drive Final drive Crown Drive shaft flange ∅...

  • Page 10

    OCTAVIA Technical Data Automatic gearbox Gearbox Code letters Manufactured from 0 .99 0 .99 Torque converter Code letters QADC QADC Control valve body Code letters .000 .000 Reverse Intermediate drive Crown ∅ Control valve body code letters KD as a Parts Sector.

  • Page 11

    OCTAVIA Technical Data Automatic gearbox Gearbox Code letters Manufactured from 01.00 02.00 02.00 Torque converter QADD QADD Code letters Slide valve body /QLB Code letters Number of disks Inner Outer Inner Outer Clutch -K1- Clutch -K2- Clutch -K3- Brake -B1-...

  • Page 12

    OCTAVIA Technical Data Automatic gearbox Gearbox Code letters Manufactured from 0 .97 0 .9 Torque converter Code letters Code letters Number of discs Inner Outer Inner Outer Clutch Clutch Clutch Assignment Engine Ratios gear gear gear .000 .000 gear Reverse Intermediate drive No.

  • Page 13

    OCTAVIA Technical Data Automatic gearbox Code letters Gearbox Manufactured from 0 .9 0 .9 Code letters Code letters 10 kW .000 .000 Crown ∅ Control body code letters KD as a Parts Sector. Edition 01.01 ------------ ------------ S00.5116.59.20...

  • Page 14

    OCTAVIA Technical Data Automatic gearbox Code letters Gearbox Manufactured from 0 .99 0 .00 Code letters Code letters Inner Outer Inner Outer Clutch Clutch Clutch 10 kW .000 .000 Reverse Crown wheel ∅ Control valve body code letters KD as a by the Parts Sector.

  • Page 15

    OCTAVIA Technical Data Automatic gearbox Gearbox Code letters Manufactured from 0 .00 Code letters Code letters .000 Crown ∅ Control body code letters as a replacement part by Parts Sector. Edition 01.01 ------------ ------------ S00.5116.59.20...

  • Page 16

    OCTAVIA Technical Data Automatic gearbox Code letters Gearbox Manufactured from 0 .99 0 .00 Code letters Code letters Inner Outer Inner Outer Clutch Clutch Clutch .000 .000 0. 4 0. 4 No. of teeth Input Output No. of teeth ∅...

  • Page 17

    OCTAVIA Technical Data Automatic gearbox Gearbox Code letters Manufactured from 0 .00 09.00 Code letters Code letters .000 .000 0. 4 Reverse Crown ∅ Control valve body code letters KD as a Parts Sector. Edition 01.01 ------------ ------------ S00.5116.59.20...

  • Page 18

    OCTAVIA Technical Data Automatic gearbox Gearbox Code letters Manufactured from 0 .00 Torque converter Code letters QCDD Control valve body Code letters .000 Reverse Crown ∅ Control valve body code letters as a Parts Sector. ------------ 00-2.10 ------------ Edition 01.01...

  • Page 19

    OCTAVIA Technical Data Edition 01.01 ------------ ------------ S00.5116.59.20...

  • Page 20: Capacities

    OCTAVIA Technical Data Capacities Planetary gear Capacities Planetary gear New filling 5.3 l Filled for life, no top-up Change required Lubricant ATF G 052 162 .. Note: For the planetary gear in automatic gearbox 01M only lubricant ATF G 052 162 .. should be used.

  • Page 21

    OCTAVIA Technical Data Repair information Scrupulous care and cleanliness, as well as pro- per tools are essential requirements for carry- ing out perfect and successful gearbox repairs. The generally valid basic rules of safety natu- rally also apply to repair work.

  • Page 22

    OCTAVIA Technical Data ♦ After removing gaskets, inspect the contact surface on the housing or shaft for burrs or damage related to removal operations. ♦ Coat the outer circumference and the seal- ing lip of seals with ATF for installing.

  • Page 23

    OCTAVIA Technical Data Bearings ♦ Position needle bearings with the inscribed side (larger sheet thickness) toward the insertion drift. ♦ Insert bearings in gearbox with ATF. Carefully oil taper roller bearings in gearbox for friction torque measurements, particularly up to gearbox date of construction 26.4.1998.

  • Page 25: Self-diagnosis

    OCTAVIA Self-Diagnosis/Electrical Test Self-diagnosis Function of self-diagnosis The control of the automatic gearbox is per- formed electronically/hydraulically. The term „self-diagnosis“ relates to this electri- cal/electronic control. Control unit -J217- with driving situation shifts (fuzzy logic) The determination of the gearbox shift point in line with the driving situation and resistance is carried out automatically.

  • Page 26

    OCTAVIA Self-Diagnosis/Electrical Test Electrical faults which may affect vehicle han- dling, can be determined with the vehicle sys- tem testers V.A.G 1552, V.A.G 1551 or VAS 5051. Notes: ♦ The description which follows relates to the vehicle system tester V.A.G 1552 using the programme card 5.0 or a higher version.

  • Page 27: Technical Data Of Self-diagnosis

    OCTAVIA Self-Diagnosis/Electrical Test Faults which are stored in the fault memory as sporadic faults, are automatically erased after driving a distance of 1000 km or driving for a period of 20 hours. Technical data of self-diagnosis Memory ♦ Permanent memory ♦...

  • Page 28: Connecting Vehicle System Tester V.a.g 1552 And Selecting Function

    OCTAVIA Self-Diagnosis/Electrical Test Carrying out self-diagnosis Connecting vehicle system tester V.A.G 1552 and selecting functions Test requirements l Selector lever in position „P“ and handbrake ap- plied. l Supply voltage of vehicle o.k. l Fuses o.k. ⇒ Current Flow Diagrams, Electrical Fault...

  • Page 29

    OCTAVIA Self-Diagnosis/Electrical Test 01M927733AG AG4 Gearbox 01M 2770 → K Readout in display: Coding 00000 WSC XXXXX Control unit identification Example: ♦ 01M 927 733 AG ♦ AG4 Gearbox 01M: Automatic gearbox 4-speed 01M ♦ 2770: EPROM (program status) ♦ Coding 00000: Is not required at present.

  • Page 30: List Of Available Functions

    OCTAVIA Self-Diagnosis/Electrical Test List of available functions Functions Page 01 - Interrogating control unit version ⇒ also: Carrying out self-diagnosis 02 - Interrogating fault memory 01-6 04 - Initiating basic setting 01-15 05 - Erasing fault memory 01-14 06 -...

  • Page 31: Fault Table

    OCTAVIA Self-Diagnosis/Electrical Test Fault table Notes: ♦ All the possible faults which can be detected by the ♦ If faults only occur occasionally or the fault memory automatic gearbox control unit -J237 and can be dis- was not erased after fault elimination, then these faults played by V.A.G 1552, are listed below according to...

  • Page 32

    OCTAVIA Self-Diagnosis/Electrical Test Read out on display of V.A.G 1552 Possible cause of fault Rectifying fault 00264 Line interruption or short-circuit to - Check wiring and plug connections accord- earth. ing to the ⇒ Current Flow Diagrams, Electri- cal Fault Finding and Fitting locations.

  • Page 33

    OCTAVIA Self-Diagnosis/Electrical Test Read out on display of V.A.G 1552 Possible cause of fault Rectifying fault 00293 Line interruption - Check wiring and plug connections accord- ing to the ⇒ Current Flow Diagrams, Electri- cal Fault Finding and Fitting locations.

  • Page 34

    OCTAVIA Self-Diagnosis/Electrical Test Read out on display of V.A.G 1552 Possible cause of fault Rectifying fault 00518 Throttle valve control unit -J338 de- - Check throttle valve control unit -J338, re- fective. place if necessary ⇒ Repair Group 01 and Throttle valve potentiometer 24 of the relevant engine.

