Skoda Octavia Mk1 - 06 - Power Transmission Gearbox 02K

SKODA OCTAVIA
MK1
Power transmission
5 speed Manual gearbox 02K
POWER TRANSMISSION..................................................................................................... 4
5 SPEED MANUAL GEARBOX 02K........................................................................................4
TECHNICAL DATA.............................................................................................................. 4
IDENTIFICATION OF THE GEARBOX.................................................................................................................. 4
Location on the gearbox up to 06.99.................................................................................................4
Location on the gearbox as of 07.99................................................................................................. 6
Identification characters, aggregate assignment, ratios, capacities..................................................7
OVERVIEW OF TRANSMISSION SYSTEM.......................................................................................................... 11
GENERAL REPAIR INFORMATION................................................................................................................... 13
CLUTCH, CONTROL.......................................................................................................... 18
REPAIRING CLUTCH CONTROL...................................................................................................................... 18
Overview......................................................................................................................................... 18
Summary of components - Foot controls......................................................................................... 19
Removing and installing the over-centre helper spring...................................................................22
Removing and installing the clutch pedal........................................................................................ 23
Removing and installing clutch pedal switch -F36-..........................................................................24
Removing and installing the clutch pedal switch -F36- (angular housing).....................................................24
Removing and installing the clutch pedal switch -F36- (round housing).......................................................25
Summary of components - Hydraulics............................................................................................. 25

Check hydraulic clutch control........................................................................................................ 28
Removing and installing the master cylinder..................................................................................30
Removing and installing the slave cylinder.....................................................................................34
Bleeding the clutch system............................................................................................................. 35
REPAIRING CLUTCH................................................................................................................................... 37
Fault finding power transmission - problems with the clutch and clutch control.............................37
Summary of components - repairing the clutch...............................................................................42
Removing and installing clutch....................................................................................................... 44
GEARBOX MECHANICS,OPERATION, CONSTRUCTION,DIFF..................................................48
REPAIRING THE GEARSHIFT MECHANISM........................................................................................................ 48
Fitting location of shift mechanism.................................................................................................. 48
Summary of components - shift housing / shift lever......................................................................50
Removing and installing shift housing with shift lever and shift rod................................................53
Removing and installing shift lever from shift housing....................................................................57
Summary of components - reverse-shift mechanism at the gearbox..............................................58
Setting the shift mechanism............................................................................................................ 63
REMOVING AND INSTALLING THE GEARBOX.................................................................................................... 68
Removing the gearbox.................................................................................................................... 68
Transporting the gearbox............................................................................................................................. 77
Installing the gearbox...................................................................................................................... 78

Tightening torques....................................................................................................................................... 79
INSPECT GEAR OIL.................................................................................................................................... 84

DISASSEMBLING AND ASSEMBLING THE GEARBOX............................................................................................ 86
Gearbox overview........................................................................................................................... 86
Summary of components - disassembling and assembling the gearbox.........................................87
Summary of components - Removing and installing gearbox housing cover and 5th gear.............88
Summary of components - removing and installing gearbox housing and shift mechanism...........90
Summary of components - Removing and installing the drive shaft, output shaft, differential gear
and shift forks................................................................................................................................. 94
Mounting sequence - disassembling and assembling the gearbox..................................................98
Disassembling gearbox................................................................................................................................ 98
Assembling gearbox................................................................................................................................... 110
Repairing gearbox housing and gearshift shaft.............................................................................122
Repairing clutch housing............................................................................................................... 127

Repairing gearbox housing cover.................................................................................................. 134
DISASSEMBLING AND ASSEMBLING THE DRIVE SHAFT.....................................................................................139
Disassembling and assembling the drive shaft.............................................................................139
OUTPUT SHAFT...................................................................................................................................... 150
Disassembling and assembling the output shaft...........................................................................150
Setting output shaft...................................................................................................................... 158
FINAL DRIVE, DIFFERENTIAL, DIFFERENTIAL LOCK..........................................................162
REPLACING THE FLANGE SHAFT GASKET RINGS (GEARBOX ASSEMBLED).............................................................162
Replacing the left flange shaft gasket ring....................................................................................162
Removing................................................................................................................................................... 162
Install......................................................................................................................................................... 163
Replacing the right flange shaft seal ring......................................................................................163

Removing................................................................................................................................................... 164
Install......................................................................................................................................................... 164
DIFFERENTIAL GEAR............................................................................................................................... 166

Disassembling and assembling the differential gear.....................................................................166
Adjusting the differential gear....................................................................................................... 175
SETTING OVERVIEW................................................................................................................................ 180
Power transmission
5 speed Manual gearbox 02K
Technical Data
Identification of the gearbox
Assignment Chapter.
Location on the gearbox as of 07.99

Identification characters and
manufacturing data of the gearbox on the
top of the clutch housing -arrow 1Gearbox 02K -arrow 2-
Location on the gearbox up to 06.99
Identification characters and manufacturing data

of the gearbox on the bottom of the clutch
housing -arrow 1Gearbox 02K -arrow 2-

of the gearbox -arrow 1-
Example:
CZD
I
I
Identification characters
27
I
I
Day
08
I
I
Month
6
I
I
Manufacturing year -1996-
Additional data depend on the manufacturing.

Note
The gearbox identification characters also appear on the vehicle data stickers.
Gearbox 02K -arrow 2-
Location on the gearbox as of 07.99

of the gearbox on the top of the clutch housing
-arrow 1Gearbox 02K -arrow 2-

of the gearbox -arrow 1-
Example:
DUU
I
I
14
I
I
Day
09
I
I
Month
9
I
I
Manufacturing year (1999)
Additional data depend on the manufacturing.

Note
The gearbox identification characters also appear on the vehicle data stickers.
Gearbox 02K -arrow 2-
Identification characters, aggregate assignment, ratios, capacities

Assignment:
Engine
Ratio:
Z
:Z
CZE
DUT
1.6 ltr./55 kW
Final drive
67 : 15 = 4,467
67 : 15 = 4,467
67 : 15 = 4,467
1st gear
38 : 11 = 3,455
38 : 11 = 3,455
38 : 11 = 3,455
2nd gear
35 : 18 = 1,944
35 : 18 = 1,944
35 : 18 = 1,944
3rd gear
36 : 28 = 1,286
36 : 28 = 1,286
36 : 28 = 1,286
4th gear
31 : 33 = 0,939
31 : 33 = 0,939
31 : 33 = 0,939
5th gear
38 : 51 = 0,745
38 : 51 = 0,745
38 : 51 = 0,745
Reverse gear
Speedometer
38 : 12 = 3,167
2,08
Capacity
Specification
DRY
2,14
2,14
1.9 litres
Electronic Catalogue of Original Parts
Gear oil change interval
Filled for life

7
Clutch control
hydraulic
Clutch disc diameter
Drive shaft flange
90 mm
Assignment:
:Z
DLP
Engine
Ratio:
Z
CZD
1.6 ltr./74kW
Final drive
67 : 15 = 4,467
68 : 16 = 4,250
68 : 16 = 4,250
1st gear
38 : 11 = 3,455
38 : 11 = 3,455
38 : 11 = 3,455
2nd gear
35 : 18 = 1,944
35 : 18 = 1,944
35 : 18 = 1,944
3rd gear
37 : 27 = 1,370
37 : 27 = 1,370
36 : 28 = 1,286
4th gear
32 : 31 = 1,032
32 : 31 = 1,032
31 : 32 = 0,969
5th gear
34 : 40 = 0,850
34 : 40 = 0,850
33 : 41 = 0,805
Reverse gear
Speedometer
38 : 12 = 3,167
2,08
2,14
Capacity
Filled for life
Clutch control
hydraulic
Drive shaft flange
90 mm
Ratio:
Z
:Z
2,14
1.9 litres
Specification
Assignment:
DNZ
DUU
Engine
DUV
1.6 ltr./74 kW
DUU
1.6 ltr./75 kW
Final drive
68 : 16 = 4,250
68 : 16 = 4,250
68 : 16 = 4,250
1st gear
38 : 11 = 3,455
38 : 11 = 3,455
38 : 11 = 3,455
2nd gear
35 : 18 = 1,944
35 : 18 = 1,944
35 : 18 = 1,944
3rd gear
37 : 27 = 1,370
36 : 28 = 1,286
37 : 27 = 1,370
4th gear
32 : 31 = 1,032
31 : 32 = 0,969
32 : 31 = 1,032
5th gear
34 : 40 = 0,850
33 : 41 = 0,805
34 : 40 = 0,850
Reverse gear
38 : 12 = 3,167
Speedometer
2,14
Capacity
1.9 litres
Specification
Filled for life
Clutch control
hydraulic
Drive shaft flange
90 mm
Assignment:
Engine
Ratio:
Z
:Z
DUS
DRZ
1.9 ltr./50 kW SDI

68 : 16 = 4,250
68 : 16 = 4,250
67 : 15 = 4,467
1st gear
38 : 11 = 3,455
38 : 11 = 3,455
38 : 11 = 3,455
2nd gear
35 : 18 = 1,944
35 : 18 = 1,944
35 : 18 = 1,944
3rd gear
36 : 28 = 1,286
36 : 28 = 1,286
36 : 28 = 1,286
4th gear
31 : 33 = 0,939
31 : 33 = 0,939
31 : 32 = 0,969
5th gear
37 : 52 = 0,712
37 : 52 = 0,712
33 : 41 = 0,805
38 : 12 = 3,167
Speedometer
2,14
Capacity
1.9 litres
Filled for life
Clutch control
1.4 ltr./55 kW
Final drive
Reverse gear
Specification
DUW
hydraulic
Drive shaft flange
90 mm
10
Overview of Transmission System
Designation
Note
-Arrows- in direction of travel
123456-
Engine
Clutch
Manual gearbox
Drive shaft
Output shaft
Differential gear
-Arrows- in direction of travel
11
III III IV VRAT-
1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse gear
Final drive
Speedometer drive
General repair information

To carry out gearbox repairs successfully and correctly, scrupulous care and cleanliness, as
well as the proper tools, are essential requirements. Obviously, the generally valid basic
safety rules apply to repair work.
A number of generally valid notes for individual repair operations - which are otherwise listed
12
several times at numerous points in the workshop manual - are summarized here.
Gearbox
t
When installing, ensure the dowel sleeves are correctly located between the engine and
gearbox.
t When replacing the gearbox check the oil level and if necessary top up Chapter.
t
t
Filling capacity Chapter.

