Fabia Gearbox 0A8

8/9/2019 Fabia Gearbox 0A8

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Service 5

Service Department. Technical Information Printed in Czech RepublicS00.5329.00.20

Workshop ManualFABIA 2003

Gearbox 0A8Edition 10.03Gearbox code

FJW FSM HDS


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Service5

The Workshop Manual is intended only for use within the Organisation koda.It is not permitted to pass it on to other persons.

KODA AUTO a. s.

Printed in Czech RepublicS00.5329.00.20


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FABIA 2003 Gearbox 0A8

List of SupplementsEdition 02.04S00.5329.01.20

List of Supplements to Workshop Manual

FABIA 2003

Gearbox 0A8

Edition 10.03

Supple-ment

Edition Subject Article Number

10.03 Basic Edition S00.5329.00.20

1 02.04 Supplement to manual gearbox with code HDS S00.5329.01.20


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List of Supplements Edition 02.04S00.5329.01.20


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Table of ContentsEdition 02.04S00.5329.01.20

I

Table of Contents

00 Technical Data

Identification of the gearbox .........................................................................

- Location on the gearbox ................ ................. ................. ................. ...........

- Identification characters, aggregate assignment, ratios, capacities .. .. .. .. .. .. .. .. .. .. .. .. .. .

Overview of Transmission System .................................................................

General Repair Information ..........................................................................

30 Clutch

Repairing the clutch control .........................................................................

- Summary of components - Foot controls ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .... .....

- removing and installing, setting clutch pedal switch -F36- ... .. ... ... ... ... .. ... ... ... ... .. ... ..

- Removing and installing the over-centre helper spring ... ... ... ... ... ... ... .. ... ... ... ... .. ... ..

- Removing and installing the clutch pedal ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .... .....

- Summary of components - Hydraulics ..... ..... .... ..... ..... .... ..... .... ..... ..... .... ..... .....

- Removing and installing the master cylinder ..... ..... .... ..... .... ..... ..... .... .... ..... .... ....

- Bleeding the clutch system ................ ................. ................. ................. .......

Repairing the clutch control .........................................................................

Repairing the clutch ...................................................................................

- Clutch - Overview of components .... ..... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .... .....

- removing and installing clutch ................ ................. ................. ................ .....

34 Control/Housing

Repairing the gearshift mechanism ................................................................

- Fitting location of shift mechanism .... .... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .... .....

I - Summary of components - gearshift knob and cover ......................................

- Separating collar from gearshift lever .... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .... .....

II - Summary of components - shift lever and shift housing .................................

III - Summary of components - Control cables ..................................................

Removing and Installing Shift Mechanism .......................................................

- Removing ... . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . . .

- Installing .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. .

Setting the shift mechanism .........................................................................

- Operation ... . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . .. . . . . . . . . .

Removing and installing the gearbox .............................................................

- Removing ... . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . . .

- Installing .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. .

Inspecting gear oil .....................................................................................

Disassembling and assembling the gearbox for gearbox as of gearbox manufacturingdate 07.03 ................................................................................................

- Gearbox overview ................ ................. ................. ................ ............... ....

- Summary of components ............... ................. ................. ................. ...........

- Gearbox housing and gearshift mechanism - Summary of components .. .. .. .. .. .. .. .. .. .. .

- Drive shaft, output shafts (input shafts), differential and gearshift rods - Summary ofcomponents ................ ................. ................. ................. ................. ........

- Mounting sequence ................. ................. ............... ................ ................. .

00-1 page 1

00-1 page 1

00-1 page 3

00-2 page 1

00-3 page 1

30-1 page 1

30-1 page 1

30-1 page 3

30-1 page 3

30-1 page 4

30-1 page 5

30-1 page 6

30-1 page 8

30-2 page 1

30-3 page 1

30-3 page 1

30-3 page 2

34-1 page 1

34-1 page 1

34-2 page 1

34-2 page 2

34-3 page 1

34-4 page 1

34-5 page 1

34-5 page 1

34-5 page 2

34-6 page 1

34-6 page 3

34-7 page 1

34-7 page 1

34-7 page 7

34-8 page 1

34-9 page 1

34-9 page 1

34-9 page 2

34-9 page 3

34-9 page 4

34-9 page 5


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Table of Contents Edition 02.04S00.5329.01.20

II

Repairing the gearbox housing .....................................................................

- Repairing the gearbox housing for gearbox up to gearbox manufacturing date 06.03 .. .. .

- Repairing the gearbox housing for gearbox as of gearbox manufacturing date 07.03 .. .. .

Repairing the clutch housing .......................................................................

- Repairing the clutch housing for gearbox up to gearbox manufacturing date 06.03 .. .. .. ..

- Repairing the clutch housing for gearbox as of gearbox manufacturing date 07.03 .. .. .. ..

Disassembling and assembling the gearshift mechanism on the gearbox side ........- Disassembling and assembling the gearshift mechanism on the gearbox side for gearbox

up to gearbox manufacturing date 06.03 .... .... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .

- Disassembling and assembling the gearshift mechanism on the gearbox side as of gearboxmanufacturing date 07.03 ..... .... ..... .... .... ..... ..... .... ..... ..... .... ..... .... ..... .... ..... ...

Disassembling and assembling the gearshift forks ...........................................

- Disassembling and assembling the gearshift forks for gearbox up to gearbox manufacturingdate 06.03 ............... ................. ................. ................. ................. ...........

- Disassembling and assembling the gearshift forks for gearbox as of gearbox manufacturingdate 07.03 ............... ................. ................. ................. ................. ...........

35 Wheels, shaftsDisassembling and assembling the drive shaft .................................................

- Disassembling and assembling the drive shaft for gearbox up to gearbox manufacturingdate 06.03 ............... ................. ................. ................. ................. ...........

- Disassembling and assembling the drive shaft for gearbox as of gearbox manufacturingdate 07.03 ............... ................. ................. ................. ................. ...........

Setting drive shaft .....................................................................................

- Setting drive shaft for gearbox up to gearbox manufacturing date 06.03 .. .. .. .. .. .. .. .. .. ..

- Setting drive shaft for gearbox as of gearbox manufacturing date 07.03 .. .. .. .. .. .. .. .. .. .. .

Disassembling and assembling output shaft gears 1 through 4 ............................

Setting output shaft gears 1 through 4 ...........................................................

Disassembling and assembling output shaft 5th/6th and reverse gear ...................

Setting output shaft 5th/6th and reverse gear ...................................................

39 Final drive/Differential

Replacing the flange shaft gasket rings (gearbox assembled) ..............................

- Replacing the left flange shaft seal ring ..... ..... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .

- Replacing the right flange shaft seal ring .... .... ..... .... ..... ..... ..... ..... ..... ..... ..... .... ..

Disassembling and assembling the differential .................................................

- Disassembling and assembling the differential for gearbox up to gearbox manufacturingdate 06.03 ............... ................. ................. ................. ................. ...........

- Disassembling and assembling the differential for gearbox as of gearbox manufacturingdate 07.03 ............... ................. ................. ................. ................. ...........

Setting overview ........................................................................................

- Setting overview for gearbox up to gearbox manufacturing date 06.03 .. .. .. .. .. .. .. .. .. .. ..

- Setting overview for gearbox as of gearbox manufacturing date 07.03 .. .. .. .. .. .. .. .. .. .. ..

Adjusting the differential gear ......................................................................

34-10 page 1

34-10 page 1

34-10 page 1

34-11 page 1

34-11 page 1

34-11 page 1

34-12 page 1

34-12 page 1

34-12 page 1

34-13 page 1

34-13 page 1

34-13 page 1

35-1 page 1

35-1 page 1

35-1 page 1

35-2 page 1

35-2 page 1

35-2 page 1

35-3 page 1

35-4 page 1

35-5 page 1

35-6 page 1

39-1 page 1

39-1 page 1

39-1 page 2

39-2 page 1

39-2 page 1

39-2 page 1

39-3 page 1

39-3 page 1

39-3 page 1

39-4 page 1


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Identification of the gearboxEdition 02.04S00.5329.01.20

00-1page 1

00

00-1 Identification of the gear-box

Assignment 00-1page 3

Location on the gearbox

Identification characters and manufacturing data ofthe gearbox -arrow 1-

Gearbox 0A8 -arrow 2- and -arrow 3-

Identification characters and manufacturing data ofthe gearbox -arrow 1-

Additional data depend on the manufacturing.