  • Page 35

    OCTAVIA Self-Diagnosis/Electrical Test Read out on display of V.A.G 1552 Possible cause of fault Rectifying fault 00596 Plug connection between ribbon ca- - Check wiring and plug connections accord- ble/slide valve body and wiring har- ing to the ⇒ Current Flow Diagrams, Electri- ness.

  • Page 36

    OCTAVIA Self-Diagnosis/Electrical Test Read out on display of V.A.G 1552 Possible cause of fault Rectifying fault 00660 Wire defective between Kick-down - Check wiring and plug connections accord- switch and gearbox control unit. ing to the ⇒ Current Flow Diagrams, Electri- cal Fault Finding and Fitting locations.

  • Page 37

    OCTAVIA Self-Diagnosis/Electrical Test Read out on display of V.A.G 1552 Possible cause of fault Rectifying fault 01312 Line interruption or short-circuit in - Check CAN databus ⇒ Chassis; Anti-lock the Databus cables/plug connec- brake system Repair Group 45. tions. Databus drive in emergency run- ABS control unit is wrongly coded.

  • Page 38: Erasing Fault Memory

    OCTAVIA Self-Diagnosis/Electrical Test Erasing fault memory Fault memory interrogated ⇒ page 01-6. After completing interrogation of fault memo- Test of vehicle systems HELP K Readout in display: Select function XX Press keys 0 and 5 (the function „Erase fault memory“ is selected with 05) and confirm entry with the key Q.

  • Page 39: Initiating Basic Setting

    OCTAVIA Self-Diagnosis/Electrical Test Initiating basic setting Note: The basic setting must be carried out after the following repairs: ♦ Replacing engine ♦ Replacing engine control unit ♦ Replacing throttle valve control unit -J338 ♦ Replacing gearbox control unit -J217 ♦ Replacing clutch and control valve body ♦...

  • Page 40

    OCTAVIA Self-Diagnosis/Electrical Test ⇒ ⇒ ⇒ in display (example) Display Display Designation -N93 -N93 ------------ ------------ Edition 08.98 S00.5116.54.20...

  • Page 41: Test Table

    OCTAVIA Self-Diagnosis/Electrical Test Readout in display (example) Display Display Designation group block Read measured value block 5 ATF temperature → Shift outputs Gear to be engaged 45 °C 0011001 900 rpm Engine speed Read measured value block 6 Can be ignored at present →...

  • Page 42

    OCTAVIA Self-Diagnosis/Electrical Test Display Dis- Designation Test conditions Readout Measures if readout differs group play on V.A.G from specification number block 1552 Specifica- tion Signal voltage of throt- station- Idling 0.0 V... When accelerating from idling to tle valve control unit ...0.8 V...

  • Page 43

    OCTAVIA Self-Diagnosis/Electrical Test Display Dis- Designation Test conditions Specifica- Measures if readout differs group play tion or from specification number block readout Switch positions Kick- Read- Kick- - Test kickdown switch down out 4 down operated ⇒ page 01-29 switch switch...

  • Page 44

    OCTAVIA Self-Diagnosis/Electrical Test Display Dis- Designation Test conditions Specifica- Measures for deviations from group play tion or nominal value number field readout Actual current of sole- Vehicle in For fault finding, observe the fol- noid valve 6 -N93 standstill Full throttle 0.0 A...

  • Page 45: Reading Measured Value Block

    OCTAVIA Self-Diagnosis/Electrical Test Dis- Designation Test conditions differs tion Gear engaged Driving Neutral - Test solenoid valves ⇒ page 01-29, Electrical test Reverse 1 Hydraulic 1 Mechanical 2 Hydraulic 2 Mechanical 3 Hydraulic 3 Mechanical 4 Hydraulic Further measures ⇒ 4 Mechanical...

  • Page 46

    OCTAVIA Self-Diagnosis/Electrical Test Readout in V.A.G 1552 in display block 1 Readout 1 Readout 2 Readout 3 Readout 4 Readout 5 Readout 6 -N88 -N89 -N90 -N91 -N92 -N94 ♦ Solenoid valves not operated are displayed ♦ Solenoid valves operated variably are iden- with „0“, solenoid valves operated with „1“.

  • Page 47

    OCTAVIA Self-Diagnosis/Electrical Test Dis- Designation Test conditions differs tion Solenoid valves/ Selector 0 1 1 0 00 The solenoid valves are operated readout in display lever in: in line with the driving state 0 1 1 0 00 - Electrical test ⇒ page 01-29...

  • Page 48

    OCTAVIA Self-Diagnosis/Electrical Test Display Dis- Designation Test conditions Readout Measures if readout differs group play on V.A.G from specification number block 1552 Specifica- tion 4 Hydraulic Further measures ⇒ 4 Mechanical Display group number 005, dis- play block 3 Selector lever position...

  • Page 49

    OCTAVIA Self-Diagnosis/Electrical Test Display Dis- Designation Test conditions Readout Measures if readout differs group play on V.A.G from specification number block 1552 Specifica- tion Switch outputs Driving - Test wiring according to CFD Influencing ignition timing - Test engine control unit:...

  • Page 50

    OCTAVIA Self-Diagnosis/Electrical Test Display Dis- Designation Test conditions Readout Measures if readout differs group play on V.A.G from specification number block 1552 Specifica- tion Readout 7 Park/Neutral signal - Test wiring according to CFD Selector lever in P, N 1, 2, 3, D...

  • Page 51

    OCTAVIA Self-Diagnosis/Electrical Test Dis- Designation Test conditions differs on V.A.G 1552 tion Uphill or downhill driving downhill max. -32 °C Can be ignored stretch uphill max. +31.75 °C Readout is computed from sig- nals of speedometer sender, ac- celerator pedal value and engine...

  • Page 52

    OCTAVIA Self-Diagnosis/Electrical Test Display Dis- Designation Test conditions Read out Measures for deviations from group play on display nominal value number field of V.A.G 1552 nomi- nal value Engaged gear 3 mechanical 3M + 3M - 4 hydraulic 4H +...

  • Page 53

    OCTAVIA Self-Diagnosis/Electrical Test The term bus designates a system for trans- porting and distributing data. Controller Area Network is a bus system which operates with two wires. These are known as bus wires. The data are transmitted along the bus wire serially, in other words in turn, to the connected control units.

  • Page 54

    OCTAVIA Self-Diagnosis/Electrical Test Is there still a problem with the communica- tion of the control units, then you have to check the bus wires. fault finding ♦ Two control units communicate over a „two- wire bus system“. ♦ Three or more control units communicate over a „two-wire bus system“.

  • Page 55

    OCTAVIA Self-Diagnosis/Electrical Test con- trol ♦ ♦ ♦ ♦ ⇒ ♦ ♦ ♦ ♦ Edition 08.98 ------------ ------------ S00.5116.54.20...

  • Page 56

    OCTAVIA Self-Diagnosis/Electrical Test ⇒ ♦ ♦ ♦ ⇒ to detect a ------------ ------------ Edition 08.98 S00.5116.54.20...

  • Page 57

    OCTAVIA Self-Diagnosis/Electrical Test Gearbox: Electrical test Special tools, testers and aids required ♦ Hand-held multimeter (e.g. V.A.G 1526 A) ♦ Auxiliary cable (e.g. V.A.G 1594) ♦ Test box (e.g. V.A.G 1598/18) Test requirements: l Voltage supply of vehicle o.k. l Fuses o.k.