Specification electronic catalogue of original parts.
O-rings, gasket rings, gaskets, sealant

On gearboxes with paper gaskets:
t
Replace paper gaskets.
On gearboxes with sealants:

Thoroughly clean the housing contact surfaces before applying the sealant.
Apply sealant -AMV 188 200 03- evenly and not too thickly.
Always replace O-rings, gasket rings and gaskets.
After removing gaskets, check the contact surface on the housing or shaft for burrs or
damage which occured during the disassembly.
Lightly oil radial shaft seals at outside
diameter before mounting and fill half the
space between the sealing lips -arrowwith
sealing grease -G 052 128 A1-.
The open side of the sealing rings is turned
towards the fluid to be sealed.
Press in new gasket ring in such a way that
the sealing lip is not located on the same
point as the sealing lip of the old gasket
ring (use tolerance for insertion depth).
Before inserting lightly oil the O-rings, in
order to prevent the rings being squashed
during installation.
Inspect the gearbox oil level and top up if
necessary after replacing the gaskets and
gasket rings Chapter.
Circlips and tensioning sleeves
Do not over-tension the circlips.
Always replace damaged or over-tensioned
circlips.
Circlips must be positioned in the base of
13
the groove.
Replace roll pins. Fitting position: Slot -Alongitudinal to power flow -arrow-.
Screws, nuts
t
Slacken the bolts and nuts against the

tightening sequence.
Slacken and tighten nuts and bolts for

attaching covers and housings without
t
tightening sequence diagonally across in
stages.
Do not twist particularly sensitive parts t e.g. clutch pressure plates - and slacken
and tighten diagonally across in stages.
t
Tightening torques apply for non-oiled

nuts and bolts.
Always replace the self-locking nuts and

screws.
Clean the thread of the screws that are

inserted with a locking agent with a wire
t
brush. Insert bolts with locking agent
-AMV 185 101 A1-.
t The threaded holes into which self-locking
screws or screws with locking agent were
screwed in (e.g. with a screw-tap) must
14
be cleaned. Otherwise there is a risk that

the screws will shear at the next
disassembly.
Bearings
t
Position needle bearing with the lettered

side (thicker end) towards the drift pin.
Fit all bearings to the gearbox with some

gearbox fluid.
Jointly replace tapered-roller bearings on

t the same shaft and use products of the
same manufacturer.
Before installing, heat the inner rings of
the tapered-roller bearings on a heating
plate or with the induction heater unit,
t
e.g. -VAS 6414-, to approx. 100C. When
assembling, press up to the stop until
there is no axial play.
Do not exchange the outer and inner
t rings of bearings of the same size bearings go in pairs.
Shims
Gauge shims at several points with a
micrometer. Different tolerances allow to
t
measure the required thickness for each
washer very precisely.
t
t
Inspect for burrs and damage.

Install only shims which are in perfect
condition.
Synchronizer rings
These are not interchangeable. If ret using, allocate synchronizer rings to the
same gear.
t
t
Inspect for wear, replace if necessary

Electronic Catalogue of Original Parts.
Insert with some gearbox fluid.
Gear pinions and synchronizer body

Clean and heat on a heating plate or with
t the induction heater unit e.g. -VAS 6414to approx. 100C before pressing on.
t When assembling, press up to the stop
15
until there is no axial play.

t
Check fitting position.
Sliding gears
t
Inspect wheels 1st to 5th gear for small

axial play or clearance after installation.
Clutch control
t
When removing gearbox, remove slave

cylinder without opening the line system.
If the slave cylinder with connected

hydraulic line is removed, do not depress
t
the clutch pedal. Otherwise the piston is
pressed out of the slave cylinder.
Do not tilt the clutch pressure plate,
t release or tighten in small stages
crosswise
If the clutch pedal does not return to its
initial position after the coupling
t procedure - clutch pedal in home position
- the clutch system must be bled (further
measures Chapter).
In order to reduce unpleasant odours if
the clutch is burnt, thoroughly clean the
t
clutch housing as well as the flywheel and
the engine on the side of the gearbox.
16
Clutch, control
Repairing clutch control
Overview
Note
If the master or slave cylinder should be replaced due to a suspected defect, first check the
clutch control Chapter.
If the battery earth strap is disconnected and connected, carry out additional operations
Electrical System Rep. Gr.27.
On models fitted with a coded radio set, determine the coding.
t Grease all bearing and contact surfaces with Polycarbamide Grease -G 052 142 A2-.
t
Prior to working on the foot controls remove the storage area on the driver's side Body
Work Rep. Gr.70.
I-
Summary of components - Foot controls Chapter

17
II -
Summary of components - Hydraulics Chapter
Summary of components - Foot controls
1q
2q
3q
4-
Bulkhead
with mount for bracket and master cylinder
Gasket
always replace Electronic Catalogue of Original Parts
Bracket
for support of clutch pedal
Screw
18
5q
Bracket
for support of accelerator pedal and brake pedal
6q
q
7-
25 Nm
self-locking
Connecting plate
8q
q
9-
25 Nm
self-locking
Bushing
10 -
Bearing bolt
11 -
Clutch pedal
removing and installing Chapter
12 q
Support
13 q
q
14 q
25 Nm
self-locking
Master cylinder
15 16 q
17 q
q
18 q
19 -
Tubing
Over-centre helper spring
Bearing/over-helper centre spring
insert in bracket
to replace, remove and install the master cylinder Chapter
Clutch pedal switch -F36removing and installing Chapter
Limit stop yoke
for the clutch pedal
Fitting position Chapter

19
20 -
25 Nm
q
q
self-locking
Removing and installing the over-centre helper spring

Special tools and workshop equipment required
t
Assembly clamps -3317-
Removing
Remove the bottom left storage area on the driver's side Body Work Rep. Gr.70.
Using the clutch pedal stretch the over centre helper spring and while doing so
push down the assembly clamp -3317from above.
Note
The bore hole -arrow- points towards the

clutch pedal.
Position the clutch pedal in home position

and remove the over-centre helper spring
together with assembly clamp -3317-
Install
Put the clutch pedal in home position.
First position the over-centre helper

spring in the over-centre helper spring
bearing -B-, then press the clutch pedal
down until the centering pin of the clutch
pedal -A- touches the over-centre helper
spring.
Using the clutch pedal stretch the overcentre helper spring, while doing so
remove the assembly clamp -3317-.
20
Removing and installing the clutch pedal

Removing
Remove the bottom left storage area on the driver's side Body Work Rep. Gr.70.
Remove clutch pedal switch -F36- (if present) Chapter.
Removing the over-centre helper spring Chapter.
Separate the clutch pedal from the master cylinder Chapter.
Unscrew the nut -A- and pull screw out of

the bracket.
Remove clutch pedal.
Install
Installation is performed in the reverse
order, pay attention to the following points:
The support -A- must

be located on the
actuating rod -B- of
the master cylinder.
Press the clutch
pedal until its locks
in -direction of
arrow- and make
sure it catches
correctly.
Installing the overcentre helper spring

Chapter.
If present, install
clutch pedal switch
-F36- Chapter.
Tightening torque
Component
Nm
21
251)
Clutch pedal to bracket
1)
Always replace nut Electronic Catalogue of Original Parts
Removing and installing clutch pedal switch -F36-
Note
The clutch pedal switch may only be installed once to ensure that it has an adequately tight fit.
Removing and installing the clutch pedal switch -F36- (angular housing)
Press down clutch pedal up to the stop by hand.
Turn clutch pedal switch 90 to the left and

remove from its bracket/clutch pedal -arrows-.
Press down clutch pedal up to the stop by
hand.
Insert clutch pedal switch into the assembly
opening.
Then turn the switch 90 to the right for
securing.
Put the clutch pedal in home position.
The clutch pedal must be in end position.
Removing and installing the clutch pedal switch -F36- (round housing)
Turn clutch pedal switch 45 to the left and remove from the bracket/clutch pedal.
l
l
l
Pull out the tappet -arrow- completely before

assembly of the clutch pedal switch.
Insert the switch with the catch pegs -1- and -2in the recesses provided for it in the assembly
opening and attach by turning it 45 to the right.
The clutch pedal must be put into home position
(do not depress).
The clutch pedal must not be operated when
installing it.
The plunger is adjusted automatically when
inserting the clutch pedal switch.
22
Summary of components - Hydraulics
1-
Brake fluid reservoir
23q
Tubing
Master cylinder
Support
only replace if the master cylinder has been removed
removing Fig.
installing Fig.
5q
Clutch pedal
6q
25 Nm
self-locking
23
q
7q
8q
9q
10 -

Support
Mounted at the structure
Release shaft
Slave cylinder
Collar screw, 25 Nm
11 q
12 q
13 14 15 q
Support
for tube-hose line pos. 12
Tube-hose line
assign according to Electronic Catalogue of Original Parts
Pipe connection/plug connection
Dust cap
Bleed valve
Bleed the clutch system Chapter
16 -
O-ring
pull onto line connection
insert with brake fluid
17 18 -
Clamp
Gearbox
24
Lift off the support -A- in -the direction of

the arrow-.
Push the actuator rod/master cylinder in

the support -A- in -direction of the arrow-.
Check hydraulic clutch control

l The pedal actuation must not be obstructed by moved or additional foot mats.
l
Bleed the clutch system if necessary Chapter.
25
First of all check the brake fluid level in

the brake fluid reservoir.
Note
The clutch hydraulic is connected to one

of the chambers -arrow 2- of the brake
t
fluid reservoir by the return hose -arrow
1-.
t
t
t
If there is no or little brake fluid in this

chamber, there is a leak in the system.
Subsequently check the following
components of the hydraulic clutch
control for external leak:
Return hose between brake fluid reservoir
and master cylinder
Master cylinder
Tube-hose line between master and slave

cylinder
Connection points (plug and screw

connections) also in a non-visible area
Slave cylinder
Note
Symptoms of an external leak are,

amongst others, traces of brake fluid on
t
or below the gearbox, as well as on the
noise insulation under the gearbox.
Check the correct routing of the tubehose line between the master and slave
t
cylinder. The line must not be kinked or
trapped.
Subsequently depress the clutch pedal
carefully, at the same time hold the pedal
in five different positions for approx. 20
seconds over the entire distance the
pedal has to travel. While doing so, a
second person must check if fluid is
leaking from the components of the
hydraulic clutch control Anchor. At the
same time the first person must check if
the clutch pedal falls through on its own
26
while being held.
Remove the slave cylinder from the

gearbox last, - do not open the line
system - and check the collar for brake
fluid leak.
To this end take off the collar from the

tappet -arrow-.
Removing and installing the master cylinder

t
Hose clamps up to 25 mm -MP7-602 (3094)-
Pliers -T10005-
Removing
Note
t
t
If the master cylinder must be replaced, first of all check the hydraulic clutch control
Chapter.
Unscrew the master cylinder from within the passenger compartment.
When performing the following work, make sure that no brake fluid comes into contact with
t the frame side rail or the gearbox. If this is the case, these points must be cleaned
thoroughly.
Remove air filter Engine Rep. Gr.23 or Engine Rep. Gr.24.
If necessary, remove ABS control unit with hydraulic unit Chassis Rep. Gr.45.
27
Disconnect the return hose -A- to the

brake fluid reservoir with the hose clamp
-MP7-602 (3094)- and detach.
Pull clamp -B- out of the master cylinder.
Release and cut off the tube-hose line -Cfrom the master cylinder.
Remove the bottom left storage area on

the driver's side Body Work Rep.
Gr.70.
Remove clutch pedal switch -F36- (if

present) Chapter.
Note
To remove the master cylinder completely

remove the clutch control. Before removing
first separate the master cylinder from the
clutch pedal.
Unlock the actuating rod/master cylinder

from the clutch pedal as follows:
Insert pliers -T10005- in the clutch pedal

recesses.
Press together support in -direction of
arrow- and separate the clutch pedal
from the master cylinder.
28
Unscrew nuts -arrows 1- and remove

connecting plate -arrow A-.
Unscrew the nuts -arrows 2- and remove
the clutch controls -arrow B- together
with the master cylinder.
Turn clutch pedal stop -A- in -direction of

arrow- and remove.
29
Then press the master cylinder up to the

stop in -direction of arrow 1-.
It must not be covered in the upper area

from the bearing for over-centre helper
spring -arrow 2-.
Then swivel the master cylinder in

-direction of arrow 3- out of the bracket.
Install
The support -A- must

be located on the
actuating rod -B- of
the master cylinder.
Press the clutch
pedal until its locks
in -direction of
arrow- and make
sure it catches
correctly.
30
Re-insert stop -A- for the clutch pedal.