00 Technical Data

2

1

3

S34-0692

1

S34-0693

Exam-ple:

FJW 20 06 3

I I I I

Identifi-cation

charac-ters

Day Month Manufac-turingyear -2003


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Identification of the gearbox Edition 02.04S00.5329.01.20

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00

Gearbox 0A8 -arrow 2- and -arrow 3-

The identification 0A8 on the gearbox housing -arrow 3-is only present on gearboxes as of 07.03.

Distinguishing features of the gearboxes 0A8

I - Gearbox up to 06.03: The gearbox housing is closedin the area of the bearing for the drive shaft -arrowA-

II - Gearbox as of 07.03: Gearbox housing in the area

of the bearing for the drive shaft is provided with acap -arrow B-.

1

3

S34-0694

2

Note

B

A

II

I

S34-0697


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Identification of the gearboxEdition 02.04S00.5329.01.20

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00

Identification characters, aggregate assignment, ratios, capacities

Gearbox 6 speed 0A8

Identification characters FJW FSM1)

1) Drive shaft must not be adjusted (firm/loose bearing).

HDS

Manufacturingdate

fromthrough

05.0306.03

07.03 01.04

Assignment: Engine 1.9 ltr./96 kW TDI 1.9 ltr./96 kW TDI 1.9 ltr./96 kW TDI

Ratio: Final drive for 1st gear through

4th gear

65 : 22= 2,955 65 : 22= 2,955 68 : 21= 3,238

Final drive for5th gear

through 6thgear

65 : 27= 2,407 65 : 27= 2,407 68 : 26= 2,615

1th gear 49 : 13 = 3,769 49 : 13 = 3,769 49 : 13 = 3,769

2th gear 48 : 23 = 2,087 48 : 23 = 2,087 48 : 23 = 2,087

3th gear 45 : 34 = 1,324 45 : 34 = 1,324 45 : 34 = 1,3244th gear 41 : 45 = 0,911 41 : 45 = 0,911 42 : 43 = 0,977

5th gear 37 : 41 = 0,902 37 : 41 = 0,902 39 : 40 = 0,975

6th gear 34 : 45 = 0,756 34 : 45 = 0,756 35 : 43 = 0,814

Reverse gear 36 : 13 x 23: 14 = 4,549 36 : 13 x 23: 14 = 4,549 36 : 13 x 23: 14 =4,549

Speedometer2)

2) Only on vehicles without ABS.

electronic

Capacity 2.3 liters

Specification Gearbox oil G 005 100 SAE 75W90 (synthetic oil)

Gearbox oil G 052 171 SAE 70W75 (syn-

thetic oil)

Gearbox oil G 052171 SAE 70W75

(synthetic oil)

Gear oil change interval Filled for life

Clutch control hydraulic

Clutch plate 240 mm 240 mm 240 mm

Drive shaft flange 108 mm 108 mm 108 mm


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Identification of the gearbox Edition 02.04S00.5329.01.20

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00


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Overview of Transmission SystemEdition 10.03S00.5329.00.20

00-2page 1

00

00-2 Overview of TransmissionSystem

Overview of Transmission system 6 speed Gearbox02M, Rep. Gr. 00.


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Overview of Transmission System Edition 10.03S00.5329.00.20

00-2page 2

00


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General Repair InformationEdition 10.03S00.5329.00.20

00-3page 1

00

00-3 General Repair Informa-tion

To carry out gearbox repairs successfully and correctly,scrupulous care and cleanliness, as well as the propertools, are essential requirements. Obviously, the general-ly valid basic safety rules apply to repair work.

Below is a summary of the general instructions to be ap-plied to individual repair operations (also given elsewhereat various parts of the workshop manual). They apply tothis workshop manual.

Contact corrosion!

The gearbox housing is made out of magnesium.

Bolts and other attachments that come into direct con-tact with the gearbox can have varying finishes de-pending on whether the gearbox housing is ofmagnesium.

The use of substitute components causes contact cor-

rosion (screws, nuts, washers ). This will result indamage to the gearbox housing.

If you have any doubts about re-using parts, alwaysuse new parts in accordance with Spare Parts cat-alogue.

Gearbox

When installing, ensure the dowel sleeves are correct-ly located between the engine and gearbox.

If replacing the gearbox, pour in gear oil up to loweredge of filler hole.

Capacity and specification Chap. 00-1.

Gaskets, seals

Clean contact surfaces thoroughly and apply sealant-AMV 188 200 03-.

Apply sealant evenly, and not too thickly.

Replace O-rings.

Replace radial shaft seals.

Before installing:

Lightly oil the outer diameter and pack half the space be-tween the sealing lips -arrow- with sealing grease

-G 052 128 A1-.

After installing:

Check gear oil level, if necessary pour in up to lower edgeof filler hole, specification Chap. 34-8.

Locking elements


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General Repair Information Edition 10.03S00.5329.00.20

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00

Replace circlips.

Do not over-tension the circlips.

Circlips must be positioned in the base of the groove.

Replace roll pins. Fitting position: slot longitudinally topower flow -arrow-.

Bolts, nuts

Slacken and tighten nuts and bolts for attaching cov-ers and housings diagonally across.

Do not twist particularly sensitive parts - e.g. clutchpressure plates - and slacken and tighten diagonallyacross in stages.

Tightening torques apply for non-oiled nuts and bolts.

Always replace the self-locking nuts and bolts.

It is important to ensure at all bolted connections thatthe contact surfaces as well as the nuts and bolts arewaxed only after being installed, should this be neces-sary.

Bearings

New taper roller bearings are fitted as supplied and donot require any additional lubrication.

Fit needle bearings to the gearbox with some gearboxfluid.

Replace all taper roller bearings belonging to oneshaft at the same time. As far as possible use bear-ings of the same make!

Heat inner races to about 100 C for installing.

Do not exchange the outer and inner rings of bearingsof the same size - bearings go in pairs.

Position needle bearing with the lettered side (thickerend) towards the drift pin.

Shims

Gauge shims at several points with a micrometer. Dif-ferent tolerances allow to measure the required thick-ness for each washer very precisely.

Inspect for burrs and damage.

Install only shims which are in perfect condition.

Synchronizer rings

These are not interchangeable. If re-using, allocatesynchronizer rings to the same gear.

Inspect for wear, and replace if necessary.

Insert with some gearbox fluid.

Gears

Clean and heat on a heating plate to about 100 C be-fore pressing on.

Temperature can be checked with a temperaturemeasuring instrument.


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Repairing the clutch controlEdition 10.03S00.5329.00.20

30-1page 1

30

30-1 Repairing the clutch con-trol

Summary of components - Foot controls

Special tools, test and measuring equipment andauxiliary items required

Pliers -T10005-

Polycarbamide grease -G 052 142 A2-

Summary of components - Hydraulics 30-1page 5.

Disconnect earth strap from battery.

Before disconnecting the battery determine the codeof radio sets fitted with anti-theft coding.

If the battery earth strap is disconnected and connect-ed, carry out additional operations Electrical Sys-tem; Rep. Gr. 27.

Grease all bearing and contact surfaces with Polycar-bamide Grease -G 052 142 A2-.

Prior to working on the foot controls remove the stor-age area on the driver's side Body Work;Rep. Gr. 70.

30 Clutch

Note


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1 - Support/Front wall

for master cylinder andbracket

2 - Gasket

always replace

3 - Bracket

4 - Screw

5 - Gas/brake foot controls

6 - 28 Nm

always replace

7 - Clutch pedal switch

before removing the clutchpedal item 11 remove theswitch by rotating it 45to theright and drawing it throughthe assembly opening.

removing and installing, set-ting 30-1page 3

8 - Over-centre helper spring removing and installing

30-1page 3

9 - Spacer bush

10 - Bushing

11 - Clutch pedal

removing and installing 30-1page 4

12 - Support


13 - 28 Nm always replace

14 - Master cylinder


15 - Retaining clip

to remove and install the tube-hose line pull out retaining clip up to the stop.

16 - Tubing

17 - Bearing

insert in bracket always replace Fitting position: the peg -arrow- locks into the master cylinder recess

18 - Screw Pedal stop on bracket

19 - Pedal stop

screw onto bracket with screw item 18 with the master cylinder installed

20 - 25 Nm

always replace

1

2

3

4 5

6

8

9

12

9

13

14

19

7

16

17

11

10

18

20

15

S30-0087


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30-1page 3

30

removing and installing, setting clutchpedal switch -F36-

Removing

Removing bottom part of dash panel Body Work;Rep. Gr. 70; dash panel.