  • Page 58

    OCTAVIA Self-Diagnosis/Electrical Test The automatic gearbox control unit -J217 is lo- cated in the centre right of the plenum cham- ber. Switch off ignition, release multi-pin connec- tor in direction of arrow and unplug from the control unit. Plug test box (e.g. V.A.G 1598/18) into the multi-pin connection (1) and lock in direction of arrow (2).

  • Page 59

    OCTAVIA Self-Diagnosis/Electrical Test connector of control unit on . 1- Earth (terminal 31) 35- Not assigned 2- Not assigned 36- Not assigned 3- CAN bus 37- Not assigned 4- Not assigned 38- Not assigned 5- Not assigned 39- Not assigned...

  • Page 60: Servicing Shift Mechanism

    OCTAVIA Self-Diagnosis/Electrical Test ♦ Carry out only the test steps listed for the particular component from the fault table and the measured value block. Test of Test of Supply voltage of control unit - Carry out test step 1 Solenoid valve 5 -N92...

  • Page 61

    OCTAVIA Self-Diagnosis/Electrical Test Switch on measuring range: Voltage measurement 20 V Test V.A.G Tested • Test conditions Nominal Measures for deviations from step 1598/18 - Additional operations value nominal value Sockets 18 + 1 Supply voltage for • Ignition switched on approx.

  • Page 62

    OCTAVIA Self-Diagnosis/Electrical Test Switch on measuring range: Resistance measurement 200 Ω Test V.A.G Tested • Test conditions Nominal Measures for deviations from step 1598/18 - Additional operations value nominal value Sockets 47 + 67 Solenoid valve 4 • Ignition switched off 4...7 Ω...

  • Page 63

    OCTAVIA Self-Diagnosis/Electrical Test Switch on measuring range: Resistance measurement 20 kΩ Test V.A.G Tested • Test conditions Nominal Measures for deviations from step 1598/18 - Additional operations value nominal value Sockets 20 + 65 Vehicle speed • Ignition switched off...

  • Page 64

    OCTAVIA Self-Diagnosis/Electrical Test Switch on measuring range: Resistance measurement Test V.A.G Tested • Test conditions Nominal Measures for deviations from step 1598/20 - Additional operations value nominal value Sockets 3 + 1 Short-circuit to earth • Ignition switched off endless Ω...

  • Page 65

    OCTAVIA Self-Diagnosis/Electrical Test List of plug connections which must be dis- connected for the test. 1 - Plug connection for slide valve body ⇒ Test; page 01-36.1 2 - 3-pin plug connection for vehicle speed sender -G68 slide valve body ⇒ Test;...

  • Page 66

    OCTAVIA Self-Diagnosis/Electrical Test Switch on measuring range: Resistance measurement 200 Ω Plug contact Test box V.A.G 1598/18 Nominal value Measures for deviations from Socket nominal value ≤ 1.5 Ω - Rectify open circuit in wiring Current Flow Diagrams, ≤ 1.5 Ω...

  • Page 67

    OCTAVIA Self-Diagnosis/Electrical Test Ω Ω Ω Ω Ω Test differs contact ≤ Ω ≤ Ω ≤ Ω ≤ Ω ≤ Ω ≤ Ω ≤ Ω ≤ Ω oltage Test differs contact Notes: ♦ If test step 4 of the test table on page 01-32 does not ♦...

  • Page 68

    OCTAVIA Self-Diagnosis/Electrical Test Testing connection to road ⇒ Test 1598/18, differs contact socket Note: ♦ If ⇒ ------------ ------------ Edition 08.98 S00.5116.54.20...

  • Page 69

    OCTAVIA Self-Diagnosis/Electrical Test ⇒ Test Specification differs contact specification Note: ♦ If ⇒ Edition 08.98 ------------ ------------ S00.5116.54.20...

  • Page 70

    OCTAVIA Self-Diagnosis/Electrical Test ------------ ------------ Edition 08.98 S00.5116.54.20...

  • Page 71: Electrical And Electronic Components - Fitting Locations

    OCTAVIA Self-Diagnosis/Electrical Test Electrical and electronic components - Fitting locations 1 - Automatic gearbox control unit -J217 Note: ♦ Fitting location: in right of plenum cham- If engine or gearbox control unit is replaced, the system must be restored to the basic setting ♦...

  • Page 72

    OCTAVIA Self-Diagnosis/Electrical Test 4 - Control valve body 5 - Printed conductor with integrated ATF ♦ Fitting location: temperature sender -G93 ♦ Fitting location: in oil ♦ ⇒ ♦ ♦ ⇒ ♦ Do not kink ♦ ♦ 6 - Multifunction switch -F125 ♦...

  • Page 73

    OCTAVIA Self-Diagnosis/Electrical Test sender 11 - Kickdown ♦ Fitting location: at ♦ Fitting location: i in t ♦ ⇒ ♦ To ♦ sender - ♦ ♦ Fitting location: at ⇒ ♦ Can in E ♦ ⇒ ⇒ ♦ ⇒ 12 - B ♦...

  • Page 74

    OCTAVIA Self-Diagnosis/Electrical Test Removing and installing automatic gearbox control unit -J217 Fitting location: The control unit is located in the centre right of the plenum chamber. Removing Open flap at front. Remove right wiper arm: ⇒ Electrical System; Repair Group 92 Remove cover for plenum chamber: ⇒...

  • Page 75: Torque Converter

    OCTAVIA Torque Converter Torque converter The torque converter is equipped with a lockup clutch. The lockup clutch is closed in line with engine load and vehicle speed and drives the 1st, 2nd, 3rd and 4th gear mechanically irrespec- tive of slip.

  • Page 76: Identification Of Torque Converter

    OCTAVIA Torque Converter Identification of torque converter There are different torque converters. K Old version of torque converter is equipped with a friction bearing on the turbine shaft (arrow). New version of the torque converter is equipped with an integrated needle bearing. This version must not have a friction bearing fitted to the tur- bine shaft (arrow).

  • Page 77

    OCTAVIA Torque Converter (Gearbox installed) torque required ♦ Extraction device, e.g. V.A.G 1358 ♦ Adapter, e.g. V.A.G 1358 A/1 If the ATF is contaminated by abrasion, or if a major overhaul has been carried out on the gear- box, the torque converter should be drained as follows: Extract ATF from torque converter (e.g.

  • Page 78

    OCTAVIA Torque Converter Note: The open side of the seal points toward the gear- box. Apply a thin film of ATF to outer circumfer- ence and sealing lip of seal. torque converter Push torque converter hub through the seal as far as the first stop onto the gearbox shaft.

  • Page 79: Inspecting Shift Mechanism

    OCTAVIA Shift Mechanism/Housing Servicing shift mechanism Important! Before carrying out work on the engine when it is running, move selector lever into position „P“ and apply handbrake. Inspecting shift mechanism Selector lever in position „P“ and ignition switched on: l Brake pedal is not operated: The selector lever is locked and cannot be shifted out of position „P“.

  • Page 80: Disassembling And Assembling Shift Mechanism

    OCTAVIA Shift Mechanism/Housing Disassembling and assembling shift mechanism 1 - Bolt, 8 Nm 4 - Bolt, 4 Nm ♦ Move selector lever into „P“ for slack- 2 - Locking segment ening and tightening 3 - Contact spring 5 - Bolt, 1.5 Nm ♦...

  • Page 81

    OCTAVIA Shift Mechanism/Housing ♦ Route wiring harness so that it can- not be damaged either by the selec- tor lever or by the selector lever lock solenoid ♦ Can be tested in the Electrical test ♦ With splines ⇒ page 01-29 and in Measured value ♦...

  • Page 82

    OCTAVIA Shift Mechanism/Housing Removing and installing and set- ting selector lever cable Note: After installation the selector lever cable must be set ⇒ page 37-5. Removing Shift the selector lever to position ”P”. In the engine compartment push back the...