Fitting position:
The clamp -arrow- points towards the
master cylinder -B-.
If present, install clutch pedal switch

-F36-.
If removed, install ABS control unit with

hydraulic unit Chassis Rep. Gr.45.
After installing the master cylinder bleed

the clutch system Chapter.
Install air filter Engine Rep. Gr.23 or

Engine Rep. Gr.24.
Tightening torques
Component
Nm
Bracket to bulkhead
251)
Connecting plate to bracket
251)
Master cylinder to bulkhead
251)
1)
Replace nuts Electronic Catalogue of Original Parts
Removing and installing the slave cylinder

t
Hose clamps up to 25 mm -MP7-602 (3094)-
Removing
Remove noise insulation below engine/gearbox.
31
Pull the tube-hose line out of the holder

on the slave cylinder.
Subsequently release the screws -arrowsand remove the slave cylinder from the
release shaft of the gearbox.
Pinch off the tube-hose line to the slave

cylinder with the hose clamp -MP7-602
(3094)-.
Pull out the clamp Item and

subsequently the tube-hose line from the
slave cylinder. Close the line.
Install
Press the clamp Item into the slave

cylinder up to the stop.
Push the tube-hose line into the slave

cylinder until it can be heard to engage.
Grease tappet end with grease for plug

serration of clutch disc -G 000 100-.
Insert the slave cylinder in the release

shaft and screw it onto the gearbox.
After installing the slave cylinder bleed

the clutch system Chapter.
Install noise insulation below

engine/gearbox.
Tightening torque
Slave cylinder to gearbox
25 Nm
Bleedingtools
the clutch
system equipment required
Special
and workshop
Note
t When performing the following work, make sure no brake fluid comes into contact with the
32
gearbox.
t
t
First open the bleeder valve before switching on the bleeding device.
A pre-filling of the system is not necessary!
Before bleeding, the clutch pedal must be pulled back in home position and the brake fluid
reservoir must be filled with brake fluid up to the max marking.
Perform the procedure for bleeding the clutch system intermittently when bleeding the
brake system.
Brake fluid specification Chassis Rep. Gr.00.

Use a bleeder hose (approx. 670 mm long) to bleed.
Then connect the bleeder hose -A- with
the drip bottle -B- of the brake bleeding
device.
Insert the bleeder hose on the slave
cylinder -arrow- and open the bleeder
valve.
Now switch on the bleeding device and
allow approx. 100 cm3 brake fluid to flow
out.
Note
Pay attention to the correct position of the

bleeder hose during the bleeding
procedure.
Shut the bleeder valve.

After completing the bleeding procedure
activate the clutch pedal repeatedly.
33
Repairing clutch
Fault finding power transmission - problems with the clutch and clutch control
Note
Check hydraulic clutch control Chapter.

Before each clutch repair, examine and reconstruct the complaint of the customer. In each
individual case, it must be determined if indeed there are problems with the clutch or the
incorrect setting of the gearshift is cause for complaint.
Fault
Fault type
Clutch pedal does not t

return to initial
position.
Measure
Air in line system.
Line system, master

t cylinder or slave cylinder
leaking.
t
Fault
Membrane spring of the

pressure plate broken.
Fault type
Actuating force Over-centre helper

t
on the clutch
spring defective.
pedal too high.
Clutch release force
increased due to
t
wear of clutch
linings.
Pressure plate with
t wrong spring
identification.
Replace defective component, vent air

from the line system; top up with brake
fluid.
Replace pressure plate.
Measure
Replace over-centre helper spring.
Inform customer (higher release force with

increased wear).
Replace clutch disc, when the distance base/rivet is

below 0.1 mm.
Assign pressure plate according to Electronic

Catalogue of Original Parts.
Mechanical fault at
t the pressure plate or

the clutch disc.
Clutch disc on the
t serration
sluggish/jams.
Vent air from the line system; top up

with brake fluid.
Replace defective parts.
Check serration of the hub for damage (burrs).

Replace the clutch disc if necessary.
Clean the hub and the drive shaft serration from

corrosion and residues of lubricant and grease with
34
grease for plug serration of clutch disc -G 000 100 -.

Move clutch disc back and forth, remove excess
grease.
Clutch push rod and
release plate
t
(pressure plate)
sluggish.
Fault
Clutch
control
noises.
Fault
Fault type
Lightly grease contact points with grease for plug

serration of clutch disc -G 000 100-.
Lightly grease clutch push rod.
Measure
Release bearing
defective.
Centre displacement of
engine/gearbox.
Clutch disk incorrectly

mounted.
Wrong clutch disc

installed.
Replace release bearing.
Check dowel sleeves.
Correct the fitting.
Use the Electronic Catalogue of Original Parts

for the assignment of the clutch disc.
Fault type
Measure
Scratch noises when the

Air in the system, clutch
t
forward or reverse gear is
does not separate fully.
engaged, gearschift jams,
hooks, is sluggish, shifting
not possible, clutch without
operation.
Master cylinder or slave
t cylinder is leaking, line is
leaking.
Check and bleed system, top

up with brake fluid.
Replace defective component,

top up with brake fluid, vent air
from the system.
The travel of the clutch

pedal is not sufficent
t (carpet, foot mat under the
pedal), pedal is not fully
depressed.
t Pressure plate uneven due

to incorrect installation,
clutch disc warped due to
Check components, if
necessary replace, make sure
the centering pins are correctly
35
Inform customer.
improper handling.
fitted.
If afterwards scratching still
occurs, check the serration of
the clutch disc on the drive
shaft for ease of movement, if
necessary carry out gearbox
repair.
Clutch disc too thick.
Lining glued to the flywheel

t (long immobilization time,
high humidity).
Use the Electronic Catalogue

of Original Parts for the
assignment of the clutch disc.
Slightly rub down the friction

surfaces of the clutch lining, if
necessary when corrosion

occurs in a larger area, replace
the component completely.
Clutch disc on the serration

Check the hub for damage, if
sluggish/jams. Corroded hub, necessary replace the clutch
t damaged during assembly.
disc.
Hub profile knocked out on
Remove corrosion from the hub
one side.
and the shaft as well as
residues of lubricant. Lightly
grease shaft with grease for
plug serration of clutch disc
-G 000 100 -.
The stroke of the pressure

t plate is too low (wrong
pressure plate installed).
Move clutch disc back and

forth, remove excess grease.
Check the position of the dowel
sleeves when the hub profile is
knocked out.
Use the Electronic Catalogue

of Original Parts for the
assignment of the pressure
plate.
Displacement of
Before installing the gearbox,
engine/gearbox too large

insert the dowel sleeves.
t (dowel sleeves missing),
support panel of clutch plate Check clutch disc and pressure
plate for damage, if necessary
bent through this.
replace.
The lining is spalled off
because of too high revs
t
(shift back into lower gears
during high speeds).
36
Replace clutch disc. Inform

customer.
When starting, linings are

t spalled off through slipping
for too long a time.
t
Clutch push rod too short

due to wear.
Replace clutch push rod. Check

release bearing, replace if
necessary.
Lightly grease contact points of

clutch push rod to release
bearing with grease for plug

serration of clutch disc
-G 000 100 -.
Fault
Fault type
Load alteration shocks when

pushing the accelerator pedal
down sharply and when the
engine speed drops suddenly.
Measure
Assembly bracket is
too soft.
Inform customer. Use the

Electronic Catalogue of
Original Parts for the
assignment of the hanger.
Irregular engine
running.
Check engine setting, correct.
Clutch disc with

t predamper is built in
against gear rattling.
t
Fault
Clutch slips,
no or poor
acceleration
Inform customer.
Centre displacement of
Test dowel sleeves, replace if
engine/gearbox.
necessary.
Fault type
t
Measure
Wrong clutch disc fitted, wrong pressure

plate installed.
Use the Electronic

Catalogue of Original Parts
for the assignment of the

clutch disc and the pressure
plate.
Clutch disc worn out, burnt, pressure plate
overheated, scoring, pressure plate warped

t through incorrect assembly, contact pressure
of the pressure plate too low, driving error,
natural wear.
t Clutch disc, pressure plate, flywheel - oily.
37
Replace clutch disc.

Inform customer.
Shaft seal of the engine or the gearbox

defective. Grease on the contact surface
through excess greasing of the hub.
t
Clutch disk incorrectly mounted.
Correct the fitting, check

clutch disc, replace if
necessary.
Gasket ring for push rod in the drive shaft

t leaks. Bearing bushing for push rod in the
drive shaft knocked out.
Fault
Fault type
Clutch
t
grabbing,
Air in the system.
t
t
Check bearing bushing for

clutch push rod, replace if
necessary.
Clean pressure plate,
flywheel.
Measure
unit
shaking
t
Replace gasket ring, clutch

disc.
Engine does not run clean.
Driving error, speed too low when

starting.
Wrong clutch disc installed.
Bleed system, check brake fluid level,

check system for leaks.
Replace defective part.
Check engine setting, correct.

Inform customer.
Use the Electronic Catalogue of Original

Parts for the assignment of the clutch disc.
Assembly bracket too soft, knocked

Use the Electronic Catalogue of Original
out.
Parts for the assignment of the assembly
bracket.
Clutch lining oily, contact surface of

Check shaft seal of the drive shaft for
t pressure plate and flywheel oily (oil clutch or check crankshaft, if necessary
leakage from the clutch housing).
replace.
Replace clutch disc, clean pressure plate

and flywheel.
Drive schaft too heavily greased

Clean pressure plate and flywheel free of
t (traces of grease on the clutch disc,

grease, replace in the event of damage
pressure plate and flywheel).
(traces of wear, overheating, grooves).
Remove traces of grease from hub and
shaft, grease shaft lightly with grease for
38
plug serration of clutch disc -G 000 100-.
Fault
Move clutch disc back and forth, remove

excess grease.
Fault type
Acoustic load alteration

shock clicking when
t
coupling (release clutch
pedal).
Measure
Carrier earth/drive shaft is accelerated with sudden

coupling. The drive shaft serration of the pinions in
mesh knocks; for clutch discs with predamper the
noise increases as the predamper reaches the stop.
Fault
Fault type
Measure
Noises
in idle.
t Torsional damper spring broken.
Clutch disc fitted without predamper

(idle rattling).
Pressure plate warped, broken,

imbalance.
Irregular engine running.
The displacement of the engine to the

t gearbox is too large (dowel sleeves are
missing).
t Intermediate plate rubs on the flywheel.
Inform
customer.
Replace clutch disc.
Use the Electronic Catalogue of