Unplug connector -1- from the clutch pedal switch-F36-.

Turn clutch pedal switch -F36- -2- at the bracket 45to the left and remove it from the support.

Installing

The installation occurs in reverse order, while paying at-tention to the following.

Move the clutch pedal -4- up to the stop into home po-sition (clutch pedal not actuated).

Pull out the tappet -3- of the clutch pedal switch -F36-fully.

Now insert the clutch pedal switch -F36- in the assem-bly opening.

For locking turn the clutch pedal switch -F36- at thebracket 45to the right.

Insert connector at the clutch pedal switch -F36-.

Install the bottom part of the dash panel BodyWork; Rep. Gr. 70; dash panel.

Removing and installing the over-centrehelper spring

Removing


Remove clutch pedal switch -F36- 30-1page 3.

Unlock the actuating rod/master cylinder from the clutchpedal as follows:

Insert pliers -T10005- in the clutch pedal recesses. Compress the support and separate the clutch pedal

from the master cylinder.

Press over-centre helper spring towards the front wall-in the direction of the arrow- and remove downwardsfrom the bracket.

1

2

34 S30-0086

T10005

S30-0051

S30-0064


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30-1page 4

30

Installing

Insert bearing for over-centre helper spring -arrow 1-in the bracket.

The peg of the bearing is located in the recess of the mas-ter cylinder -arrow 2-.

Insert over-centre helper spring in the bearing.

Press over-centre helper spring towards the bearingand position on the support of the clutch pedal -ar-row-.

Connect clutch pedal to master cylinder 30-1page 4.

Installing the clutch pedal switch 30-1page 3.

Install the bottom part of the dash panel BodyWork; Rep. Gr. 70; dash panel.

Removing and installing the clutch pedal

Removing

Remove the over-centre helper spring 30-1page 3

Unscrew hexagon nut -A- and remove hexagon screwfrom bracket.

Remove clutch pedal.

Installing

Installation is performed in the reverse order. Pay atten-tion to the following points:

S30-0068

1

2

S30-0065

A

S30-0054


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30-1page 5

30

The support -A- must be located on the actuating rod-B- of the master cylinder.

To click in the support push the clutch pedal towardsthe front wall -direction of the arrow- and make sure itcatches correctly.

Summary of components - Hydraulics

1 - Brake fluid reservoir

2 - Tubing

3 - Master cylinder


4 - Retaining clip

only replace if the master cyl-inder has been removed

dismantling Fig. 1 in30-1page 6

push on Fig. 2 in 30-1

page 65 - Clutch pedal


6 - 25 Nm

always replace

7 - O-ring

pull onto line connection insert with brake fluid

8 - Tube-hose line

9 - Bracket

Mounted at the structure10 - O-ring

pull onto line connection insert with brake fluid

11 - Breather

12 - O-ring

pull onto connection insert with brake fluid

13 - Retaining clip

to remove and install pull out the retaining clip only up to the stop.

14 - Bleed valve

Bleed the clutch system 30-1page 815 - Dust cap

V30-0419B A

10

15

S30-0088

1 2 3 4 5

7

18

6

8

9

14

13

1112

16

17


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30-1page 6

30

16 - Retaining clip

to remove and install pull out the bleeder only up to the stop.

17 - Slave cylinder

for removing and installing, remove gearbox 30-2page 1

18 - Retaining clip

to remove and install pull out the retaining clip only up to the stop.

Fig. 1: Lift off the support -A- in -the direction ofthe arrow-.

Fig. 2: Push the actuator rod/master cylinder in thesupport -A- -direction of the arrow-.

Removing and installing the master cyl-inder


Pliers -T10005-

A

N30-0024

A N30-0025


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30-1page 7

30

Removing

Disconnect the earth strap from the battery with the ig-nition off.

Removing air filter 1.9/96 TDI Engine, Fuel Injec-tion; Rep. Gr. 23

Release and cut off tubing -A- to the brake fluid reser-

voir. Remove the retaining clip -B- on the master cylinder

up to the stop.

Release and cut off the tube-hose line -C- from themaster cylinder.


Remove clutch pedal switch -F36- 30-1page 3.

To remove the master cylinder completely remove theclutch control. Before removing first separate the mastercylinder from the clutch pedal.

Unlock the actuating rod/master cylinder from the clutchpedal as follows:

Insert pliers -T10005- in the clutch pedal recesses.

Compress the support and separate the clutch pedalfrom the master cylinder.

C

S30-0075

MP 7-602

B

A

Note

T10005

S30-0051


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30-1page 8

30

Unscrew the hexagon nuts -arrow 1- and remove theclutch controls -arrow A- together with the master cyl-inder.

Removing the over-centre helper spring 30-1page 3.

Unhook the bearing/over-centre helper spring fromthe bearing.

Unscrew pedal stop.

Remove the master cylinder.

Installing


The support -A- must be located on the actuating rod-B- of the master cylinder.

To click in the support push the clutch pedal towardsthe front wall -direction of the arrow- and make sure itcatches correctly.

After installing the master cylinder bleed the clutchsystem 30-1page 8.

Bleeding the clutch system


Brake filling and bleeding device -ROMESS S15-

Brake fluid specification Running Gear; Rep. Gr. 47.

Connect the brake filling and bleeding device

-ROMESS S15-. Insert the bleeder hose -A- on the slave cylinder -ar-

row- and open the bleeder valve.

Activate system with a pressure of 2 bar.

Allow approx. 100 cm3of brake fluid to flow out untilno more air bubbles are visible.

Shut the bleeder valve.

Activate pedal forcefully from stop to stop between 10and 15 times.

Open the bleeder valve.

Again allow approx. 100 cm3brake fluid to flow out.

Shut the bleeder valve.

1

1

A

1

S30-0052

V30-0419B A

N30-0248

A


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30-1page 9

30

After completing the bleeding procedure activate theclutch pedal repeatedly.

Disconnect brake filling and bleeding device.


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30-1page 10

30


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30-2page 1

30

30-2 Repairing the clutch con-trol

Repairing the clutch control 6 speed Gearbox 02M,Rep. Gr. 30.


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30-2page 2

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Repairing the clutchEdition 10.03S00.5329.00.20

30-3page 1

30

30-3 Repairing the clutch

Pressure plate and clutch disc are assigned to each otherand must be replaced together.

Clutch - Overview of components

1 - Flywheel

removing and installing 1.9/96 Engine, Mechan-ics; Rep. Gr. 13

make sure the centering pinsare tight

The locating face for theclutch lining must be freefrom grooves, oil and grease

2 - Clutch disc


must be replaced togetherwith pressure plate

Fitting position Fig. 1 in30-3page 2

Diameter of clutch disc Chap. 00-1

3 - Pressure plate


Check the extremities of the

membrane spring Fig. 2 in30-3page 2

Check feather joints and riv-eted joints Fig. 3 in 30-3page 2

must be replaced togetherwith clutch disc

4 - M7 screw - 22 Nm

release or tighten in smallstages crosswise

Note

S30-0114

1 2 3 4


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Repairing the clutch Edition 10.03S00.5329.00.20

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30

Fig. 1: Fitting location of clutch disc

Legend side of gearbox -arrow- points to the gear-box.

Fig. 2: Check the extremities of the membranespring

Wear is allowed up to half the membrane spring -ar-rows- thickness.

Fig. 3: Check feather joints and riveted joints

Check the feather joints between pressure plate andcover for cracks as well as the riveted joints for firmseating.

A pressure plate with damaged feather joints or withloose riveted joints -arrows- must be replaced.

Replace pressure plate and clutch disc together. Assignpressure plate and clutch disc via engine identificationcharacters Spare Part Catalogue.

removing and installing clutch


Pressure pad -MP 1-223-

Centering mandrel -T10097-

Grease for plug serration of clutch disc -G 000 100-

S30-0115

Note


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30

Removing

Remove the gearbox Chapter 34-7.

Insert counterholder -MP 1-223- to slacken the bolts.

Release fixing screws (6 in total) in small stagescrosswise.

Remove pressure plate and clutch disc.

Installing


Replace the clutch discs and pressure plates if the riv-eting is damaged or loose.

Always replace clutch disc and pressure plate togeth-er.

Assign clutch disc and pressure plate via engine iden-tification characters Spare Part Catalogue.