  • Page 83

    OCTAVIA Shift Mechanism/Housing Setting Move selector lever into position „P“. Slacken screw -2- at the front ball socket -1- of the selector lever cable. Likewise move gearbox selector lever -4- into position „P“ (rear stop). The parking lock should be engaged.

  • Page 84

    OCTAVIA Shift Mechanism/Housing esting and aids ♦ Vehicle system tester V.A.G 1552 ♦ V.A.G 1551/3 ♦ Pressure tester (e.g. V.A.G 1702) Note: First of all carry out self-diagnosis ⇒ page 01-4, and if it is not possible to determine and rectify the cause of the problem, then test the auto- matic gearbox as follows.

  • Page 85

    OCTAVIA Shift Mechanism/Housing Shift points in km/h Code letters of auto- Additional test conditions Gearshifts Kickdown matic gearbox 01M km/h ♦ Driven on flat road 1 H - 2 H 40...46 74 kW engine ♦ ATF temperature not higher than 2 H - 3 H 83...89...

  • Page 86

    OCTAVIA Shift Mechanism/Housing Measure limit speed of hydraulic converter Note: ♦ The limit speed of the hydraulic converter refers to the engine speed on the braked vehicle with the selector lever in position D. Start engine and read off engine speed at V.A.G 1552 ⇒...

  • Page 87

    OCTAVIA Shift Mechanism/Housing If the final speed is not reached, the follow- ing faults may be present: Speed too high Forward clutch slips, overrunning clutch slips Speed too low Check engine setting by up to 200 rpm: Speed too low by...

  • Page 88: Fault Finding Table

    OCTAVIA Shift Mechanism/Housing Specified main pressure in bar (MPa) Selector lever positions and test conditions Connector for solenoid valve unplugged Idling Idling Engine speed Engine speed approx. 2000 rpm approx. 2000 rpm Main pressure 3.4...3.8 5...6 12.2...13.2 23...24 in bar (MPa) (0.34...0.38)

  • Page 89

    OCTAVIA Shift Mechanism/Housing Note: Check wiring and plug connections according to the Current Flow Diagrams, repair if neces- sary. Pay attention to the following points and rectify the defect. 1. Contamination or corrosion of contacts 2. Plug connection at slide valve body 3.

  • Page 90

    OCTAVIA Shift Mechanism/Housing cause of Driven plate fractured No centring bushes for engine/gearbox - Insert engine/gearbox centring bushes and replace driven plate Gearbox has oil stains Gearbox leaking - Clean engine/gearbox and pinpoint leak at gearbox or engine; use leak oil detection spray ND G001...

  • Page 91

    OCTAVIA Shift Mechanism/Housing Complaint Possible fault cause Fault removal Selector lever position: D, 3 through 3 gear clutch -K1- or free- - Repair 1 through 3 gear clutch -K1- or 2, automatic gearbox does wheel defective ⇒ page 38-5 not shift to 1 gear (no power - Repair freewheel ⇒...

  • Page 92

    OCTAVIA Shift Mechanism/Housing Problem Possible cause of fault Rectifying fault Noises in final drive Taper roller bearings loud - Replace taper roller bearings ⇒ page 39-4 Drive pinion loud - Replace drive pinion ⇒ page 39-8 Output gear loud - Replace output gear ⇒ page 39-8 Input gear loud - Replace input gear ⇒...

  • Page 93

    OCTAVIA Shift Mechanism/Housing Removing and installing gear- Special tools, testers and aids required ♦ Hose clamp MP 7-602 ♦ Supporting device MP 9-200 ♦ Gearbox mount 3282 ♦ Adjusting plate 3282/2 ♦ Transporting device MP 3-478 ♦ Gearbox holder MP 3-501 Exchange components of ”shift el-...

  • Page 94

    OCTAVIA Shift Mechanism/Housing Replacement component with more than two shims for the brake -B1- or -B2- Only if more than two shims are supplied; ad- just reverse gear-brake ⇒ page 37-54 or set 2nd and 4th gear-brake -B2- ⇒ page 37-61.

  • Page 95

    OCTAVIA Shift Mechanism/Housing Move selector lever into position “P”. Use a screwdriver to press off selector lever cable -1- at the gearbox selector lever -4-. Pull off locking clasp -3- at the support bear- ing. Take off selector lever cable and place to the side.

  • Page 96

    OCTAVIA Shift Mechanism/Housing Continued for all models Models with 1.6-ltr./74 kW, 1.8-ltr./110 kW, 1.9-ltr./66 kW and 2.0-ltr./85 kW engine ------------ ------------ Edition 01.01 S00.5116.59.20...

  • Page 97

    OCTAVIA Shift Mechanism/Housing Insert supporting device MP 9-200 with sup- ports. Bolt holder MP 1-224 to the right suspen- sion eye and attach to supporting device MP 9-200. Lightly pre-load engine/gearbox unit at the spindles. Note: When inserting the hooks for the supporting...

  • Page 98

    OCTAVIA Shift Mechanism/Housing ⇒ ⇒ ------------ ------------ Edition 01.01 S00.5116.59.20...

  • Page 99

    OCTAVIA Shift Mechanism/Housing Unbolt left gearbox support box from gear- box -arrows-. Unscrew all engine/gearbox connecting screws from the top. Lower gearbox by adjusting the spindle on the supporting device MP 9-200 about a = 60 mm. Align gearbox mount 3282.

  • Page 100

    OCTAVIA Shift Mechanism/Housing Move gearbox jack (e.g. V.A.G 1383 A) with gearbox mount 3282 below the gearbox and support gearbox. Position drift of the locking mount onto the oil sump and secure on the gearbox hous- ing (arrow). Remove the bottom bolts connecting engine/ gearbox.

  • Page 101

    OCTAVIA Shift Mechanism/Housing Mount intermediate plate onto the dowel sleeves. Ensure that no lines or cables are jammed in-between when pushing together engine and gearbox. Use only genuine nuts (M10 x 1) for attach- ing the torque converter at the driven plate.

  • Page 102

    OCTAVIA Shift Mechanism/Housing Tightening torques K Gearbox to engine 1.8 l/92 kW, 2.0 l/85 kW and 1.8 l/110 kW Item Bolt M12 x 55 M12 x 55 M12 x 180 M12 x 180 M10 x 50 M10 x 50 M10 x 50...

  • Page 103

    OCTAVIA Shift Mechanism/Housing Component Tightening torque Drive plate to torque M10 x 1 57 Nm converter Gearbox support to gearbox 50 Nm + 90° Drive shaft to gearbox ⇒ Chassis; Repair Group 40 Gearbox - protection plate to gearbox 45 Nm Pendulum support to gearbox ⇒...

  • Page 104

    OCTAVIA Shift Mechanism/Housing and aids ♦ ATF filling system, e.g. V.A.G 1924 ♦ Vehicle system tester V.A.G 1552 Notes: ♦ Only ATF with the Part No. G 052 162 .. (col- our: colourless-yellow) may be used for top- ping up. It is not permitted to use any addi- tives! ♦...

  • Page 105

    OCTAVIA Shift Mechanism/Housing Press keys 0 and 8 (function „Read meas- ured value block“ is selected with 08) and confirm the entry with the key Q. Press keys 0, 0 and 5 („Display group number 005“ is selected with 005) and con- firm the entry with the key Q.

  • Page 106

    OCTAVIA Shift Mechanism/Housing If ATF drips out of the hole: It is not necessary to top up the ATF. Insert screw plug with new seal and tighten to 15 Nm. The ATF inspection is thus com- pleted. K If only the ATF present in the overflow pipe drips out of the hole: ATF needs to be topped up.