Original Parts for the assignment of the
clutch disc.
Check engine setting, correct if

necessary.
Before installing the gearbox, insert the

dowel sleeves.
Insert intermediate plate on sealing

flange and push onto the dowel sleeves.
Summary of components - repairing the clutch

t
Grease for the plug serration of the clutch disc -G 000 100Note
t Before replacing the clutch disc and pressure plate fault finding power transmission 39
observe complaints of the clutch and clutch control Chapter.

t
If the dowel sleeves are not present, this can result in difficulties to shift, clutch problems
and if necessary noises from gearbox (gear rattling).
t Replace the clutch discs and pressure plates if the riveting is damaged or loose.
t
Assign the clutch disc and the pressure plate according to the Electronic catalogue of
original parts and engine identification characters.
Assemble the clutch in such a way that the centering pins in the flywheel grip in the
t centering holes or the centering slots in the pressure plate. Otherwise TDC is no longer
correct on the flywheel.
1q
2q
q
Screw, 20 Nm
Release or tighten gradually and crosswise
Flywheel
removing and installing Engine Rep. Gr.13
make sure the centering pins are tight
40
q
q
The locating face for the clutch lining must be free from grooves, oil and grease
The insertion depth of the TDC sender must be adapted to the various sizes of the
flywheels. Therefore two screw plugs in the clutch housing marked in different colours.
Assignment Chapter
3-
Clutch disc
q
q
center Chapter
Diameter Electronic Catalogue of Original Parts
4q
Clutch push rod

grease in the area of the bearing bushing in the drive shaft
5-
Retaining loop
6-
Release plate
q Apply a very thin layer of grease for plug serration of clutch disc -G 000 100- to the contact
surface and support for the clutch push rod.
7q
Fixing screw of pressure plate at crankshaft

removing and installing Engine Rep. Gr.13
8-
Intermediate plate
9q
q
q
Pressure plate
Distortion of the inner pressure plate - max. 0.2 mm
Replace the pressure plate if the riveting is damaged or loose
Removing and installing clutch

t
t
t
t
Grease for the plug serration of the clutch disc -G 000 100Counterholder -MP1-221 (VW 558)Locating disc -T10268Centering device -MP2-400-
Removing
Removing the gearbox Chapter.
41
Remove flywheel, to do so lock with

counterholder -MP1-221 (VW 558)-.
Remove clutch disc.
Lever and remove the retaining ring -Afor the release plate -B- out of the holes
using a screwdriver -arrows-.
Remove release plate -B-.
Unscrew pressure plate, to this end lock

counter holder -MP1-221 (VW 558)- at
pressure plate with screw -A-.
Remove pressure plate and intermediate
plate.
Install
Position pressure plate.
Fit the intermediate plate.
42
Fitting location of intermediate plate: The

raised part -arrow- points away from the
pressure plate.
Note
Insert new fixing screws.

Tighten the fixing screws, to this end lock
the pressure plate with the counter
holder -MP1-221 (VW 558)- as for the
removal.
Insert release plate -B- and fasten with

retaining ring -A- at pressure plate. Insert
both ends of the wire into the holes of
the pressure plate -arrows-.
Apply a very thin layer of grease for plug
serration of clutch disc -G 000 100- to the
splines of the clutch disc. Subsequently
move the clutch disc up and down on the

drive shaft of the gearbox until the hub
fits smoothly on the shaft. Remove all
excess grease.
Position clutch disc with flywheel at

pressure plate.
Insert locating disc -T10268- and

alternatively tighten fixing screws for
flywheel crosswise.
Tightening torques Chapter.

Note
43
On certain vehicles the previous centering

device -MP2-400 (3178)- can also be used.
Lock flywheel for tightening the fixing

screws using the counter holder -MP1221 (VW 558)- as for the removal.
Installing the gearbox Chapter.
44
Gearbox mechanics,operation, construction,diff.

Repairing the gearshift mechanism
Fitting location of shift mechanism

The coupling rod -C- serves as countersupport for the selector movements
Double arrow -A- shift movement
Double arrow -B- selector movement
A-
Gear shift rods for shift movement
B-
Coupling rods for selector movement
45
Note
On models fitted with a coded radio set, determine the coding.
Disconnect earth strap at battery before carrying out work on the shift mechanism in the
engine compartment Electrical System Rep. Gr.27.
When the battery is reconnected, pay attention to the work after connecting the battery
I-
Grease all bearing and contact surfaces with grease -G 000 450 02-.
Summary of components - shift housing / shift lever Chapter
II - Summary of components - reverse-shift mechanism at the gearbox Chapter

Removing and installing shift housing Chapter.
Setting the shift mechanism Chapter.
46
Summary of components - shift housing / shift lever

Note
Grease all bearing and contact surfaces with grease -G 000 450 02-.
1q
q
Gearshift knob
removing and installing together with the collar Pos. 2
removing Fig. and Fig.
2q
q
q
q
3-
Collar
removing and installing together with the gearshift knob Pos. 1
removing Fig. and Fig.
Separate collar from gearshift knob Fig.
before installing, assemble with gearshift knob Fig.
Sound absorption
47
q
4q
q
5q
q
q
q
6q
789q
10 q
q
only for vehicles fitted with a 1.9 litre/50 kW engine

Clamping sleeve
connects collar with gearshift knob
removing and installing Fig.
Open warm-type clamp
for securing the gearshift knob to the gearshift lever
open Fig.
attach with hose binding claw -V.A.G 1275- onto the gearshift knob
Shift lever
removing and installing from shift housing Chapter
Spacer bush
Collar screw, 25 Nm
Shift housing
Gear shift rod
after installing set shift mechanism Chapter
11 -
20 Nm
12 -
25 Nm
13 -
Pressure spring
14 q
Stop
after installing set shift mechanism Chapter
15 q
16 q
17 18 19 -
25 Nm
Coat thread with locking agent -D 000 600 A2Ball socket
removing Chapter
Bushing
Shock absorber
15 Nm
48
Remove gearshift knob and collar
Pull out the collar for the shift lever

towards the top -arrows-.
Open the open warm-type clamp -arrowand pull off gearshift knob together with
the collar.
49
Separate gearshift knob from collar and

assemble with collar
Turn collar inside out.

Lever off clamping sleeve -arrowwith
screwdriver.
Detach clamping sleeve from shift lever.
Turn gearshift knob inside out and detach

from collar.
Install
Turn collar inside out.

Insert gearshift knob into collar.
Push clamping sleeve over gearshift

knob and collar.
Press together clamping sleeve until it

clicks into place.
Removing and installing shift housing with shift lever and shift rod
t
Hose binding claw -V.A.G 1275-
Removing
50
Pull out the collar for the shift lever

towards the top -arrows-.
Pull the collar upwards over the gearshift

knob.
Open the open warm-type clamp -arrowand pull off gearshift knob together with
the collar.
Remove sound absorption Item, if
present.
51
Release fixing nuts -arrows-.
Release clamping sleeve -arrow A- and

separate the exhaust system.
Remove the cross member -B- below the

exhaust system.
Remove heat shields -arrow C and D-.
52
Loosen warm-type clamp -arrow-.

Separate the connection of the shift
rod/selector lever.
Release both lower fixing screws for the

shift housing.
Lower shift housing and pull out

complete with shift rod to the rear.
Install
Align the shift housing parallel to the

vehicle body.
The distance to the vehicle body must

then be the same on both sides.
Assemble exhaust system Engine

Rep. Gr.26.
Cross member to body Engine Rep.

Gr.26.
Attach new warm-type clamp -arrowwith hose binding claw -V.A.G 1275- onto
the gearshift knob.
Tightening torques
Shift housing to body
screw M8
25 Nm
Shift housing to body

nut M8
25 Nm
Shift rod to selector lever
25 Nm
53
Removing and installing shift lever from shift housing

Removing
Remove shift housing Chapter.
Release screw -arrow- and remove shift

rod from shift lever.
Unscrew screw -1- and remove bushing

-2- with shock absorber -3-.
Unscrew screws -arrows- for stop -4-.
54
Press in hooks of the (6 pieces) ball

socket -arrows- using a screwdriver and
carefully pull shift lever out of the shift
housing towards the top.
Press off ball socket in -direction of

arrow- from the shift lever.
Installing:
Installation is carried out in the reverse
order.
Note
Install shift housing Chapter.
t Setting the shift mechanism Chapter.
Tightening torques
Shift rod to shift lever
20 Nm
Stop for shift lever to shift housing
25 Nm
Summary of components - reverse-shift mechanism at the gearbox

Note
Grease bearing and friction surfaces with grease -G 000 450 02-.
55
1q
q
q
2q
20 Nm
self-locking
Shift lever on gearbox
Gearbox shift lever
only fits in one position on the gearshift shaft
3-
Gasket ring
4-
Selector rod
5-
Shift rod - front
6q
q
q
Console
with relay lever and intermediate lever
Removal and installation of relay lever and intermediate lever Fig.
Modification as of 08.98 new console Fig.
56
q
78-
Installation of the new console on the gearbox up to 07.98 Fig.

Coupling rod
Shift rod with balancing weight
9q
Shield
is fitted on the selector lever
10 q
11 -
Screw
for warm-type clamp Pos. 11 to shift rod Pos. 13
12 -
Plug
13 -
Gear shift rod
14 -
Collar nut, 20 Nm
q
q
self-locking
for warm-type clamp Pos. 11 to shift rod Pos. 13
15 -
Selector lever
16 q
q
Bracket
with guide shaft
Removal and installation of the guide shaft Fig.
17 -
Shield
18 -
25 Nm
19 -
25 Nm
Console to gearbox
20 -
Gearbox
Removing and installing relay lever and

intermediate lever
4-
Console
57
56-
Bearing bushing; must lock in the

console
Reversing lever
New console for relay lever and

intermediate lever as of 08.98
The new console -1- is located in the
rubber grommets -2- and the bearing
bushings -3-.
Console with larger location holes for
1 - the rubber grommets and the bearing
bushings
2345-
Rubber grommet
Bushing
Hexagon screw M8 x 135
Hexagon nut M8; always replace
Installation of the new console on the

gearbox up to 07.98
Fit a chamfer with a depth of 2.5 mm on

the gearbox -arrow-.
Dimension -a- = 20 mm
Thus, it is excluded that the coupling rods

can touch the gearbox when engaging the
2nd and 4th gear.
Removing
and installing
1
Cap guide shaft
3-
Bushing
58
4-
Ball; press off using a screwdriver; press

out up to the stop
56-
Bracket
Reversing lever
Setting the shift mechanism

t
Shift lever gauge -3421Note
The following are required for correct setting of the shift mechanism:
t Operating and transmission elements of the shift mechanism are in perfect condition.
t
t
l
Shift mechanism operates freely.

Gearbox, clutch and clutch control must be in perfect condition.
Gearbox in Neutral.
Remove gearshift knob with collar Chapter.
Loosen warm-type clamp -arrow-. The

shift rod/selector lever should move
freely.
59
Remove the bushing -3- from the shift

lever Anchor.
Slacken screw -1- and -2- and on the
right side press downwards to the stop
-arrow-. Tighten screw again -1-.
Position shift lever gauge -3421-, for this

step move shift lever completely to the
right (into the gate).
Press shift lever to the left into the

support of the shift lever gauge -3421-.
After this align shift lever and selector

lever free of stress.
Note
Make sure that no gear is engaged at the

gearbox (neutral position).
60
Tighten nut -arrow- for warm-type clamp

to 20 Nm and take out shift lever gauge
-3421-.
Install bushing for shift lever Chapter.
Depress clutch.
Engage reverse gear.
Release screw -1-.