In order to reduce unpleasant odours if the clutch isburnt, thoroughly clean the clutch bell as well as theflywheel and the engine on the side of the gearbox.

Clean the drive shaft serration and hub serration on aused clutch disc, remove corrosion and only apply avery thin layer of grease for plug serration of clutchdisc -G 000 100- onto the serration. Subsequentlymove the clutch disc up and down on the drive shaftuntil the hub fits smoothly on the shaft. Remove all ex-cess grease.

The pressure plates are protected against corrosionand are greased. Only clean the thrust surface as oth-erwise the life of the clutch may be considerably short-ened.

The thrust surface of the pressure plate and the clutchdisc lining must fully rest against the flywheel. Onlythen may the fixing screws be inserted.

Pay attention to the fitting position of the clutch disc.

The legend side of gearbox -arrow- points to thegearbox.

Insert counterholder -MP 1-223- to tighten the bolts.

Position the pressure plate on the dowel pins of theflywheel

Screw in all the screws by hand uniformly, until thebolt head rests against the pressure plate.

Tighten the screws in small stages crosswise so asnot to damage the centering holes on the pressureplate and the centering pins of the flywheel.

Install the gearbox Chapter 34-7.

MP 1-223

S30-0116

Note

S30-0115

T10097

MP 1-223

S30-0113


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34

34-1 Repairing the gearshift mechanism

Fitting location of shift mechanism

A - Shift cable for shift movement

B - Selector cable for selectormovement

C - Heat shield

take off before removing theshift mechanism

Arrow -A- Shift movementArrow -B- Selector movement

1 - Gearshift lever

2 - Reversing lever

Before disconnecting thebattery determine the code ofradio sets fitted with anti-theftcoding.

Remove shift mechanism forreplacing control cables 34-5page 1.

Do not kink the control ca-bles.

34 Control/Housing

B

A

R1

35 4

2

6

S34-0674

2

CB

A

1

B

A

Note


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34-1page 2

34

I - Summary of components -gearshift knob and cover 34-2page 1

II - Summary of components -Shift lever and shift housing 34-3page 1

III - Summary of components -Control cables 34-4page 1Removing and installing shiftmechanism 34-5page 1Setting the shift mechanism 34-6page 1

III II

I

S34-0675


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34

34-2 I - Summary of components - gearshift knob and cover

1 - Gearshift knob

with collar the gearshift knob and collar

cannot be separated always replace together removing and installing

34-2page 2

2 - Warm-type clamp

for securing the gearshiftknob to the gearshift lever

3 - Surround of centre console

4 - Sound insulation

1

2

3

4

I

S34-0676


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I - Summary of components - gearshift knob and cover Edition 10.03S00.5329.00.20

34-2page 2

34

Separating collar from gearshift lever

Removing

Lever the collar upwards and out of centre consolesurround -arrows-.

Pull the collar upwards over the gearshift knob.

Open clamp -arrow- and pull off gearshift knob togeth-er with the collar.

Installing

Turn collar inside out.

Insert gearshift knob and collar and compress collarclamp -arrow-.

When inserting the gearshift knob on the selector leverthe gearshift knob must lock into the round slot of thegearshift lever.


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II - Summary of components - shift lever and shift housingEdition 10.03S00.5329.00.20

34-3page 1

34

34-3 II - Summary of components - shift lever and shift housing

Grease bearing and friction surfaces with Polycarbamide Grease -G 052 242 A2-.

1 - Lock washer

removing and installing Fig. 1 in 34-3page 2

2 - Bush

3 - Pressure spring

4 - Bush

5 - 5 Nm

6 - Cover

7 - Damping

8 - Bearing shell

9 - Shift lever guide

10 - Insulating washer

11 - Gasket

between shift housing andbody

adhesive stick onto shift housing

12 - Shift lever

13 - Damping

14 - Shift housing

15 - Bushing

16 - Bearing bolt

17 - Guide bush18 - Pressure spring

installing Fig. 2 in 34-3page 2

19 - Selector lever

20 - 5 Nm

21 - Floor plate

bend up tabs for removing replace

22 - Selector cable

at selector angle plate

Fitting position Chapter Fitting location of shift mechanism in 34-123 - Shift cable

press onto shift lever guide Fitting position Chapter Fitting location of shift mechanism in 34-1

24 - Lock washer

25 - 25 Nm

4 pieces

26 - Bushing

fits in one position only

27 - Lock washer

Note


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II - Summary of components - shift lever and shift housing Edition 10.03S00.5329.00.20

34-3page 2

34

Fig. 1: Removing and installing circlip

To remove and install the circlip -arrow A- press spac-er bush -arrow B- with screwdriver up to the stop in thedirection of the arrow -arrow C- and remove circlip.

Do not twist bush when pressing down. Mounting slot in shift lever for circlip must be visible.

Release spring carefully.

Fig. 2: Installation of pressure spring

Insert pressure spring so that leg -A- is positioned

above the stud -arrow-. After this, pull the leg -B- down far enough so that it

moves underneath the stud -arrow-.

A

B

C

N34-1363

Note


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III - Summary of components - Control cablesEdition 10.03S00.5329.00.20

34-4page 1

34

34-4 III - Summary of components - Control cables

Grease bearing and friction surfaces with Polycarbamide Grease -G 052 242 A2-.

1 - Shift cable

press onto shift lever guide Fitting position Chapter

Fitting location of shiftmechanism in 34-1

2 - Selector cable

at selector angle plate Fitting position Chapter

Fitting location of shiftmechanism in 34-1

3 - Lock washer

4 - Shift housing

5 - Lock washer

do not damage cables whenremoving

6 - 23 Nm

2 pieces for support

7 - Support

8 - Grommet

mounting of support to gear-box

9 - Spacer

10 - 23 Nm

11 - Cable lock

for selector cable at relay le-ver item 18

12 - Cable lock

for shift cable at gearbox shiftlever item 16

13 - Lock washer

14 - Bushing

insert in gearshift shaft cover

15 - 23 Nm

16 - Gearshift lever

with balancing weight insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft after installing set shift mechanism 34-6page 1 Fitting position Fig. 1 in 34-4page 2

17 - Sliding shoe

18 - Reversing lever

Fitting position Fig. 1 in 34-4page 2

Note

1 3

4

5

1

2

7

8

9

11

16

565

2

S34-0677

III

812

8

9

10

13

15

17

14

18


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34

Fig. 1: Fitting location of gearbox shift lever/relaylever

1 - Gearbox shift lever with balancing weight

2 - Relay lever is inserted over the sliding shoe into thesliding rail of the gearbox shift lever -arrow-

2

1

S34-0678


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34

34-5 Removing and InstallingShift Mechanism

Removing



Lever the collar upwards and out of centre consolesurround -arrows-.

Pull the collar upwards over the gearshift knob.

Open clamp -arrow- and pull off gearshift knob togeth-er with the collar.

Remove the centre console Body Work;Rep. Gr. 68.

Remove noise insulation.

Unscrew nuts -arrows- attaching the shift housing.

Remove air filter Rep. Gr. 23; Removing and in-stalling air filter.

Remove battery and battery tray Electrical System;Rep. Gr. 27.

S34-0499


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Removing and Installing Shift Mechanism Edition 10.03S00.5329.00.20

34-5page 2

34

Remove circlip -2- from gearbox shift lever -1- and cir-clip -4- from relay lever -3-.

Remove shift cable and selector cable from the studs-arrows-.

Remove cable support -A- from the gearbox -arrows-.

Detach bracket -1- below the exhaust system.

Unhook front exhaust pipe from bracket -2-.

Unbolt bracket for front exhaust pipe -2-.

Separate exhaust system at the double clamp -3-.

Remove exhaust pipe.

The front silencer remains hanging in the hanger -4-.

Remove heat shield -5-.

Swivel shift housing down and remove with control ca-bles.

Installing


Assemble exhaust system free of stress 1.9/96 En-

gine, Mechanics; Rep. Gr. 26. Pay attention to the fitting location of the strut -1-.

S34-0683

4

2

1

3

S34-0680

A

3

1

54

2

S34-0489

Note


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Removing and Installing Shift MechanismEdition 10.03S00.5329.00.20

34-5page 3

34

The cable locks are bored through with holes contin-uously for attaching to the gearbox shift lever or tothe relay lever.

The holes in the cable locks have different diameters.