  • Page 107: Inspecting Atf Level

    OCTAVIA Shift Mechanism/Housing Warning! Always replace cap without clasp lock. The cap secures the plug. Notes: ♦ Pay attention to disposal instructions. ♦ The engine must not be started and the car must not be towed if there is no ATF in the system! ⇒...

  • Page 108: Position Of Shift Elements

    OCTAVIA Shift Mechanism/Housing with shift elements of shift elements 7 = T Position of shift elements 1 = 2nd and 4th -B2- clutch -K2- When dealing with problems regarding poor performance in terms of acceleration and vehi- cle speed or generally in the case of faults to...

  • Page 109

    OCTAVIA Shift Mechanism/Housing Gear clutches, brakes or freewheel Engaged/ locked hydraulic mechanical Edition 03.97 ------------ ------------ S00.5116.51.20...

  • Page 110

    OCTAVIA Shift Mechanism/Housing on automatic ♦ Thoroughly clean connection points and the surrounding area before disconnecting. ♦ Place removed parts down on a clean sur- face and cover over. Use sheeting and pa- per. Do not use fluffing cloths! ♦ Carefully cover over or seal opened compo- nents if repairs are not carried out immedi- ately.

  • Page 111

    OCTAVIA Shift Mechanism/Housing Removing and installing ATF cooler and ATF filler pipe 1 - O-ring ♦ Always replace 2 - Banjo bolt, 35 Nm 3 - ATF cooler 4 - O-ring ♦ Always replace 5 - Cap ♦ For securing plug; always replace af- ter inspecting ATF level ⇒...

  • Page 112: Iii - Removing And Installing Free Wheel And Reverse Gear Brake -b1-

    OCTAVIA Shift Mechanism/Housing Disassembling and assembling planetary gear -Summary- I - Removing and installing supporting Notes: tube for -B2- up to ATF pump ⇒ page It is not necessary to remove the input gear 37-31 (arrow). II - Removing and installing large sun Removing and installing input gear ⇒...

  • Page 113

    OCTAVIA Shift Mechanism/Housing I - Removing and installing ATF pump up to supporting tube for -B2- 5 - Spring bowl ♦ Insert 3 spring bowls after installing first externally-toothed disc ♦ Install 3 spring bowls before inserting the last externally-toothed disc 6 - Spring ♦...

  • Page 114

    OCTAVIA Shift Mechanism/Housing and 4th bine shaft ♦ Is supplied as replacement part as- signed to gearbox code letters ♦ Clutches -K1- and -K3- are pressed together ♦ Disassembling and assembling ⇒ page 38-10 ♦ Different versions ⇒ page 32-2 ith 3 shaft ♦...

  • Page 115

    OCTAVIA Shift Mechanism/Housing III - Removing and installing freewheel and reverse gear brake -B1- 4 - Disk spring ♦ curved side points to freewheel 5 - Actuating plate -B1- ♦ fit smooth side towards the disks ♦ different thickness depending on the number of inside disks fitted ♦...

  • Page 116

    OCTAVIA Shift Mechanism/Housing IV - Removing and installing planet carrier 7 - Input gear ♦ do not remove to disassemble the planetary gear ♦ removing and installing input gear or axial needle bearing ⇒ page 39-5 8 - Adjusting dial for planet carrier ♦...

  • Page 117

    OCTAVIA Shift Mechanism/Housing Disassembling and assembling planetary gear Special tools, testers and aids required ♦ Mounting ring MP 3-491 ♦ Sealant AMV 185 101 A1 ♦ Thrust plate MP 3-407 ♦ Plunger MP 3-408 ♦ Pipe section MP 3-409 ♦ Pipe section MP 3-450 ♦...

  • Page 118

    OCTAVIA Shift Mechanism/Housing Drill additional bore holes in gearbox holder = 55 mm = 96 mm ∅ C = 12 mm Remove cover and seal (arrow) of gearbox housing. Remove oil sump. Remove ATF strainer. Remove control valve housing with conduc- tor foil ⇒...

  • Page 119

    OCTAVIA Shift Mechanism/Housing Remove seal plug for -B1- (arrow). Remove sender for gearbox speed -G38- ⇒ page 38-20. Note: The seal plug and sender for gearbox speed must be removed to prevent damage to these parts. Remove screws -arrows- for ATF pump.

  • Page 120

    OCTAVIA Shift Mechanism/Housing Grab turbine shaft and pull out all clutches with supporting tube for -B2-, disks for -B2-, springs and helical springs together. Clutches -K1- and -K3- are pressed together. -K1- need only be pressed away from -K3- if one of the clutches must be disassembled or replaced.

  • Page 121

    OCTAVIA Shift Mechanism/Housing Remove large drive shaft (arrow). Remove large sun wheel (arrow). Note: Before removing the freewheel the gearbox speed sender -G38 and seal plug must have been removed. Remove circlip for supporting tube -a- and circlip for freewheel -b-.

  • Page 122

    OCTAVIA Shift Mechanism/Housing Pressing off clutch -K1- from -K3- Clutches -K1- and -K3- are pressed together. -K1- and -K3- need only be pressed off if one of the clutches is to be disassembled or replaced. Make sure the pressure areas of the tools are not damaged.

  • Page 123

    OCTAVIA Shift Mechanism/Housing Make sure the pressure areas of the tools are not damaged. Prepare -K1- and -K3- for pressing as shown here. Before pressing centre MP 3-409 on the sur- face for the axial needle bearing (this figure shows the bottom side of -K3-).

  • Page 124

    OCTAVIA Shift Mechanism/Housing Position the axial needle bearing with washer in planet carrier in the input gear. Install planet carrier with assembled toroidal sealing ring Washer for axial needle bearing Axial needle bearing Washer for axial needle bearing, fit smooth side in input gear Input gear is installed in gearbox hous- ing ⇒...

  • Page 125

    OCTAVIA Shift Mechanism/Housing Notes: When replacing ♦ Gearbox housing ♦ Freewheel ♦ Piston for reverse gear brake -B1- ♦ Or the disks Set -B1- ⇒ page 37-54 Insert adjusting dial(s) Insert inside and outside disks of -B1- Insert actuating plate with the smooth side to the disks.

  • Page 126

    OCTAVIA Shift Mechanism/Housing Install circlip for freewheel -b- and circlip for supporting tube -a-. The circlip openings point to the freewheel retaining wedge (arrow). Install the sender for the gearbox speed -G38- ⇒ page 38-20. Perform check measurement of -B1- ⇒ page 37-57.

  • Page 127

    OCTAVIA Shift Mechanism/Housing Install screw for small drive shaft -1- with washer -2- and adjusting dial -3-, torque 30 Notes: ♦ Position adjusting dial -3- on the small drive shaft collar (arrow). ♦ Determine the thickness of the adjusting dial ⇒...

  • Page 128

    OCTAVIA Shift Mechanism/Housing Install 1 through 3 gear clutch -K1- with and 4 gear clutch -K3-. Note: Turn the 1 through 3 gear clutch -K1- with 3 and 4 gear clutch during mounting until all disks are in the gearing.

  • Page 129

    OCTAVIA Shift Mechanism/Housing Note: When replacing the ♦ Gearbox housing ♦ Supporting tube ♦ ATF pump ♦ Retaining ring ♦ Or the disks Set the 2 and 4 gear brake -B2- ⇒ page 37-61. Install the -B2- disks as follows: First install a 3 mm thick outside disk.

  • Page 130

    OCTAVIA Shift Mechanism/Housing Install the ATF pump seal. Fit the toroidal sealing ring to the ATF pump. Note: Make sure the toroidal sealing rings are correctly fitted. Install the ATF pump. Tighten the screws evenly crosswise. Torque: 8 Nm. Note: The toroidal sealing ring must not be damaged.