Note
Then press down the left side of the stop

-direction of arrow-.
Tighten screws-1- and -2- to 25 Nm.
Take out reverse gear.

Depress clutch.
Shift through all gears several times. Pay
particular attention to proper operation
of the reverse gear lock.
If a gear catches when repeatedly

engaging, proceed as follows:
Engage 1st gear.
Eliminate the play in the shift mechanism

by carefully pressing the shift lever to the
left.
61
l The distance -a- must then be 2.0 mm
If this is not the case, carry out fine

adjustment.
Fine adjustment
l
Shift lever must be positioned in Neutral

in the gate of 3rd/4th gear.
Slacken screws -1- and -2- only so far so

that the stop remains in a new position
when adjusting.
Engage 1st gear.
Eliminate the play in the shift mechanism

by carefully pressing the shift lever to the
left.
Set dimension -a- (2.0 mm) by carefully

adjusting the stop.
Tighten again the screws -1- and -2- in

this position to 25 Nm. Thus, hold stop
and shift lever in the correct position.
Install gearshift knob with collar

62
Chapter.
Removing and installing the gearbox

t
Alignment rails -MP3-457 (VW 457)- (change Anchor)
Supporting device for engine -MP3-470 (3300 A)-
Gearbox attachment device -MP3-478 (3336)-
Supporting device -MP9-200 (10-222A)-
Gearbox mount -3282-
Adjusting plate -3282/5-
t
t
Grease for the plug serration of the clutch disc -G 000 100Hexagon screw M8 x 25
Change alignment rail -MP3-457 (VW 457)
The alignment rail -MP3-457 (VW 457)- is required when removing and installing the
gearbox.
An additional hole -arrow- is necessary for

attaching the alignment rail -MP3-457 (VW
457)- to the assembly carrier.
Dimensions in mm.
If this hole is not yet present, a hole of

8.5 mm -arrow- must be drilled into the
alignment rail -MP3-457 (VW 457)-.
Removing the gearbox

Note
be fitted again in the same location when the gearbox is installed again.
On models fitted with a coded radio set, pay attention to the coding.
63
Disconnect the earth strap from the battery with the ignition off.
For vehicles with 1.6 l/74 kW and 1.9 l/50 kW engine:
Detach air guide hose -1- and unplug

connector -2- from air mass meter.
For vehicles with 1.9 litre/50 kW engine:
Remove the air hose -3- from the air

filter.
For vehicles with 1.6 l/74 kW and 1.9 l/50

kW engine:
Remove the complete air filter housing,

to do so release bolts -4- and -5-.
Remove air filter -arrows- and lay

aside.
Up to gearbox manufacturing date 02

08 8
64
Unplug connector from reversing light

switch -F4--arrow-.
As of gearbox manufacturing date 03 08 8
Unplug plug of the reversing light switch

-F4--arrow 3-.
Vehicles with 1.4 ltr. engine
Remove the bracket for the wiring of the

lambda probe -arrow 1-, to this end
release the fixing screw -arrow 2-.
Continued for all vehicles
Lever off front shift rod -1- from shift

lever -2- with screwdriver, remove lock
washer -3- and remove console -4upwards.
Separate console -4- by turning 90 to
the right from the shift rod with mass
damper -5-. Swing shift rod with mass

damper to the top and remove from
bracket -6-.
Use a screwdriver to lever off the long

coupling rods from the selector lever
-arrows-.
Unscrew the gearbox shift lever -1- from
65
the gearbox.
Release screws -2- and remove control

console -3- with coupling rods and
gearbox shift lever from gearbox.
Unscrew the slave cylinder from the

gearbox -arrows- place to the top and
secure with wire, do not open the line
system.
Note
Do not depress the clutch pedal.
Remove the earth strap from the

engine/gearbox connecting screw -1-.
Unscrew cable clip -3- at top starter

-arrow- and lay aisde.
Release top fixing screw -2- for starter.
Release all connecting screws of the

engine/gearbox accessible from the top.
66
Install supporting device -MP9-200 (10222A)-.

Note
When installing the lifting hooks of the

supporting device, pay attention to hose
and cable connections in the area of the
lifting eyes to avoid damaging them with
the engine.
Slightly raise the engine/gearbox unit via

the spindles of the supporting device
-MP9-200 (10-222A)-.
Unscrew bracket for PAS line from the

double screw -arrow 1-.
Unscrew the fixing screws -arrows 2from the gearbox mount.
Remove gearbox console from gearbox

-arrows 3- and -arrow 1-.
Unplug plug of the speedometer sender

-G22--arrow 4-.
Remove all other electrical connections

and earth cables from the gearbox and
from the fixing screws for the
engine/gearbox.
67
Remove noise insulation completely. To

this end unscrew screws -arrows-.
Remove the left wheelhouse liner Body

Work Rep. Gr.66.
Remove the starter Electrical System

Rep. Gr.27.
If present, remove heat shield for drive

shaft from the engine -arrows-.
Turn wheels to full left.

Remove drive shafts from flange shafts
and tie up as far as possible; do not
damage the surface protection.

kW engine:
68
Remove small cover plate -A- for flywheel

behind the right flange shaft -arrows-.
Unbolt pendulum support -arrows-.
Unscrew rear engine/gearbox connecting

screw -arrow A-.
Remove catalytic converter 1.6 l/74 kW

Engine, Mechanics Rep. Gr.26.

kW engine:
69
Release clamping sleeve -A- and

separate the exhaust system.

Separate front exhaust pipe from
catalytic converter, to do so unscrew
nuts -arrows-.
Unbolt pendulum support Anchor,

figure A34-0059.
70
Unscrew rear engine/gearbox connecting

screws -A and B- and remove small cover
plate fo flywheel -C-.
Note
Pay attention to the correct fitting position

of the cover plate when installing.
Continued for all vehicles:
Tighten the alignment rail -MP3-457 (VW

457)- on both threaded holes for the
fixing screws/pendulum support at
assembly carrier.
Spacer washers with a total thickness of
6 mm must then be inserted between the
assembly carrier and the alignment rail
-MP3-457 (VW 457)-.
-A- 2 hexagon screws M8 x 25
Insert supporting device for engine -MP3470 (3300 A)- and tighten -arrows-.
Carefully press engine/gearbox forward.

Note
Observe PAS line.
Complete the gearbox jack with gearbox

mount -3282-, adjusting plate -3282/5for 020 gearbox and mounting
elements as follows:
Position adjusting plate -3282/5- onto

gearbox mount -3282-. (Adjusting plate
fits in one position only).
Align arms of the gearbox mount to

match the holes in the adjusting plate.
Screw in the mounting elements -A- as

shown on adjusting plate.
71
Position gearbox jack below vehicle,

arrow symbol -B- ( Anchor, Fig. V342577) on adjusting plate points in the
direction of travel/vehicle.
Align adjusting plate parallel to the
gearbox and lock securing mount at
gearbox.
Remove the bottom fixing screws for the

engine/gearbox.
Press gearbox off the engine and swivel

towards the assembly carrier.
Change the gearbox position at the

spindles of the gearbox mount -3282when lowering.
Note
Observe PAS line when lowering the

gearbox.
Transporting the gearbox
Screw down gearbox suspension device -MP3478 (3336)- onto clutch housing.
72
Adjust supporting arm at slide with locking pin

-arrow-.
Number of visible holes = 8.
Raise gearbox with workshop crane and
gearbox suspension device -MP3-478 (3336)-.

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

The installation of the gearbox occurs in reverse order. Install engine/gearbox mounting free
of stress Relevant Engine, Mechanics; Rep.-Gr. 10.
Note
If the gearbox is replaced, if provided always refit the gearbox shift lever and the console for
the shift mechanism Chapter.
Clean spline of drive shaft and apply a thin film of grease for the plug serration of the clutch
disc -G 000 100 -.
Check whether the dowel sleeves for centering the engine/gearbox are present in the
t cylinder block; insert if necessary. If the dowel sleeves are not present, this can result in
difficulties to shift, clutch problems and perhaps noises from the gearbox (gear rattling).
t If the gearbox is inserted, ensure the intermediate plate is correctly installed.
t
Install the drive shafts on the gearbox Chassis Rep. Gr.40.
Installing starter and cable Electrical System Rep. Gr.27.
t
t
t
t
Check gear oil level Chapter.

Adjust assembly bracket Engine Rep. Gr.10.
If the battery earth strap is disconnected and connected, carry out additional operations
Tightening torques
73
Gearbox to engine
Vehicles with 1.6 ltr./55 kW
engine
Position
Screw
Qty
Nm
M12 x 55
80
M12 x 55
80
M12 x 120
80
M12 x 55
80
6,7
M10 x 50
45
M12 x 35
20
M12 x 55
80
2,3
4
1)
1)
A
1)
Dowel sleeves for centering
Screw with threaded pin M8
74
Gearbox to engine
Vehicles with 1.6 ltr./74 kW and 1.6 ltr/75
kW engine
Position
Screw
Qty
Nm
M12 x 65
80
M12 x 65
80
M12 x 140
80
5, 6, 7
M10 x 50
45
M12 x 80
80
1)
3,4
1)
A
1)
Gearbox to engine
Vehicles with 1.9 ltr./50 kW engine
Position
Screw
Qty
Nm
M12 x 55
80
75
1)
M12 x 55
80
M12 x 140
80
5, 6, 7
M10 x 50
45
M12 x 55
80
3,4
1)
A
1)
Gearbox to engine
Vehicles with 1.4 ltr./55 kW
engine
Position
Screw
Qty
Nm
M12 x 65
80
M12 x 65
80
M12 x 140
80
M12 x 65
80
6,7
M10 x 50
45
M12 x 35
20
M12 x 65
80
2,3
4
1)
1)
A
1)
76
Gearbox to body
Replace screws -A- and -B-.
Screws -A-
60 Nm 901)
Screws -B-
40 Nm 901)
1)
90 corresponds to a quarter turn.
Component
Tightening torque
Cover plate for flywheel
10 Nm
Slave cylinder to gearbox
25 Nm
Console for shift mechanism on gearbox up to 07.98
25 Nm
Console for shift mechanism on gearbox as of 08.98

Shift rod to gearbox
1)
1)
Gearbox shift lever to gearbox
25 Nm
20 Nm
1)
20 Nm
Drive shaft to flange shaft
Chassis Rep. Gr.40
Pendulum support
Engine Rep. Gr.10
Heat shield of drive shaft to engine
Chassis Rep. Gr.40
1)
Replace nut Electronic Catalogue of Original Parts
77
Inspect gear oil

Gearbox oil specification Electronic Catalogue of Original Parts.
Turn steering to full left lock.
Remove the left noise insulation, if present, below the engine/gearbox Body Work
Rep. Gr.50.
Unscrew screw -arrow- for inspecting

gear oil.
The gear oil level is at the correct level if

the gear is filled up to the lower edge of
the oil filler hole.
Screw in plug -arrow-.
Tightening torque
Oil filler plug
25 Nm
If re-filling, do the following:
Release screw -arrow-.