Fig. 1: Assignment

Apply a small quantity of grease onto the studs -ar-rows- of the gearbox shift lever -1- and of the relay le-ver -3-.

Replace the circlips -2- and -4- after each removal.

Secure the shift cable with the circlip -2- and the se-lector cable with the circlip -4-.

Setting the shift mechanism 34-6page 1.

Install the centre console Body Work; Rep. Gr. 68.

Replace clamp -arrow-.


Install Electrical System; Rep. Gr. 27.

Pay attention to the work steps after connecting thebattery Electrical System; Rep. Gr. 27; Battery; dis-connect and connect battery.

Tightening torques

Cable lock for: Dimensiona

Shift cable at gearbox shift lever 10 mm

Selector cable at relay lever 8 mm

S34-0683

4

2

1

3

Components Torque

Shift housing to body 25 Nm

Strut to body 25 Nm

Cable support to gearbox 23 Nm

Bracket to body 25 Nm


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34


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Setting the shift mechanismEdition 10.03S00.5329.00.20

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34

34-6 Setting the shift mecha-nism


Rig pin -T10027-

The following are required for correct setting of theshift mechanism:

Operating and transmission elements of the shiftmechanism are in perfect condition.

Shift mechanism operates freely.

Gearbox, clutch and clutch control must be in perfectcondition.

Gearbox in Neutral.



Pull forward the locking mechanism at shift cable andat selector cable as far as the stop -direction of arrow1-, then lock by turning to the left -direction of arrow 2-.

Determine gearshift shaft for gearboxes up to 06.03:

Carefully press the gearshift shaft down in direction of-arrow 1-.

When pressing down the gearshift shaft push the lock-ing bolt -A- into the gearbox -direction of arrow-, untilit locks in place.

This locks the gearshift shaft, it can no longer be moved.

Determine gearshift shaft for gearboxes as of 07.03:

Carefully press the gearshift shaft down in -directionof arrow 1-.

When pressing down the gearshift turn the locking bolt-A- in -direction of arrow 3- upwards and while doingso press it simultaneously in -direction of arrow 2-, un-til it locks into the gearshift shaft.

This locks the gearshift shaft, it can no longer be moved.

Continued for all gearboxes

Note

2

2

1

1

S34-0681

1

A

S34-0686

1

S34-0728

2

3

A


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Setting the shift mechanism Edition 10.03S00.5329.00.20

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34

Lever the collar upwards and out of centre consolecover -arrows-.

If available remove the noise insulation.

Guide shift lever in Neutral to the left into the 1st/2ndgear gate.

Insert rig pin -T10027- through hole -A- into hole -B-.

Now turn the locking mechanism at the shift cable and

at the selector cable to the right as far as the stop -di-rection of the arrow 1-.

The spring pushes the locking mechanism into the initialposition -direction of arrow 2-.

Gearbox up to 06.03:

A

22

1

1

S34-0682


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34

Now pull the locking bolt -A- back to the initial position-in direction of arrow-.

Gearbox as of 07.03:

Now turn the locking bolt -A- back to the initial positionin -direction of arrow 2-.

The locking bolt -A- must be pressed in -direction of arrow1-.

Continued for all gearboxes

Pull rig pin -T10027- out of hole -A- and -B-.

Perform the functional test 34-6page 3.

Insert noise insulation.

Press collar into the cover.



Pay attention to the work steps after connecting thebattery Electrical System; Rep. Gr. 27; Battery; dis-connect and connect battery.

Operation

Shift lever must be positioned in Neutral in the gate of3rd/4th gear.

Depress clutch.

Shift through all gears several times. Pay particular at-tention to proper operation of the reverse gear lock.

If the gearshift lever catches when repeatedly engaging agear, check the play (stroke) of the shift shaft as follows:

A

S34-0687

A1

2

S34-0729

A


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34

Carefully guide shift lever in Neutral to the left into the1st/2nd gear gate.

The gearshift shaft must move downwards -arrow 1-.

If the gearshift mechanism is correctly set, now thelocking bolt -A- must be pushed into the gearbox -di-rection of arrow- and thus into the sliding-block of thegearshift shaft (2nd mechanic).

If this is not the case set gearshift mechanism 34-6page 1.

1

A

S34-0686


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34

34-7 Removing and installingthe gearbox

Removing


Gearbox attachment device -MP 3-478-

Hose clamp -MP 7-602-

Supporting device -MP 9-200-

Lifting device -MP 9-201-

Gearbox mount -3282-

Adjusting plate -3282/27-

Engine and gearbox jack (e.g. -V.A.G 1383 A-)

Grease -G 000 100-



Remove the engine trim panel.

Remove air filter with air guide hose Rep. Gr. 23;Removing and installing air filter.


Pull forward the locking mechanism at shift cable andat selector cable as far as the stop -direction of arrow

1-, then lock by turning to the left -direction of arrow 2-. Remove cable support -2- from the gearbox -arrows-

and tie up.

2

2

1

1

S34-0681

S34-0680

A


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34

Detach circlip -arrow A- from the relay lever -1- and re-move relay lever.

Remove the gearshift lever -2-, for this step unscrewnut -arrow B-. To this end use if necessary a puller,e.g. Kukko -20-10-.

Unscrew earth strap -3- from the top starter.

Disconnect plug -4- from the reversing light switch-F4-.

Detach line -5- from the starter.

Unplug the connector from the speedometer sender-G22-.

Remove engine/gearbox connecting screws at thetop.

Remove fixing screw for starter at the top.

Raise vehicle and remove front left wheel.

Remove noise insulation -arrows-.

Unscrew bracket from starter -arrow- and lay aside to-

gether with lines. Remove the starter Electrical System; Rep. Gr.

27.

Remove the front left wheelhouse liner Body Work;Rep. Gr. 66; Wheelhouse liner.

Remove drive shafts from the flange shafts.

Separate exhaust system at the double clamp and tieup front exhaust pipe 1.9/96 TDI Engine, Mechan-ics; Rep. Gr. 26.

S34-0679

5

4

2

3

1

B

A

S10-0114

S34-0492


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34-7page 3

34

Mark installation position of bolts -1- for left and rightsteering joint, otherwise the steering geometry mustbe checked.

Release screws -1-.

Unbolt left and right coupling rod -2- from the anti-rollbar -arrow-.

Turn left coupling rod upwards.

Swivel out the left wheel-bearing housing.

For this step guide the left drive shaft into the wheel-house and secure to the suspension strut with e.g.wire.

Tie up the right drive shaft as far as possible. Avoiddamaging the paintwork on the drive shaft during thisoperation.

Remove pendulum support -A- -arrows 1 and 2-.

Remove assembly carrier -B-, to do so use fixing de-

vice -T10096-

Chassis; Rep. Gr. 40; Repairingfront axle.

Remove small cover plate -A- for flywheel behind theright flange shaft -arrows-.

B

1

11

2

A

S34-0690

A

V34 - 3005


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34-7page 4

34

Unclamp the hose to the slave cylinder with hoseclamp -MP 7-602-.

Lever out clamp -arrow- for tube-hose line up to thestop using a screwdriver.

Pull out tube-hose line in -direction of arrow-.

Do not depress the clutch pedal.

Remove the support for the engine cover in the left lift-ing eye of the engine -arrow-.

Install supporting device -MP 9-200-.

When installing the lifting hooks of the supporting device,pay attention to hose and cable connections in the areaof the lifting eyes of the engine to avoid damaging them.

MP 7-602

S34-0535

Note

S34-0493

MP 9-200 MP 9-200/3

S34-0685

MP 3-4013

MP 9-201

Note


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34-7page 5

34

Remove the lug from the central bore hole of the liftingdevice -MP 9-201-.

Place the bolt -arrow 1- back in the central bore holeof the lifting device.

Then insert the bolt -arrow 1- in the spindle of the sup-porting device -MP 9-200-.

Hang the lifting device -MP 9-201- in the lifting eyes atthe front -arrow 2- and rear -arrow 3- on the engine, asshown in the illustration.

Use securing pins on the hooks and rig pins.

Take up the weight of the engine/gearbox unit at thespindles.

Loosen screws -arrows- for engine mount to enginesupport by about 5 turns.

Unscrew screws -arrows- of unit mounting for gearbox-2- from the console -1-.

Move engine/gearbox unit carefully into oblique posi-tion. To do so screw down the left spindle about 50mm on the supporting device -MP 9-200-.