  • Page 131

    OCTAVIA Shift Mechanism/Housing Summary of all setting operations on planetary gear I = Planet carrier IV = 2 and 4 gear brake -B2- ♦ A - adjusting dial ♦ D - adjusting dial ♦ Determine thickness ⇒ set planet car- ♦...

  • Page 132

    OCTAVIA Shift Mechanism/Housing I - Setting planet carrier 6 - Washer ♦ insert in the large sun wheel ⇒ assemble planetary gear, page 37-41 7 - Large sun wheel 8 - Axial needle bearing 9 - Washer 10 - Gearbox housing ♦...

  • Page 133

    OCTAVIA Shift Mechanism/Housing K Shim to gauged ⇒ Note: If it is not possible to engage the parking lock, block the large input shaft with an additional second screwdriver. Edition 03.97 ------------ ------------ S00.5116.51.20...

  • Page 134

    OCTAVIA Shift Mechanism/Housing ------------ ------------ Edition 03.97...

  • Page 135

    OCTAVIA Shift Mechanism/Housing Reading obtained 2.00 mm Insert an 1.7 mm thick shim. Remove bolt for small input shaft. Place calculated size of shim -3- onto the small input shaft (arrow). Tighten bolt for small input shaft -1- together with washer -2-.

  • Page 136

    OCTAVIA Shift Mechanism/Housing II Setting Note: Install the components in the gearbox housing without the shim(s) -item 7- for setting the re- verse gear brake -B1-. Note: Before removing or installing the freewheel, re- move control valve housing and take out seal- ing plug ⇒...

  • Page 137

    OCTAVIA Shift Mechanism/Housing The thickness of the shim is determined by the size of gap „x“ and should be selected by refer- ring to the table ⇒ page 37-56. x = K + (I : 2) - m ♦ B = Shim ♦...

  • Page 138

    OCTAVIA Shift Mechanism/Housing Mount onto of shims ------------ ------------ Edition 04.00 S00.5116.58.20...

  • Page 139

    OCTAVIA Shift Mechanism/Housing After determining the adjusting dial for -B1- perform check measurement. Check measurement of reverse gear brake -B1- Install parts up to freewheel and secure with circlip ⇒ assemble planetary gear, page 37-41. Measure the play between the disks with a feeler gauge ”A”.

  • Page 140

    OCTAVIA Shift Mechanism/Housing K The thickness of the shim(s) depends on the size of the gap „x“. It is calculated using the for- mula below: Size of gap x = a - b 1 - ATF pump 2 - Reverse gear clutch -K2-...

  • Page 141

    OCTAVIA Shift Mechanism/Housing Edition 03.97 ------------ ------------ S00.5116.51.20...

  • Page 142

    OCTAVIA Shift Mechanism/Housing Table of shims -C-: Gap dimension „x“ (mm) Shims (mm) Colour of shims ... 2.54 white 2.55 ... 3.09 1 + 1 blue + blue 3.10 ... 3.49 1.2 + 1.2 green + green 3.50 ... 3.89 1.4 + 1.4...

  • Page 143

    OCTAVIA Shift Mechanism/Housing IV - Setting 2 and 4 gear brake -B2- 5 - Helical spring ♦ insert 3 helical springs after installing the first outside disk (Pos. 4) 6 - Helical spring ♦ do not install to set -B2- ♦...

  • Page 144

    OCTAVIA Shift Mechanism/Housing K Determining the thickness of adjusting dial The thickness of the adjusting dial is determined by gap dimension ”x” and must be selected from the table ⇒ page 37-64. Gap dimension x = a - b - 2.65 mm To make this formula more understandable the figure represents the measuring situation.

  • Page 145

    OCTAVIA Shift Mechanism/Housing Measure with depth gauge from pump flange/gearbox housing -arrow- on 3459. Dimension a = height of 3459 in mm - meas- ured value Example: Height of 3459 60.0 mm Measured value - 32.3 mm Determined value 27.7 mm Disassemble 3459 and remove retaining ring.

  • Page 146

    OCTAVIA Shift Mechanism/Housing Table for Adjusting Dial -D-: Gap dimension ”x” (mm) Disk (mm) 3.25 ... 3.50 1.00 3.51 ... 3.75 1.25 3.76 ... 4.00 1.50 4.01 ... 4.25 1.75 4.26 ... 4.50 1.00 + 1.00 4.51 ... 4.75 1.00 + 1.25 4.76 ...

  • Page 147: Disassembling And Assembling Atf Pump

    OCTAVIA Gears/Hydraulic Control Disassembling and assembling ATF pump 1 - Piston ring ♦ Check to ensure correctly fitted ⇒ Fig. 1 ♦ Removing and installing ⇒ Fig. 2 2 - Piston ring ♦ Check to ensure correctly fitted ⇒ Fig. 1 ♦...

  • Page 148

    OCTAVIA Gears/Hydraulic Control K Fig. 1 Inspecting seat of piston rings Ensure that the gaps of the piston rings are properly hooked to each other. K Fig. 2 Removing and installing piston ring Removing: Compress piston ring and release by hand.

  • Page 149

    OCTAVIA Gears/Hydraulic Control Disassembling and assembling ♦ Installing ⇒ Fig. 2 ♦ Installing ⇒ Fig. 2 3 Cage ♦ Fitting location ⇒ Fig. 3 ♦ Removing and installing ⇒ Fig. 1 race ♦ Sealing lips are vulcanised to the pis- ♦...

  • Page 150

    OCTAVIA Gears/Hydraulic Control K Fig. Installing rollers and springs K Fig. 3 Fitting location of cage in outer race ------------ ------------ Edition 03.97 S00.5116.51.20...

  • Page 151

    OCTAVIA Gears/Hydraulic Control Disassembling and assembling 1 through 3 gear clutch -K1- 3 - Circlip ♦ different thicknesses ♦ mark after disassembly and position again in same location 4 - Thrust plate ♦ smooth side towards inside disk ♦ install together with inside disk carrier ⇒...

  • Page 152

    OCTAVIA Gears/Hydraulic Control K Fig. 1 Removing and installing circlip Press down piston cover with intermediate spring ring until the circlip (arrow) can be removed and installed. K Fig. 2 Fitting thrust plate and disks on inside disk carrier Position thrust plate -a- with the smooth side to the inside disk with the raised side towards inside disk carrier.

  • Page 153

    OCTAVIA Gears/Hydraulic Control disc carrier and Edition 03.97 ------------ ------------ S00.5116.51.20...

  • Page 154: Disassembling And Assembling Reverse Gear Clutch -k2-

    OCTAVIA Gears/Hydraulic Control Disassembling and assembling reverse gear clutch -K2- 4 - Internally-toothed disc ♦ Quantity ⇒ page 00-2 ♦ Place new internally-toothed disc in ATF for 15 minutes before installing 5 - Corrugated spring washer 6 - Circlip ♦ Removing and installing ⇒ Fig. 1 ♦...

  • Page 155

    OCTAVIA Gears/Hydraulic Control K Fig. 1 Removing and installing circlip (ar- row) Use MP 3-491 to carefully press down spring supporting disc sufficiently to allow the circlip to be removed and installed, respectively. Note: Do not damage ball valve of clutch bell.

  • Page 156

    OCTAVIA Gears/Hydraulic Control Disassembling and assembling 3 and 4 gear clutch -K3- with tur- bine shaft 3 - Inside disk ♦ part number ⇒ page 00-2 ♦ before fitting soak new inside disk in ATF for 15 minutes 4 - Outside disk ♦...