Pour in gear oil up to lower edge of filler hole.
Start engine, engage a gear and allow gearbox to rotate for about 2 minutes.
Switch off engine and unscrew plug -arrow-.
Pour in gear oil again up to lower edge of filler hole.
Tightening torque
Oil filler plug
25 Nm
Install the left noise insulation, if present, below the engine/gearbox Body Work Rep.
Gr.50.
78
Disassembling and assembling the gearbox

Gearbox overview
1q
2q
3-
Clutch housing
repairing Chapter
Differential gear
disassembling and assembling Chapter
Output shaft
disassembling and assembling

4q
567-
Drive shaft
1st gear
Reverse gear
2nd gear
79
8-
Cover for gearbox housing
repairing Chapter
9-
5th gear
10 -
4th gear
11 -
3rd gear
12 -
Gearbox housing
Summary of components - disassembling and assembling the gearbox

Mounting sequence - disassembling and assembling the gearbox Chapter
I - Summary of components - Removing and installing gearbox housing cover and 5th gear
80
Chapter
II -
Summary of components - removing and installing gearbox housing and gearshift shaft
Chapter
III -
Summary of components - Removing and installing the drive shaft, output shaft,
differential gear and shift forks Chapter
Summary of components - Removing and installing gearbox housing cover and 5th gear
1-
25 Nm
M8 x 62
4 pieces
2-
Screw cap

81
installing Anchor
3q
q
25 Nm
M8 x 85
2 pieces, one screw is located under the screw cap Pos. 2
4-
repairing Chapter
5q
Sliding sleeve/synchronizer body for 5th gear with stop ring

6-
Circlip
q always replace damaged or over-tensioned circlips Electronic Catalogue of Original Parts

78q
9q
10 q
11 q
Thrust washer
Gear pinion for 5th gear
Fitting position: groove to the top
Lock washer
5th gear shift fork
adjust Anchor
M17 x 1, 150 Nm
self-locking
new screw is micro encapsulated (thread with locking agent)
to release or tighten the screw observe mounting sequence Chapter
Summary of components - removing and installing gearbox housing and shift mechanism
82
1-
Oval-head countersunk screw, 15 Nm
M7 x 23
4 pieces
for tensioning plate/grooved ball bearing to gearbox housing
2q
3q
20 Nm
for shaft/reverse gear
Gearbox housing
repairing Chapter
q as of gearbox manufacturing date 03 08 8 with additional threaded bore for the reversing
light switch -F4 - Pos. 9
q Assembly of a gearbox housing with an additional threaded bore on gearboxes up to
gearbox manufacturing date 02 08 8 Fig.
4-
Screw cap, 50 Nm
83
5-
O-ring
6-
Pressure spring
presses gearshift shaft and shift lever into the 3rd and 4th gear gate
7-
Gearshift shaft
8-
25 Nm
M8 x 35
2 pieces
screw in below the locking screw Pos. 11 or Pos. 10
9-
Reversing light switch -F4-, 23 Nm
installed as of gearbox manufacturing date 03 08 8
coat with sealant -AMV 188 200 03-
10 q
Locking screw, 40 Nm
for gearshift shaft
11 q
Reversing light switch -F4- and locking screw for gearshift shaft, 23 Nm
installed up to gearbox manufacturing date 02 08 8
q as of gearbox manufacturing date 03 08 8, the reversing light switch -F4- Pos. 9 and the
locking screw Pos. 10 are two components Fig.
q
12 q
Circlip
holds the conical ring, stop disc and pressure spring in position when the flange shaft is
removed
13 q
q
14 q
Conical ring
with slots for thrust washer catch
Fitting position: Cone towards differential gear housing
Thrust washer
Fitting position: Collar to pressure spring, leg (if present) to conical ring
15 -
Pressure spring
16 -
Flange shaft left

84
17 -
Conical screw, 25 Nm
18 -
25 Nm
M8 x 52
12 pieces
19 q
5 Nm
Fixing screw for speedometer drive Pos. 21
20 21 -
Support
Drive for speedometer
22 q
O-ring
As of gearbox manufacturing date 03 08 8,

the reversing light switch -F4- and the
locking screw for the gearshift shaft are
two components:
t
Reversing light switch -F4--1-
t Locking screw for the gearshift shaft -2Tightening torques
23 Nm
Locking screw -2-
40 Nm
An additional threaded bore was made in the gearbox housing for the new reversing light
switch -F4--arrow-.
85
Assembly of a gearbox housing with an

additional threaded bore on gearboxes up
to gearbox manufacturing date 02 08 8
Close the additional threaded bore

-arrowwith a screw M12 x 1.5.
Then screw in a previous locking screw

with the reversing light switch -F4--2- into
the gearbox housing instead of the new
locking screw for the gearshift shaft.
Tightening torques
23 Nm
Hexagon screw M12 x 1.5 -1-
25 Nm
Summary of components - Removing and installing the drive shaft, output shaft, differential
gear and shift forks
86
1-
Circlip
q always replace damaged or over-tensioned circlips Electronic Catalogue of Original Parts

2q
4th gear pinion

Fitting position Anchor
3q
q
4-
Circlip
for 3rd gear pinion
Determining thickness again Anchor
3rd gear pinion
Fitting position Anchor
Set axial play Anchor
5-
2nd gear sliding gear
6-
Needle bearing
for 2nd gear

87
Pull off inner ring Chapter
Press on inner ring Chapter
7-
Sliding sleeve with 1st and 2nd gear synchronizer body
8-
1st gear sliding gear
9-
Thrust washer
10 11 q
25 Nm and torque a further 90

Bearing support
with outer ring/tapered-roller bearing large and stop for reverse gear
12 q
Output shaft complete

13 q
Differential gear
14 q
Gasket ring
for right flange shaft
do not remove for disassembling and assembling the gearbox
replace Chapter
15 q
removed
16 q
q
17 q
18 q
19 q
20 q
Circlip
Conical ring
Thrust washer
Fitting position: Collar to pressure spring, leg (if present) to conical ring
Pressure spring
for flange shaft
Right flange shaft
for attaching the flange shaft
88
21 -
Clutch push rod
22 -
Clutch housing
repairing Chapter
23 -
Reverse gear wheel
24 -
Reverse shaft support
25 -
Drive shaft
Press off grooved ball bearing -arrow- before installing Chapter
Install grooved ball bearing in the gearbox housing Chapter
26 -
Adjusting washer
It is not necessary to adjust the drive shaft. However it is important that the adjusting
washer, conforming to the dimensions determined during the production, is reinstalled
q
after repairs. It is also possible that an adjusting washer is not provided. Then reinstall
without adjusting washer. When replacing the bearing, the clutch housing or the gearbox
housing, it is no longer required to insert the washer.
27 -
Pressure spring
28 -
shift fork for 1st and 2nd gear
29 -
shift fork for 3rd and 4th gear
30 -
Switching bridge with shift tube for 5th gear
31 -
Gear shift rod
32 -
Pressure spring
33 -
for reverse gear shift fork
Mounting sequence - disassembling and assembling the gearbox
Removing and installing the gearbox housing cover, gearbox housing, shift mechanism, drive shaft, output
shaft, differential and gearshift forks
t
Drive bushing -MP3-402 (VW 244 B)t
Pressure plate -MP3-410 (VW 434)t
Press-on sleeve -MP3-412 (VW 455)t Assembly device for drive shaft -MP3-422 (VW 391)t
Supporting bridge -MP3-425 (30-211 A)t
Pressure plate -MP3-431 (3002)t
Pipe wrench -MP3-433 (3059)89
t
t
t
t
t
t
t
t
t
t
t
t
t
Extractor -MP3-432 (3042)Driver -MP3-435 (3097)Pressure washer -MP3-455 (VW 447 H)Gearbox mount -MP3-501Drive bushing -MP3-512Press sleeve -MP6-504Assembly stand -MP9-101Drawing ring -T30036/3 (2003/3)Pressing tool -T30087 (3367)Two-arm extractor -Kukko 20/10Extraction hook -Kukko 1-250Extraction hook -Matra V 170Sealant -AMV 188 200 03-
Disassembling gearbox
Place catch pan underneath.
Drain gear oil, to this end unscrew oil

drain plug -arrow-.
90
Clamp the gearbox into the assembly

stand. Pay attention to note.
Note
Before fastening the gearbox for the first

time, the gearbox holder must be reworked
in accordance with the dimensions stated
below.
Attach additional holes to gearbox

holder.
-A-
= 118.5 mm
-B-
= 23.5 mm
-C-
= 11.0 mm
-D-
= 40 mm
-E-
= 55 mm
-F-
= M10
91
Note
The gearbox can also be attached to the

gearbox mount -T30109 (VW 353)- in
combination with the retaining plate
-T30108-.
Pull clutch push rod out of the drive

shaft.
92
Mount supporting bridge -MP3-425 (30211 A)- for drive shaft.
Counternut M12
Lift the pressing tool -T30087/2 (3367/2)over the screw onto the drive shaft up to
the stop and lock with nut -A-.
Remove the screw cap -arrow 1- from the

gearbox housing cover.
Unscrew the cover -arrow 2- for the

gearbox housing (6 screws).
Note
One of the 6 screws is located inside the

cover.
Remove drive -B- for speedometer.
Up to gearbox manufacturing date 02 08 8

Remove locking screw for gearshift shaft
-A- with reversing light switch -F4-arrow-.
93
As of gearbox manufacturing date 03 08

8
Remove locking screw for gearshift

shaft -2-.
Remove switch for reversing lights

-F4--1-.
Continued for all gearboxes
Unscrew cover for the gearshift shaft e.g.

with a spark plug wrench -A- or with 27
mm wrench socket and take out with
pressure spring.
Put the gearshift shaft in neutral position

and pull out of the gearbox housing.
Unscrew torx screw to secure the reverse

shaft support -arrow-.
Remove the left

flange shaft.
Remove the flange

shaft with pressure
94
spring, stop disc and

conical ring.
Engage 5th gear -arrow 1-.

Engage reverse gear -arrow 2- (front shift
fork to the bottom).
Unscrew screw for synchronizer body

-arrow- using a 12 mm polygon head
wrench.
Release lock washer for shift

tube.
95
Screw out the shift tube - towards the left

- from the shift fork.
Note
Do not pull the shift rod out of the shift

tube.
Remove synchronizer body completely

with sliding gear and shift fork for 5th
gear or slightly release with two tyre

levers, thus do not damage the housing
of the sealing surface.
Observe thrust washer for 5th gear

sliding gear below the synchronizer body.
Remove circlip and thrust washer -A- for

5th gear pinion.
96
Remove 5th gear pinion.
-A-Two-arm extractor, e.g. -Kukko 20/10with hook -Matra V/170-.
Uncrew tensioning plate (bracket for ball

bearing/drive shaft) -arrows-.
Remove the fixing screws for the gearbox

housing on the clutch housing.
Attach assembly device -MP3-422 (VW

391)- with screw (M8) -arrow- to gearbox
housing. First remove dowel sleeve if
necessary.
Secure the extractor -MP3-432 (3042)- as

illustrated.
Insert the spindle of the extractor

precisely into the hole of the drive shaft.
Detach gearbox housing.
Pull shift rod -A- out of the hole in the

clutch housing and swivel out the
gearshift forks -B-.
Remove circlip for 4th gear pinion/output
97
shaft.
Remove 4th gear pinion.
-A-Two-arm extractor, e.g. -Kukko 20/10with hook -Matra V/170-.
Remove drive shaft -A- completely.