S34-06842

3

MP 9-201

1

MP 9-200

Note

max

min

S10-0149

1

2

S34-0688


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34-7page 6

34

Remove console -1- from the gearbox -arrows A C-.

Remove the engine/gearbox rear connecting screwbelow the right flange shaft.

Remove engine/gearbox connecting screws below.

Insert engine mount -3282- into engine and gearboxjack, e.g.-V.A.G 1383 A-.

The gearbox mount -3282- is aligned for removal of thegearbox 0A8 by using the adjusting plate - 3282/27-.

Align arms of the gearbox mount with the holes in theadjusting plate.

Screw in mounting elements -A-, as shown on the ad-justing plate.

Position engine and gearbox jack below vehicle, ar-row symbol -B- ( 34-7page 6) on adjusting platepoints in the direction of travel/vehicle.

Align the adjusting plate -3282/27- parallel to the gear-box.

Secure the gearbox on the gearbox support -3282-using screw -A-.

For gearboxes with cover in gearbox housing (for firm/loose bearing of the drive shaft) place a nut M10 as aspacer between gearbox and mount onto the screw -A-.

Remove engine/gearbox connecting screw -arrow-.

Press gearbox from engine.

Position the gearbox via the spindles of the gearboxmount -3282- inclined to the left.

After this lower gearbox carefully.

C

1

B

A S34-0689

N34-1052

A

02M

AB

A

N34-1053

3282/27

3282

A

Note


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34-7page 7

34

Transporting the gearbox

Screw down gearbox suspension device -MP 3-478-onto clutch housing.

Adjust supporting arm at slide with locking pin -arrow-.

Number of visible holes = 6

Raise gearbox with workshop crane and gearbox sus-pension device -MP 3-478-.

Place down gearbox, e.g. in a transport container.

Installing

The installation of the gearbox occurs in reverse order.Install engine/gearbox mounting free of stress 1.9/96Engine, Mechanics; Rep. Gr. 10.

Clean splines of drive shaft and apply a thin film ofgrease -G 000 100-.

The clutch plate must slide freely up and down thedrive shaft.

If the gearbox is installed, ensure the intermediateplate between the engine and gearbox is correctly in-stalled.

Check whether the dowel sleeves for centering theengine/gearbox are present in the cylinder block; in-sert if necessary.

Installing engine mounting on engine support 1.9/96 Engine, Mechanics; Rep. Gr. 10.

Assemble exhaust system free of stress 1.9/96 En-gine, Mechanics; Rep. Gr. 26.

Installing starter/cable Electrical System;Rep. Gr. 27.

Check gear oil Chap. 34-8.

Bleed the clutch system Chap. 30-1.

Install assembly carrier Chassis; Rep. Gr. 40; Re-pairing front axle


Fit the drive shaft to the flange shaft

Chassis;Rep. Gr. 40; Repairing front axle

Setting shift mechanism Chap. 34-6.



If the battery earth strap is disconnected and connect-ed, carry out additional operations Electrical Sys-tem; Rep. Gr. 27.

Tightening torques

Gearbox at engine

MP 3-478

S34-0695

Note

N34-1057

A

B 2

4

3

5

3

1


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34-7page 8

34

Pos. A + B - dowel sleeves

Pendulum support to gearbox -screws 1- and assem-bly carrier -screw 2-

Position the screws -1- in the elongated holes of the pen-dulum support in such a way that there is maximum dis-tance between the gearbox and the assembly carrier.

1 - 30 Nm + 90(1/4turn)

2 - 40 Nm + 90(1/4turn)

Replace bolts

Gearbox console -1- to gearbox

When installing the gearbox console, observe the follow-ing mounting sequence:

Screw in all screws -arrows A, B and C- by hand.

Tighten bolt -A- to 40 Nm + 90(1/4turn).

Tighten bolts -B and C- to 40 Nm + 90(1/4turn).

Replace bolts

Gearbox to body

Replace bolts

Pos. Screw Pieces Nm

11) M 12 x 55 2 80

21) M 12 x 70 1 80

32) M 12 x 165 2 80

41) M 10 x 55 2 40

51)

M 10 x 105 1 401) Replace bolts2) additional starter to gearbox

S34-0691

1 2

Note

C

1

B

A S34-0689

1

2

S34-0688

Screws -arrows- 40 Nm + 90

Components TorqueCable support to gearbox 23 Nm

Gearbox shift lever to gearbox 23 Nm

Steering joint to track control arm1)M8

20 Nm + 90

Coupling rod to anti-roll bar 40 Nm

Wheel bolts to wheel hub 120 Nm

Nut for attaching double clamp of ex-haust system

40 Nm

1) Always replace these bolts.


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34

34-8 Inspecting gear oil


Socket wrench insert -T30023-

Gear oil specification Chapter Identification charac-

ters, aggregate assignment, ratios, capacities in00-1

Remove noise insulation -arrows-.

Unscrew plug for inspecting gear oil -arrow-.

The oil is at the correct level if the gear is filled up to the

lower edge of the oil filler hole. Screw in screw -arrow- using a new sealing ring and

tighten to 45 Nm.

If re-filling, do the following:

Unscrew plug -arrow-.

Pour in gear oil up to lower edge of filler hole.

Screw in screw -arrow- using a new sealing ring andtighten to 45 Nm.

Install the noise insulation.

S10-0114

S34-0696


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Disassembling and assembling the gearbox for gearbox as ofgearbox manufacturing date 07.03

Edition 10.03S00.5329.00.20

34-9page 1

34

34-9 Disassembling and as-sembling the gearbox forgearbox as of gearboxmanufacturing date 07.03

Disassembling and assembling the gearbox for gear-box up to gearbox manufacturing date 06.03 (gear-

box identification characters FJW) 6 speedGearbox 02M; Rep. Gr. 34; Disassembling and as-sembling gearbox for vehicles with front-wheel drive

Gearbox overview

1 - Clutch housing

2 - Reverse shaft

3 - Output shaft 5th/6th gear andreverse gear

4 - Slave cylinder with release

bearing5 - Drive shaft

6 - Output shaft gears 1 through4

7 - Differential

8 - Right flange shaft

9 - Flange shaft left

10 - 2nd gear sliding gear

11 - 1st gear sliding gear

12 - 4th gear sliding gear

13 - 3rd gear sliding gear



16 - Reverse gear sliding gear

17 - Gearbox housing

7

6

5

4

3

1

2

9101112

13

14 15 16 17

8

S34-0738


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34-9page 2

34

Summary of components

l - Gearbox housing and gear-shift mechanism - Summaryof components

ll - Drive shaft, output shafts (in-put shafts), differential andgearshift rods - Summary of

components

I

S34-0698

II


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34

Gearbox housing and gearshift mechanism - Summary of components

1 - Conical screw, 33 Nm

2 - Flange shaft with pressurespring


complete Chap. 39-23 - Cap

4 - Circlip

5 - Switch for reversing lights, 20Nm

6 - Gasket ring

always replace

7 - Oil drain plug, 45 Nm

8 - Gasket ring

always replace

9 - Locking screw, 45 Nm

for gearshift shaft10 - 15 Nm + torque a further 90

(1/4 turn)

with captive washer always replace

11 - 15 Nm + torque a further 90(1/4 turn)

without washer always replace

12 - Shift mechanism

disassembling and assem-

bling Chapter 34-12 remove with the gearbox in-

stalled: to do so remove airfilter, battery with battery trayand locking screw item 9

13 - 20 Nm

always replace

14 - O-ring

always replace

15 - Clutch housing

repair Chapter 34-11

16 - Gearbox housing

repair Chapter 34-10

14

1 2 3 4

5

6

7

8

9

10111213

15

16

10

S34-0739


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34-9page 4

34

Drive shaft, output shafts (input shafts), differential and gearshift rods - Summary ofcomponents

1 - Output shaft gears 1 through4

disassembling and assem-bling Chapter 35-3

Fitting position

Fig. 1 in34-9page 5

2 - Gear shift rod with shift forkfor 1st and 2nd gear


3 - Gear shift rod with shift forkfor 3rd and 4th gear


4 - Output shaft 5th/6th and re-verse gear



5 - Gear shift rod with shift forkfor 5th and 6th gear


6 - Gearshift fork reverse gear


7 - Drive shaft


8 - Reverse shaft

with thrust washer removing and installing

34-9page 5

9 - Thrust washer

10 - Breather

Connect to slave cylinder item 14

11 - Clutch housing

12 - Gasket ring for drive shaft

13 - O-ring

always replace pull onto line connection moisten with brake fluid before installing