  • Page 157

    OCTAVIA Gears/Hydraulic Control K Fig. 1 Removing and installing piston ring Removing compress piston ring and release by hand expand piston ring on both sides and remove; do not remove from groove on one side only. Installing insert piston ring in groove.

  • Page 158

    OCTAVIA Gears/Hydraulic Control K Fig. and installing control Important! Do not run engine if oil sump is removed or with- out ATF in engine and do not tow vehicle. Notes: ♦ The control valve housing or the printed con- ductor can also be removed with the gear- box installed.

  • Page 159

    OCTAVIA Gears/Hydraulic Control Removing and installing control valve body - Overview 1 - ATF screw plug, 15 Nm ♦ Always replace seal ♦ Inspecting ATF level and topping up ⇒ page 37-22 2 - Overflow pipe ♦ Draining ATF ⇒ page 38-15 ♦...

  • Page 160: Removing And Installing Slide Valve Body

    OCTAVIA Gear/Control 14 - Ribbon cable with plug ♦ Removing and installing ⇒ page 38-18 ♦ With cable duct and connector ♦ Can also be installed or removed with the gearbox mounted 15 - Bracket for plug of ribbon cable 16 - 20 Nm ♦...

  • Page 161

    OCTAVIA Gears/Hydraulic Control K Fig. 1 Inserting sealing plug Pull out sealing plug before removing and in- stalling the freewheel in the gearbox housing otherwise the sealing plug and the O-ring will be damaged. Fit O-rings onto the sealing plug.

  • Page 162: Removing And Installing Atf Strainer

    OCTAVIA Gear/Control Tightening torques Component Tightening torque Overflow tube to oil pan 2 Nm ATF screw plug to oil pan 15 Nm Oil pan to gearbox housing (crosswise) 12 Nm Protection plate to gearbox housing 50 Nm Removing and installing ATF...

  • Page 163

    OCTAVIA Gear/Control Notes: ♦ Only the indicated fixing screws should be loosened. ♦ When loosening other screws, the function of the slide valve body can be affected or the slide valve body splits up. Remove slide valve body from gearbox. To do so release the actuator rod -2- from the manual slider -1-.

  • Page 164

    OCTAVIA Gear/Control Adjust actuator rod for manual slider Shift shift shaft into selector lever position „P“. Slacken screw for manual slider and replace. Push actuator rod with manual slider into the slide valve body up to the stop (in direction of arrow) and tighten bolt to 4 Nm.

  • Page 165

    OCTAVIA Gear/Control Removing Remove ATF strainer ⇒ page 38-16. Unbolt bracket for plug of ribbon cable and release plug. Loosen locking screw -1- for cable ducts. Press cable duct from inside to outside out of the gearbox housing. Lever off ribbon cable from solenoid valves with MP 3-495 in direction of arrow.

  • Page 166

    OCTAVIA Gears/Hydraulic Control testers and aids ♦ Locking fluid AMV 185 101 A1 ♦ Pipe section MP 3-479 ♦ Drift MP 3-481/2 Important! Do not run engine ♦ Rules for cleanliness when carrying out work on automatic gearbox ⇒ page 37-28.

  • Page 167

    OCTAVIA Gears/Hydraulic Control ♦ Insert together with shift shaft and Hand slide control engagement lever ♦ Setting ⇒ page 38-12 ♦ Removing and installing ⇒ Fig. 2 ♦ Removing and inserting ⇒ Fig. 1 ♦ Insert together with shift shaft and detent segment Edition 04.00...

  • Page 168

    OCTAVIA Gears/Hydraulic Control 11 - Circlip 14 - Restoring spring ♦ Always replace ♦ ⇒ ♦ Install 15 - Detent lever 12 - Washer ♦ ⇒ 13 - Shaft for detent lever 16 - Park lock gear ♦ ♦ 17 - 14 Nm 18 - Supporting plate ♦...

  • Page 169

    OCTAVIA Gears/Hydraulic Control ♦ Insert before supporting plate ♦ Always replace ⇒ Fig. 3 sender ♦ Is tested by self-diagnosis in vehicle ♦ Drive gear does not need to be remo- ⇒ page 01-4 ved for disassembling park lock ♦ Insert with locking fluid AMV 185 101 ♦...

  • Page 170

    OCTAVIA Gears/Hydraulic Control K Fig. 1 Removing and inserting roll pins (arrows) Removing Knock out roll pin for engaging lever and roll pin for detent segment only sufficiently far to enable the shift shaft to be pulled out. Note: Roll pin of engaging lever may drop into the plan- etary gear.

  • Page 171

    OCTAVIA Gears/Hydraulic Control detent l sender a = 60 Edition 03.97 ------------ ------------ S00.5116.51.20...

  • Page 172

    OCTAVIA Gears/Hydraulic Control ------------ ------------ Edition 04.00 S00.5116.58.20...

  • Page 173: Inspecting Axle Oil In Final Drive

    OCTAVIA Final Drive/Differential Inspecting axle oil in final drive Special tools, testers and aids required ♦ Extraction device (e.g. V.A.G 1358 A) Note: Specification and capacity of final drive ⇒ page 00-4. Axle oil level is checked with gearbox installed.

  • Page 174

    OCTAVIA Final Drive/Differential Removing and installing seal for joint flange (gearbox assembled) Special tools, testers and aids required ♦ Thrust piece MP 3-410 ♦ Pulling tool MP 3-487 ♦ Puller Kukko 20/10 with hook 1-90 ♦ Thrust piece MP 3-499 ♦...

  • Page 175

    OCTAVIA Final Drive/Differential Note: Mark the mounting location of the screws -ar- rows- as otherwise the axle geometry must be checked. Release screws -arrows-. Release the coupling rod left -1- from the axle link and turn the coupling rod upwards.

  • Page 176

    OCTAVIA Final Drive/Differential Position device MP 3-410 onto the flange of the drive shaft. Install extractor Kukko 20/10 with hooks 1-90. Pull off flange Pull out seal for drive flange with MP 3-418. Installing Fill the space between the sealing and dust lip with multipurpose grease.

  • Page 177

    OCTAVIA Final Drive/Differential Assemble steering joint with track control arm. Tighten bolts -arrows- to specified torque (20 Nm + 90°, bolts seated on old impres- sion). Attach coupling rod bracket to track control arm (45 Nm). Install drive shaft. Fit on wheel.

  • Page 178: Disassembling And Assembling Final Drive

    OCTAVIA Final Drive/Differential Disassembling and assembling final drive 1 - Planetary gear ♦ Disassembling ⇒ page 37-35 ♦ Assembling ⇒ page 37-41 2 - Input gear ♦ Removing and installing ⇒ page 39-5 ♦ Setting ⇒ page 39-27 ♦ Setting final drive (summary) ⇒ page...

  • Page 179

    OCTAVIA Final Drive/Differential Removing and installing the input gear 1 - Tensioning screw, 250 Nm ♦ set park lock to install or remove ♦ use 22 mm plug-in element ♦ fit the axial needle bearing (Pos. 7) before installing the tensioning screw.

  • Page 180

    OCTAVIA Final Drive/Differential K Fig. 1 Removing taper roller bearing in- ner race Fit thrust piece onto input gear. K Fig. 2 Pressing on taper roller bearing inner race Note: A thrust piece should be placed below the hub of the input gear in order to avoid any damage to the input gear.

  • Page 181

    OCTAVIA Final Drive/Differential K Fig. 4 Removing input gear Position compression tool MP 3-428 with collar in the threaded bore of the input gear Fit washer -A- and install MP 3-419. Carefully draw out the input gear with MP 3-419.