Note
The reverse gear -B- must not be
engaged.
Remove circlip -B- for 3rd gear

pinion.
98
Detach 3rd gear pinion with 2nd gear

sliding gear.
-A-Two-arm extractor, e.g. -Kukko 20/10with hook 250 mm clamping depth.
Remove synchronizer ring and needle

bearing.
Drive out reverse shaft support via

screwed in bolt -arrow- using a plastic
hammer.
Remove reverse gear from reverse lever.
Remove synchronizer body/sliding sleeve

and 1st gear sliding gear together with
2nd gear inner ring/needle bearing.
-A-Two-arm extractor, e.g. -Kukko 20/10with hook 250 mm clamping depth.
99
Unscrew bearing support -arrows- and

remove output shaft. Observe thrust
washer -1-.
Remove right flange shaft and take out

differential gear.
Note
Removing is identical to the left flange

shaft Anchor.
Check the correct position of the rivets

for the differential gear. In the event that
the riveted joints are loose, the fastening
t
set (screwed connection of pinion for
final drive to differential gear housing)
must be installed Chapter.
Assembling gearbox
Insert the differential gear.

Insert output shaft.
Tighten screws for the bearing support/output shaft.
Fitting position of thrust washer for

needle bearing 1st gear sliding gear:
Shoulder -A- on the inside diameter points

towards the bearing support -B-.
Position thrust washer, needle bearing,
sliding gear and 1st gear synchronizer
ring.
100
Fitting position of the 1st and 2nd gear

sliding sleeve/synchronizer body:
The groove marking on the front side -Aand the outer serration of the sliding
sleeve -B- point to the 1st gear shift gear
-C-.
Heat 1st and 2nd gear sliding

sleeve/synchronizer body to approx. 100
C, press on and drive in play-free up to
the stop.
Rotate the synchronizer ring in such a
way that the slots are flush with the
arresters.
Install reverse gear, thus drive in axle if

necessary.
101
Driving on inner ring for needle bearing

2nd gear sliding gear up to the stop.
Position needle bearing, synchronizer

ring, 2nd gear sliding gear and 3rd gear
pinion.
Fitting position of 3rd gear pinion

Collar -arrow- to 2nd gear sliding gear -A-.
Drive in 3rd gear pinion up to stop with

drive bushing -MP3-402 (VW 244 B)-.
102
Set axial play at 3rd gear pinion as follows:
Determine the thickest circlip - that can

be fitted - and insert.
The following circlips are available:
Spare part No.
Thickness (mm)
Identification
020 311 381 F
2,5
Brown
020 311 381 G
2,6
black
020 311 381 H
2,7
blank
020 311 381 J
2,8
copperize
020 311 381 K
2,9
brazen
020 311 381 L
3,0
blue
Note
t
If the drive shaft was not disassembled:
Press off grooved ball bearing for drive shaft Chapter Pos. 10.
Remove tensioning plate of ball bearing Chapter Pos. 11.
Insert drive shaft completely without grooved ball bearing.
103
Mount supporting bridge -MP3-425 (30211 A)- for drive shaft.
Counternut M12
Lift the pressing tool -T30087/2 (3367/2)over the screw onto the drive shaft up to
the stop and lock with nut -A-.
Fitting position of 4th gear pinion

Collar -arrow- points to 5th gear sliding
gear -A-.
Position 4th gear sliding gear onto output

shaft, drive in with drive bushing -MP3402 (VW 244 B)- and secure with circlip.
Press on grooved ball bearing/drive

shaft.
Fitting position:
Broad collar -arrow- at inner ring points to
the pressing tools.
Note
To ensure that the dowel sleeves for
centering the gearbox housing cover on
the gearbox housing do not get damaged,
they must be removed from the gearbox
housing beforehand.
104
Tighten tensioning plate of ball bearing

-arrow A-.
Note
The tensioning plate of the ball bearing fits

only in one position -arrow B-.
Before installing the shift fork set, secure

the lower spring -arrow- to the shift rod
or insert it into the clutch housing.
Install shift fork set and align shift gates.

-A- 1st/2nd gear shift fork. -Arrow- points to
the recess for the switching bridge -C-.
-B- 3rd/4th gear shift fork
-C- Switching bridge with shift tube for 5th
gear.
-D- Shift fork reverse gear.
Push in gearshift rod.
105
Align reverse shaft support. Distances -xare the same.
Apply sealant -AMV 188 200 03 uniformly on the sealing surface of the
clutch housing.
Drive on the gearbox housing, while

doing so pay attention that the drive
shaft is perfectly supported by the

supporting bridge -MP3-425 (30-211 A) Anchor.
Tighten reverse shaft support.

Tighten the screws for securing the
gearbox housing to 25 Nm.
Tighten oval-head countersunk screws to
15 Nm on the tensioning plate for
grooved ball bearing.
Drive in 5th gear pinion
106
Fitting position:
The groove -arrow- points upwards.
Position thrust washer and circlip.
Position 5th gear synchronizer body

completely with sliding sleeve, sliding
gear and 5th gear shift fork and new lock
washer.
Screw shift tube with pipe wrench -MP3 433 (3059)- towards the right in the shift
fork.
Screw out shift tube so far until a

projection -x- = 5.0 mm is reached.
Note
Do not pull shift rod out of the shift tube

(possibly through tilting of the pipe
wrench), otherwise the shift forks in the
gearbox come apart and the gearbox must
be dismantled again. If necessary, hold
down the shift rod with a screwdriver when
removing the pipe wrench through the
lateral slot.
Position new screw for synchronizer body

with disc spring.
The new screw must be micro

l encapsulated. If not, coat the screw with
locking agent -D 000 600 A2-.
Fitting position of the disc spring: the
l outside diameter (concave side) points to
the 5th gear.
107
Engage 5th gear -arrow 1-.
Engage reverse gear -arrow 2- (front shift

fork to the bottom).
Tighten screw for synchronizer body

using a 12 mm polygon head wrench.
Put shift forks in neutral position before

installing the gearshift shaft.
Carefully insert gearshift shaft -1- so that

the gasket ring for gearshift shaft is not
damaged. If necessary, pull the shrink

hose over the serration of the gearshift
shaft.
Insert pressure spring -2- for gearshift
shaft and tighten screw cap -3- with new
O-ring -4-.
Up to gearbox manufacturing date 02 08 8
Insert locking screw for gearshift

shaft/reversing light switch -F4--5- with
sealant -AMV 188 200 03-.
As of gearbox manufacturing date 03 08 8
Screw in the reversing light switch -F4-1-.
Screw in locking screw -2- for gearshift

shaft with sealant -AMV 188 200 03-.
Continued for all gearboxes

Set 5th gear shift fork as follows:
Note
The setting must be performed with
particular care so that jumping out of
gear can be excluded.
108
Check projection of the shift tube measurement x = 5.0 mm, if necessary

adjust with pipe wrench -MP3-433
(3059)-.
Screw the lever for the gearshift shaft
onto the gearshift shaft and engage 5th
gear (pull out gearshift shaft completely
and turn to the left).
Align sliding sleeve -1- with shift fork -2 clearance free to 5th gear sliding gear
-3-.
Control measurement: between sliding
sleeve and sliding gear there must be a
l dimension of a = 1.3 mm. Correct the
dimension if necessary by turning the
shift tube.
Remove 5th gear. The sliding sleeve

must now be in Neutral. The synchronizer
ring must travel freely.
Insert an approx. 12 mm thick base

between the shift fork and the housing,
e. g. two open-end wrench -A- of 19 mm.
Drive in new lock washer with driver
-MP3-435 (3097)-.
Note
When supporting the shift fork do not

damage the sealing surface of the gearbox
housing.
Shift through all gears.
Apply sealant -AMV 188 200 03 uniformly on the sealing surface of the
gearbox housing.
109
Install cover -arrow- for gearbox housing

(6 screws).
Note
One of the 6 screws is located inside the

cover.
Then insert the release bearing -A- in the

gearbox housing cover.
Install a new screw cap -A-, to do so use

a drawing ring -T30036/3 (2003/3)-.
Note
The sealing surface at the cap for the

gearbox housing must be free of grease.
110
Fill half the space between the sealing lip

and dust lip, the gasket rings for flange
shaft, with sealing grease -G 052 128 A1-arrow-.
Install both flange

shafts with pressure
springs, stop discs
and conical rings.
Remove supporting
bridge -30 - 211 Afor drive shaft.
111
Insert the clutch push rod -A- in the drive

shaft -direction of arrow-.
Repairing gearbox housing and gearshift shaft

t
t
t
Drift -MP3-403 (VW 295)Adapter -MP3-403/1 (VW 295 A)Drift pin -MP3-426 (30-505)-
Pressing tool -MP3-428 (40-503)-
Inserting device -MP3-436 (3128)-
Bushing -MP3-462/8 (VW 521/8)-
Interior extractor -Kukko 21/3-
Countersupport -Kukko 22/1-
112
1q
Gearbox housing
when replacing: adjust the differential gear Chapter
q as of gearbox manufacturing date 03 08 8 with additional threaded bore for the reversing
light switch -F4 - Chapter
2q
3-
Fitting sleeve
(2 pieces)
Bushing
remove with pliers
drive in up to stop
4q
5q
Cap
for gearbox bleeder
Gearshift shaft
113
6-
Stop cap
7-
Pressure spring
8-
Retaining bracket
q when removing the circlip Pos. 9 hold the retaining bracket, then carefully slacken the
pressure spring Pos. 7
9q
10 -
Circlip
Needle bearing
for output shaft
removing Fig.
installing Fig.
11 q
12 q
q
q
13 q
q
q
14 q
15 q
Reversing light switch -F4-, 23 Nm

Locking screw, 40 Nm
for gearshift shaft
coat with sealant -AMV 188 200 03Outer ring/tapered-roller bearing
for differential
Adjusting washer S1
Setting overview Chapter
Reversing light switch -F4- and locking screw for gearshift shaft, 23 Nm
installed up to gearbox manufacturing date 02 08 8
q as of gearbox manufacturing date 03 08 8, the reversing light switch -F4- and the locking
screw are two components Chapter
q
16 -
coat with sealant -AMV 188 200 03Gasket ring
for left flange shaft
replace Chapter
114
17 -
Ball sleeve
for gearshift shaft
removing Fig.
installing Fig.
18 q
q
Gasket ring
for gearshift shaft
can be replaced on an installed gearbox
removing Fig.
installing Fig.
Removing gasket ring for gearshift shaft
Lever out using a screwdriver in

-direction of the arrow-.
Install gasket for gearshift shaft
Insert up to the stop.