14 - Slave cylinder with release bearing

15 - 12 Nm

3 pieces always replace

16 - Conical screw, 33 Nm

17 - Flange shaft with pressure spring

removing and installing 34-9

page 5 complete Chap. 39-2

18

1 2 3 4 5 6 7

8

9

10

11

12

13

1415

17

16 S34-0699


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Edition 10.03S00.5329.00.20

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34

18 - Differential

disassembling and assembling Chapter 39-2

Fig. 1: Fitting position of shafts and gear shift rodsin the geabox

1 - Drive shaft

2 - Output shaft gears 1 through 4

3 - Output shaft 5th/6th and reverse gear

4 - Reverse shaft

A - Selector rod 3rd and 4th gear

B - Selector rod 1st and 2nd gear

C - Selector rod 5th and 6th gear

D - Gearshift fork reverse gear

Mounting sequence

Removing and installing the gearbox housing, shiftmechanism, drive shaft, output shafts (input shafts),differential and gear shift rods


Press-on sleeve -MP 3-412-

Multi-purpose tool -MP 3-419-

Adapter -MP 3-419/40-

Supporting bridge -MP 3-425-

Gearbox mount -MP 3-501-

Assembly stand -MP 9-101- Drift pin -3382-

Drift -T10168-

Pressure plate -T40008-

Hot-air blower

Separating device e.g. -Kukko 17/0-

Sealant -AMV 188 200 03-

Catch pan

Removing

Secure gearbox to the assembly support with screws-arrows-.

Remove breather -A- from slave cylinder, to do so pullout retaining clip up to the stop.

Turn the gearbox in the assembly support with the oildrain plug downwards.

Position catch pan underneath.

Drain out gear oil.

2

A B

1 3

C

4 D S34-0700

MP 3-501

MP 9-101A

S34-0731


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34

Remove slave cylinder with release bearing -arrows-.

Put the gearshift shaft in neutral position, while doingso the locating bolt -arrow- must be laid out.

Unscrew the locking screw -1-. Then unscrew screws -3-.

Remove reversing light switch -2-.

Pull the gearshift shaft -4- out of the gearbox housing.

Remove both flange shafts.

Unscrew screws -B-, that serve to secure the gearboxhousing from the clutch housing.

The hexagon bolt -arrow- is located outside the screw-on flange. It is fitted with a washer.

The illustration shows no gearbox mount.

MP 3-501 S34-0547

4

3

2

1

S34-0701

Note


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Interlock the drive shaft, to do so fit the press-onsleeve -MP 3-412- via the drive shaft onto the clutchhousing.

Tighten the separating device -A-, e. g. -Kukko 17/0-behind the splines of the drive shaft.

The reverse side of the separating device must rest onthe press-on sleeve with no play.

Push the rubber through the middle of the cap -1- us-ing a screwdriver -2-

Lever out the cap carefully out of the gearbox housing.

Remove the circlip -C- from the grooved ball bearing ofthe drive shaft as follows:

MP 3-412

A

S34-0732

A

C

B

S34-0734


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Hold one end of the circlip with the screwdriver -A-.

With the 2nd screwdriver -B- lever the other end of thecirclip out of the slot of the grooved ball bearing -ar-row-.

Then move screwdriver -B- around, levering out thecirclip step by step.

Remove the fixing screws -A- for the gearbox housingon the clutch housing.

Screw the Adapter -MP 3-419/40- into the threadedbore of the gearbox housing.

Heat the gearbox housing with the hot-air blower atthe bearing assembly for grooved ball bearing/driveshaft to about 100 C for around 10 minutes.

Remove the gearbox housing from the clutch housing-direction of arrow- using the multi-purpose tool-MP 3-419-.

If necessary carefully release with tyre lever from the pro-jecting housing lands and make sure the sealing surfacesare not damaged in the process.

Remove the separating device -A- and the press-onsleeve -MP 3-412- from the drive shaft.

For the removal of the shafts from the clutch housing asecond mechanic is required.

A

S34-0548

S34-0737

MP 3-419

MP 3-419/40

Note

MP 3-412

A

S34-0732


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Edition 10.03S00.5329.00.20

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Lift the differential -1- with the left hand.

With the right hand lift the output shaft gears 1 through4 together with the gear shift rods -2- -arrow A-.

At the same time the 2nd mechanic lifts the driveshaft, the reverse shaft and the output shaft 5th/6thgear -3- together with the gear shift rods out of theclutch housing -arrow B-.

If necessary the differential can be placed again in theclutch housing after lifting the shafts.

If necessary remove the gasket ring for the drive shaft.

Installing

First insert the drive shaft -1-, the output shaft 5th/6thgear -2- together with gear shift rod -3-, shift fork -4-and reverse shaft -5-.

Then insert the differential -1-.

For further installation of the shafts in the clutch housinga second mechanic is required.

As shown in the figure take the output shaft gears 1through 4 -3- with the gear shift rods -4- in the righthand.

At the same time the 2nd mechanic must slightly liftthe drive shaft, the output shaft 5th/6th gear and re-verse gear -2- together with the reverse shaft.

Now insert the output shaft gears 1 to 4 in -the direc-tion of the arrow-.

The serrations of the drive shaft, output shafts and fi-nal drive/differential must be in mesh.

3

1

2

A

B

S34-0703

Note

3

1 2

5

4 S34-0704

3 4

2

1

S34-0705

Note


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Place the shafts and the differential together with a2nd mechanic in their bearing assembly.

Secure the supporting bridge -MP 3-425- for the driveshaft to the clutch housing.

To provide a clearer illustration, the clutch housing isshown at an angle of 180.

Screw in screw -A- until the drive shaft is lifted slightly.

Heat the gearbox housing with the -Heiluftgeblse-at the bearing assembly for grooved ball bearing/driveshaft to 100 C for around 10 minutes.

Apply sealant -AMV 188 200 03- uniformly on thesealing surface.

Fit gearbox housing and tighten the connectingscrews of the clutch housing/gearbox housing.

Install circlip -1- for grooved ball bearing/drive shaft.

Remove supporting bridge -MP 3-425- for drive shaft.

In case the serrated sleeve for the gearshift shaft hasbeen removed, now drive it in with the drift -T10169-up to the stop of the tool.

Turn the gearbox with the opening for the gearshiftshaft in the assembly support upwards.

A

MP 3-466MP 3-501

MP 3-425

S34-0730

Note

1

S34-0736

MP 3-501

T10169

S34-0733


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Insert the gearshift shaft -1- into the bottom bearing-2- and into the gearshift forks -3-. The cap in the illus-tration is removed for purposes of clear presentation.

Now press the gearshift shaft -1- against the serratedsleeve -2- -direction of arrow- and guide with the shiftfinger -3- through the gearshift forks up to the stop

downwards.

The gearshift cover -4- must be positioned at thesame time parallel to the screw-on surface at thegearbox housing.

The gearshift shaft must slide easily into the selectormovement (upwards and downwards).

If the gearshift cover is positioned obliquely to the screw-on surface, the gearshift shaft is not inserted into the bot-tom bearing.

Tighten screws -3- for the cover/gearshift shaft -4-.

Screw in locking screw -1-, at the same time the lock-ing angle -arrow- must be laid out.

Install reversing light switch -2-.

Install both flange shafts with pressure springs, stopdiscs and conical rings.

2

1 3

S34-0706

2

4

1

3

S34-0707

Note

4

3

2

1

S34-0701


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Drive in the gasket ring for the drive shaft.

Install slave cylinder with release bearing and breath-er.

Shift through all gears.

Drive new cap with drift pin -3382- into the gearboxhousing.