  • Page 182

    OCTAVIA Final Drive/Differential Removing and installing drive pinion Special tools, testers and aids required ♦ Thrust washer MP 3-413 ♦ Pipe section MP 3-414 ♦ Sealing mass AKD 456 000 02 ♦ Plunger MP 3-411 ♦ V.A.G 1582 ♦ Thrust piece MP 3-411 ♦...

  • Page 183

    OCTAVIA Final Drive/Differential 7 - Outer ring/tapered roller bearing ♦ Thrust piece MP 3-472 ♦ drive out with mandrel ♦ Mounting device MP 3-424 ♦ compressing ⇒ figure 4 ♦ Compression pipe MP 3-485 8 - ATF oil guard ♦ install together with bearing cover ♦...

  • Page 184

    OCTAVIA Final Drive/Differential K Fig. 1 Note: Do not damage the output gear and the sealing surface on the gearbox housing. K Fig. roller K Fig. 3 roller inner r ------------ ------------ Edition 03.97 S00.5116.51.20...

  • Page 185

    OCTAVIA Final Drive/Differential K Fig. 4 Pressing in taper roller bearing outer race K Fig. 5 Removing and installing bearing supporting ring ⇒ K Fig. 6 Bearing supporting ring with seal for drive pinion ♦ Edition 03.97 ------------ ------------ S00.5116.51.20...

  • Page 186

    OCTAVIA Final Drive/Differential K Fig. 7 Driving in sealing ring for drive pin- Position the sealing ring in such a way that the sealing lip points outward to special tool MP 3-483. K Fig. 8 Removing the drive pinion K Fig. 9...

  • Page 187

    OCTAVIA Final Drive/Differential K Fig. Pressing on taper roller bearing inner Edition 03.97 ------------ ------------ S00.5116.51.20...

  • Page 188: Removing And Installing Differential

    OCTAVIA Final Drive/Differential Removing and installing differential Special tools, testers and aids required ♦ Puller Kukko 20/10 with hook 1-90 ♦ Thrust piece MP 3-499 ♦ Sealing mass AMV 185 101 A1 Notes: ♦ Tool MP 3-410 ♦ If tapered roller bearings are to be used again ♦...

  • Page 189

    OCTAVIA Final Drive/Differential 2 - Drive for speedometer sender -G22 15 - Screw, 12 Nm ♦ removing and installing ⇒ page 39-1 ♦ insert with locking agent AMV 185 101 3 - Output shaft/joint flange ♦ remove before removing the differen-...

  • Page 190

    OCTAVIA Final Drive/Differential 28 - Screw, 12 Nm 32 - Seal ♦ insert with locking agent AMV 185 101 ♦ always replace 33 - Cover 29 - Lock ♦ for differential 30 - Circlip 34 - Screw, 28 Nm ♦ only remove after removing the joint ♦...

  • Page 191

    OCTAVIA Final Drive/Differential K Fig. 1 Knock in seal for flange of drive shaft up to the stop K Fig. 2 Mark adjusting ring If used bearings are reused, mark fitting lo- cation (arrow) and when reinstalling position on the marking.

  • Page 192

    OCTAVIA Final Drive/Differential K Fig. 4 Removing joint flange Use flat pliers for opening circlips to remove the circlip. Remove the flange of the articulated shaft with puller Kukko 20/10 with hook 1-90 and MP 3-410 (place under cabinet). K Fig. 5...

  • Page 193

    OCTAVIA Final Drive/Differential K Fig. 7 Installing circlip Remove circlip -arrows- with two screwdriv- ers. ------------ ------------ Edition 12.98 S00.5116.55.20...

  • Page 194

    OCTAVIA Final Drive/Differential ------------ ------------ Edition 12.98 S00.5116.55.20...

  • Page 195

    OCTAVIA Final Drive/Differential differential ♦ V.A.G 1582 ♦ V.A.G 1582/3 ♦ Thrust piece MP 3-484 ♦ Insertion sleeve MP 3-427 ♦ Pressure plunger MP 6-405 ♦ Thrust plate MP 3-407 ♦ Pressure plunger MP 3-448 ♦ Thrust plate MP 3-464 Notes: ♦...

  • Page 196

    OCTAVIA Final Drive/Differential 11 T roller inner race ♦ Remove item 12 and 13 before pull- ing off ♦ Pulling off ⇒ Fig. 1 ♦ Pressing on ⇒ Fig. 2 ♦ Remove together with speedometer drive gear -item 13- ♦ Use drift for fitting on drive ♦...

  • Page 197

    OCTAVIA Final Drive/Differential off taper roller bearing ner race on taper roller bearing inner race K Fig. 3 differential bevel Edition 03.97 ------------ ------------ S00.5116.51.20...

  • Page 198

    OCTAVIA Final Drive/Differential K Fig. in taper roller bearing race K Fig. ♦ ------------ ------------ Edition 03.97 S00.5116.51.20...

  • Page 199: Setting Final Drive

    OCTAVIA Final Drive/Differential Setting final drive Setting final drive -summary- Note: 4 - Shim for drive pinion Summary of setting operations when individual components of the gearbox are replaced 5 - Shim for drive pinion ⇒ page 39-24. 6 - Shim ring for differential...

  • Page 200: Before Disassembling Final Drive

    OCTAVIA Final Drive/Differential Setting operations when replacing individual components When carrying out removal and installation work at the gearbox, it is only necessary to conduct a re-setting of input gear, drive pinion with output gear or differential housing, if components which directly affect the setting of the final drive, are replaced.

  • Page 201

    OCTAVIA Final Drive/Differential roller Oil taper roller bearings when installing up to gearbox date of manufacture 26.4.1998. From gearbox date of manufacture 27.4.1998 taper roller bearings with the modified friction coefficient have been installed. These taper roller bearings must not be oiled.

  • Page 202

    OCTAVIA Final Drive/Differential The specified bearing preload is achieved if the result of the measurement (0.93 mm), the preload of the bearings of 0.12 mm and the amount of settling 0.10 mm are deducted from the 2 x 1.5 mm thick shims.

  • Page 203

    OCTAVIA Final Drive/Differential A - Commercially available torque gauge 0...600 Ncm B - Wrench bit (width across flats 41 mm) roller date of Moisten these taper roller bearings with ATF for inspecting the friction torque. The friction torque of these taper roller bearings must be 80...120 Ncm higher than the friction...

  • Page 204

    OCTAVIA Final Drive/Differential Setting gear ♦ Measuring device MP 3-404/7 Tighten tensioning bolt to 100 Nm without dished washer and without shim. A - Torque wrench B - 22 mm bit Park lock must be engaged. Remove tensioning bolt. Measure distance between input gear and inner race of taper roller bearing.

  • Page 205

    OCTAVIA Final Drive/Differential A - Commercially available torque gauge 0...600 Ncm B - Wrench bit (width across flats 41 mm) roller date of Moisten these taper roller bearings with ATF for inspecting the friction torque. The friction torque of these taper roller bearings must be 180...220 Ncm higher than the friction...

  • Page 206: Setting Differential

    OCTAVIA Final Drive/Differential Setting differential Special tools, testers and aids required ♦ Wrench for ring nut MP 3-488 Use MP 3-488 to tighten bearing body to 150 Nm as far as the stop and secure. Tighten shim ring to 50 Nm and mark.

  • Page 207

    OCTAVIA Final Drive/Differential Friction value Drive pinion (result of measurement) = 320 Ncm Differential (mean value) 70 Ncm Friction value of differential + drive pinion = 390 Ncm Edition 03.99 ------------ ------------ S00.5116.56.20...

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  • m,safy Dec 13, 2017 08:18:
    it is not clear the problem of eliminate and discrimina​te check lamp engine .meaning this happen every about 200 km