3382

S34-0735


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34-10 Repairing the gearboxhousing

Repairing the gearbox housing for gear-box up to gearbox manufacturing date06.03

Repairing the gearbox housing for gearbox as of gearboxmanufacturing date 06.03 (identification charactersFJW 6 speed Gearbox 02M; Rep. Gr. 34; Repairingthe gearbox housing

Repairing the gearbox housing for gear-box as of gearbox manufacturing date07.03


Drive bushing -MP 3-402-

Multi-purpose tool -MP 3-419-

Pressure plate -MP 3-420-

Thrust piece -MP 3-423-

Guide piece -MP 3-454-

Gearbox mount -MP 3-501-

Pipe section -MP 3-4012-

Assembly stand -MP 9-101-

Drift -T10168-

Drift -T10169- Pressure plate -T10203-

Retaining plate -T30027-

Guide bolts -T30074-

Spindle -T30100-

Interior extractor 14.5...18.5 mm e.g. -Kukko 21/2-

Interior extractor 23.5...30 mm e.g. -Kukko 21/4-

Countersupport e.g. -Kukko 22/2-


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1 - Gearbox housing

if replaced: Setting the out-put shafts and differentialgear Chapter 39-3

2 - Cap

removing Fig. 1 in 34-10page 3

inserting Fig. 2 in 34-10page 3

3 - Oil drain plug, 45 Nm

4 - Gasket ring

always replace

5 - Oil filler plug, 45 Nm

6 - Locking bolt

is pushed into the sliding-block of the gearshift shaftfor setting the gearshiftmechanism Chap. 34-6

can be replaced without dis-assembling gearbox



inserting Fig. 5 in 34-10page 4

7 - Bushing

for selector rods removing Fig. 6 in 34-10

page 5

installing Fig. 7 in 34-10page 5

8 - Serrated sleeve

press out with gearbox disassembled Fig. 8 in 34-10page 5 drive out without disassembling gearbox Fig. 9 in 34-10page 6 inserting Fig. 10 in 34-10page 6

9 - Needle bushing

for reverse shaft replace after each removal removing Fig. 11 in 34-10page 6 installing Fig. 12 in 34-10page 7

10 - Outer ring/tapered-roller bearing for output shaft 5th/6th and reverse gear removing and installing Chap. 35-5 if replaced: Setting output shaft 5th/6th and reverse gear Chap. 35-6

11 - Adjusting washer

for output shaft 5th/6th and reverse gear Setting overview Chapter 39-3

12 - Outer ring/tapered-roller bearing

for output shaft gears 1 through 4 removing and installing Chapter 35-3 if replaced: Setting output shaft gears 1 through 4 Chap. 35-4

13 - Adjusting washer for output shaft gears 1 through 4 Setting overview Chapter 39-3

1 2 318

4

5

6

7

8

7

9

10

11

12

13

14

15

17

16

S34-0708


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for differential removing and installing Chapter 39-2 if replaced: Setting the differential gear Chap. 39-4.

15 - Adjusting washer

for differential Setting overview Chapter 39-3

16 - Bushing for gearshift shaft removing Fig. 13 in 34-10page 7 inserting Fig. 14 in 34-10page 7

17 - Plug

drive out with drift inserting Fig. 15 in 34-10page 8

18 - Gasket ring

for left flange shaft replacing Chapter 39-1

Fig. 1: Removing cap -A-

Push the rubber through the middle of the cap using ascrewdriver -B- and lever out the cap -direction of ar-row-.

Fig. 2: Drive in cap up to the stop

A

B

S34-0709

MP 3-402

S34-0710


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Fig. 3: Removing locating bolt for gearshift shaft

Break off the angle of the bolt in the released position

Insert a screwdriver -A- in the hole of the locating bolt-B-.

Lever out the locating bolt in the -direction of the ar-row-.

Fig. 4: Fitting position of locating bolt

The marking on the locating bolt -arrow- must point to

the connection of the slave cylinder -1-. The angle -a- must be approx. 45.

Fig. 5: Driving in locating bolt for gearshift shaft

The locating bolt -arrow- must be released duringdrive-in procedure.

Driving in locating bolt up to the stop of the tool.

A

B

S34-0711

1

a

S34-0712

T10203

S34-0713


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Fig. 6: Remove bushing for gear shift rod

A - Interior extractor 14.518.5 mm, e.g. -Kukko 21/2-

B - Countersupport, e.g. -Kukko 22/2-

Fig. 7: Drive in the bushing for the shiftrod up tothe stop of the tool.

Fig. 8: Press serrated sleeve -A- out of gearboxhousing

Position the gearbox housing on the pressure plates-MP 3-406- and -MP 3-407- in such a way that thedowel sleeves in the gearbox housing are not dam-aged.

S34-0714

T30027

B

A

T10168

S34-0715

A

MP 3-407MP 3-406

MP 3-454

S34-0716


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Fig. 9: Drive out serrated sleeve without disassem-bling gearbox

Locking screw and gearshift shaft removed.

Turn the gearbox in such a way that the serratedsleeve does not fall into the gearbox.

Drive out serrated sleeve with the guide bolt -T30074-.

Fig. 10: Drive in serrated sleeve

Gearbox housing screwed to clutch housing.

Drive in serrated sleeve with the drift -T10169- up tothe stop of the tool.

Fig. 11: Pull needle bushing for reverse shaft out ofthe gearbox housing

A - Interior extractor 23.530 mm, e.g. -Kukko 21/4-

B - Countersupport, e.g. -Kukko 22/2-

The needle bushing is damaged when removed and mustbe replaced.

T30074

S34-0717

MP 3-501

T10169

S34-0733

S34-0718

T30027

B

A

Note


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Fig. 12: Press needle bushing into the gearboxhousing

Position the thrust washer -B- of the reverse shaftonto the needle bushing -A- during press-in proce-dure.

Support the gearbox housing with a pipe section-MP 3-4012 - directly below the bearing support.

Fig. 13: Remove bushing for gearshift shaft

Hold the spindle -T30100- and turn the nut -B-.

A - Interior extractor 14.518.5 mm, e.g. -Kukko 21/2-

Fig. 14: Driving in bushing for gearshift shaft

Drive in flush the bushing -A- for the gearshift shaft.

MP 3-423

S34-0719

A

B

A

MP 3-419/15

S34-0720

MP 3-420

T30100

B

A

S34-0721

T10168


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34

Fig. 15: Driving in plug

Drive in plug -1- with the mandrel -T30083- to the di-mension -a- = approx. 3 mm below the upper edge ofthe housing.

S34-0722

T30083

1

a


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Repairing the clutch housingEdition 10.03S00.5329.00.20

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34

34-11 Repairing the clutch hous-ing

Repairing the clutch housing for gear-box up to gearbox manufacturing date06.03

Repairing the clutch housing for gearbox as of gearboxmanufacturing date 06.03 (identification charactersFJW 6 speed Gearbox 02M; Rep. Gr. 34; Repairingthe clutch housing

Repairing the clutch housing for gear-box as of gearbox manufacturing date07.03




Drift -T10168-

Pressure plate -T40008-

Interior extractor 14.5...18.5 mm e.g. -Kukko 21/2-

Interior extractor 23.5...30 mm e.g. -Kukko 21/4-

Countersupport e.g. -Kukko 22/2-


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1 - Bushing

for selector rods removing Fig. 1 in 34-11

page 3 inserting Fig. 2 in 34-11

page 3

2 - Shaft for reverse gear shift

fork Shaft cannot be removed

with workshop tools Press shaft into the clutch

housing Fig. 7 in 34-11page 5

3 - Needle bushing

for reverse shaft replace after each removal removing Fig. 3 in 34-11

page 3 installing Fig. 4 in 34-11

page 44 - Fitting sleeve

2 pieces

5 - Clutch housing

if replaced: Setting the out-put shafts and differentialgear Chapter 39-3

6 - Gasket ring for drive shaft


installing Fig. 6 in 34-11

page 47 - Gasket ring

for right flange shaft replacing Chapter 39-1

8 - Washer

for differential Fitting position: the shoulder on the inside diameter points towards the gasket ring i tem 7


for differential removing and installing Chapter 39-2 if replaced: Setting the differential gear Chap. 39-4.

10 - Oil deflecting washer Fitting position: Shoulder on the hole points to the output shaft


for output shaft gears 1 through 4 removing and installing Chapter 35-3 if replaced: Setting output shaft gears 1 through 4 Chap. 35-4


for output shaft 5th/6th and reverse gear removing and installing Chapter 35-5 if replaced: Setting output shaft 5th/6th and reverse gear Chap. 35-6

13 - Washer

for output shaft 5th/6th and reverse gear always 0.65 mm thick

1

S34-0723

2

3

4

1

5

11

10

9

8

4

12 13 14

7 6 16

15


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14 - Cylindrical-roller bearing

for drive shaft removing and installing Chapter 35-1

15 - Magnet

is held in position by the separator surface of the housing

16 - Cap

Fig. 1: Remove bushing for gear shift rod

A

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Fabia Gearbox 0A8