Drive in with -MP3-462/8- when the
gearbox is removed.
115
Remove ball sleeve for gearshift shaft

-A-interior extractor 18.5...23.5 mm, e.g.
-Kukko 21/3-B-countersupport, e.g. -Kukko 22/1-
Insert ball sleeve for gearshift shaft
Insert up to the stop -arrow 1-.
Fitting position:
The ball sleeve protrudes out of the hole on
the side of the gasket ring -arrow 2-.
Driving out needle bearing
116
Drive in needle bearing up to

stop
Repairing clutch housing

t
t
Extractor -MP3-401 (VW 228 B)Drift -MP3-403 (VW 295)-
Pressure washer -MP3-413 (VW 510)-
Ejection lever -MP3-418 (VW 681)-
t
t
Drift -VW 222 APressure plate -T40015-
Sealant -AMV 188 200 03-
117
1q
2q
Oil drain plug, 25 Nm

without magnet
Fitting sleeve
(2 pieces)
3-
Adjusting washer S2
always 1 mm thick
4q
q
q
5q
q
Outer ring/tapered-roller bearing

for differential
extracting and inserting Chapter
Magnet
is held in position by the separator surface of the housing
insert with the sealant -AMV 188 200 03118
6-
Adjusting washer
for output shaft
7-
q
q
q
for output shaft

extracting and inserting Chapter
when replacing: set the output shaft Chapter
8-
Needle bearing
for drive shaft
removing Fig.
inserting Fig.
9q
25 Nm
with locking teeth below the screw head
10 -
Reverse lever
11 -
Pressure spring
12 -
Support for reverse lever
13 -
Sliding block
14 q
q
Bushing for starter

not present on all gearboxes
assign according to Electronic Catalogue of Original Parts
removing Fig.
inserting Fig.
can be replaced on an installed gearbox
15 q
q
Screw plug
green - clutch diameter 210 mm
white - clutch diameter 190 and 200 mm
Note
Absolutely pay attention to the correct assignment for example when exchanging the gearbox
or refitting the clutch.
Consequences when interchanging the screw plugs:
119
1. White screw plug - 210 mm clutch
The TDC sender is destroyed and the markings at the flywheel are damaged. Parts of the
TDC sender are in the clutch area.
2. Green screw plug - 190 and 200 mm clutch
There is none or however one inexact fluctuating readout.
16 17 q
q
Cap
Clutch housing
Insert oil strainer Fig.
when replacing: Set output shaft and differential gear Chapter
18 -
Gasket ring for drive shaft
removing Fig.
inserting Fig.
19 -
Bushing
for gasket ring Pos.20
removing Fig.
inserting Fig.
20 -
Gasket ring
for right flange shaft
replace Chapter
Insert oil strainer -A- in the clutch

housing
120
Pull out needle bearing for drive shaft

A-
Interior extractor 23.5...30 mm, e.g.

-Kukko 21/4-
B - Countersupport, e.g. -Kukko 22/1-
Insert needle bearing for drive

shaft
Extract bushing for starter
121
Drive in bushing for starter
Pull out gasket ring for drive shaft with the

ejection lever -MP3-418 (VW 681)- or the
extraction hook -T20143/1-
Inserting gasket ring for drive shaft

Note
On a disassembled gearbox (drive shaft is

removed) the gasket ring for the drive
shaft can also be driven in with the bushing
-MP3-424 (30 - 21)-.
122
Levering out the bushing with a

screwdriver -arrow-
Drive in the bushing
Repairing gearbox housing cover

t
t
t
Ejector -MP1-502Insertion tool -MP1-174Driver -MP3-504-
Pressure plate -MP3-407 (VW 402)-
Pipe section -MP3-409 (VW 418 A)-
Inserting device -MP3-436 (3128)-
123
1q
q
2-
Screw cap
Release bearing
q can be replaced on installed gearbox, after removal of the screw cap Pos. 1 and removal of
the slave cylinder
3q
q
4-
Clutch lever
remove locking clip Pos. 5 for removing
fits in one position only
Bushing, small
removing Fig.
installing Fig.
5-
Locking clip
6-
Needle bearing
7-
Bushing, large
pressing out Fig.
installing Fig.
8-
Gasket ring
124
q
q
inserting Fig.
can be replaced on installed gearbox, to do so remove release shaft Pos. 9
9-
Release shaft
q removing: take off screw cap Pos. 1 and locking clip Pos. 5; pull release shaft out of needle
bearing Pos. 6 and gearbox housing cover
10 q

as spare part only version with bearing bushings Pos. 7 and Pos. 4
11 -
Oil filler plug, 25 Nm
Press on large bushing -ANote
Instead of the driver -MP3-504- it is also

possible to use the pressure spindle -MP6405 (VW 411)-.
Press on large bushing

Note
Instead of the insertion tool -MP1-174- it is

also possible to use the guide bolt -T30074
(10-15)-.
125
Pull out small bushing

-A-interior extractor 12...14.5 mm, e.g.
-Kukko 21/1-B-countersupport, e.g. -Kukko 22/1Note
The bushing is damaged when removing,

always replace.
Press in small bushing
Insert gasket ring for release shaft
Secure the cap for the gearbox housing

in a vice fitted with protective jaws.
126
Disassembling and assembling the drive shaft

Disassembling and assembling the drive shaft
t
Driver -MP1-304 (10 - 206)-
Drift -MP3-403 (VW 295)-
Multi-purpose tool -MP3-419 (VW 771)-
Thrust piece -MP3-423 (VW 407)-
Drive bushing -MP3-427 (40 - 21)-
Pipe section -MP3-429 (2010)-
Pipe section -MP3-4013 (VW 421)-
Separating device -Kukko 17/1-
Countersupport -Kukko 22/1Note
When installing new pinions observe the technical data Chapter.
t Do not over-tension the circlip Pos. 14. Always replace damaged or over-tensioned circlips.
127
1-
M17, 150 Nm
self-locking
always replace
q
q
2q
new screw is micro encapsulated (thread with locking agent)

Disc spring
Fitting position: the outside diameter (concave side) points to the 5th gear
3-
Sliding sleeve/5th gear synchronizer body
4q
Stop ring
prevents the arresters from wandering
removing Fig.
installing Fig.
128
5-
5th gear sliding sleeve
Fitting position Fig.
6-
5th gear synchronizer body
7-
Arresters
3 pieces
8-
Spring
(2 pieces)
9-
Oval-head countersunk screw, 15 Nm
M7 x 23
4 pieces
10 q
q
Grooved ball bearing

pressing off Fig.
is pressed in when installing the drive shaft into the gearbox housing Chapter
11 q
Tensioning plate
secures the grooved ball bearing
12 -
4th gear sliding gear
13 -
4th gear synchronizer ring
check for wear Fig.
14 15 -
Circlip
Sliding sleeve with 3rd and 4th gear synchronizer body
press off with 3rd gear sliding gear Fig.
Fitting position of synchronizer body Fig.
assembling Fig.
pressing on Fig.
16 -
Sliding sleeve
17 -
Synchronizer body
18 q
Arresters
3 pieces
19 q
Spring
(2 pieces)
129
20 -
Drive shaft
21 -
Clutch housing
22 -
Needle bearing
q
q
23 q
q
q
q
24 -
for drive shaft

Gasket ring for clutch push rod
can be replaced on removed (not disassenbling) gearbox
release with a screwdriver Fig.
inserting Fig.
Bushing for clutch push rod
removing Fig.
q
q
25 q
can be replaced on removed (not disassenbling) gearbox

inserting Fig.
Needle bearing
for 3rd gear sliding gear
26 -
3rd gear sliding gear
27 -
3rd gear synchronizer ring
q
28 q
check for wear Fig.

Needle bearing
for 4th gear sliding gear
29 -
Gearbox housing
30 -
Adjusting washer
for drive shaft
It is not necessary to adjust the drive shaft. However it is important that the adjusting
washer, conforming to the dimensions determined during the production, is reinstalled
q
after repairs. It is also possible that an adjusting washer is not provided. Then reinstall
without adjusting washer. When replacing the bearing, the clutch housing or the gearbox
housing, it is no longer required to insert the washer.
31 q
Thrust washer
q after mounting the 5th gear needle bearing Pos. 32, press the 5th gear synchronizer ring
130
Pos. 34 and the 5th gear sliding gear Pos. 33 onto the 5th gear synchronizer body
32 q
Needle bearing
for 5th gear sliding gear
33 -
5th gear sliding gear
34 -
5th gear synchronizer ring
check for wear Fig.
Lever out gasket ring for clutch push

rod
Fitting position of the gasket ring and the

bushing
-A- Gasket ring for clutch push rod
-B- Bushing for clutch push rod
131
Drive in gasket ring for clutch push rod

Drive in gasket ring -A- with the supplied
assembly stoppers -B- until flush.
Remove assembly stoppers. The gasket
ring has now the specified installation
depth of 0.8 ... 1.3 mm. Lightly oil sealing
lip.
Pull out bushing for clutch push rod

-A-interior extractor 8...12 mm, e.g. -Kukko
21/01Use thread adapter of countersupport,
e.g. -Kukko 22/1- for connection of
interior extractor and special tool
-VW 771/15-.
Note
When the drive shaft is fitted, pull out the

bearing bushing by means of the
countersupport, e.g. -Kukko 22/1- via the
pressure plate -MP3-460 (VW 512)-.
Drive in bearing bushing for clutch push

rod
Drive the bearing bushing into the drive

shaft approx. 7 mm.
132
Press off grooved ball bearing

A-
Separating device 12...75 mm, e.g.

-Kukko 17/1-
Press off 3rd and 4th gear synchronizer

body/sliding sleeve with 3rd gear sliding
gear
133
Check synchronizer
ring for wear
Press the
synchronizer ring on
the cone of the
sliding gear and

measure clearance
a with a feeler
gauge.
Clearance -a-
Fitting dimension
Wear limit
3rd gear
4th gear
5th gear
1.15 ... 1.75 mm

1.3 ... 1.9 mm
1.3 ... 1.9 mm
0.5 mm
Fitting position of the 3rd and 4th gear

synchronizer body
The shorter serration below the round slot
-arrow A- points towards the 3rd gear.
The groove on the front side -arrow Bpoints towards the 4th gear.
134
Assembly of the sliding sleeve/3rd and 4th

gear synchronizer body
Slide the sliding sleeve over the

synchronizer body.
The recesses for the arresters on the

synchronizer body and the sliding sleeve
must be positioned above one another.
Insert arresters and mount springs with

120 offset. The angled end of the spring
must grip into the hollow arrester.
Press on the synchronizer body with the

3rd and 4th gear sliding sleeve
Fitting position of the 5th gear sliding

sleeve

synchronizer body.

The chamfer at the rigid serration -arrow 1points at the same time towards the shaft
-arrow 2- of the 5th gear synchronizer
body.

135
Fitting position of thrust washer for 5th

gear sliding gear
The chamfer -arrow- in located opposite
the sliding gear.
Removing the stop ring

Press pipe section -MP3-429 (2010)- into
the synchronizer body/stop ring. For this
step lever out the stop ring alternatively
from the synchronizer body.
The stop ring must be located completely
on the pipe section -MP3-429 (2010) Fig..
Remove stop ring together with pipe

section -MP3-429 (2010)-.
Installing the stop ring

Insert stop ring together with pipe
section -MP3-429 (2010)- into the 5th
gear synchronizer body/sliding sleeve.
Lock the lands -arrows 1- in the recesses
-arrows 2- for the arresters of the
synchronizer body.
Remove pipe section -MP3-429 (2010)-,

simultaneously the lands must engage in
the synchronizer body.
136
Output shaft
Disassembling and assembling the output shaft
t
Drift -MP1-178-
Ejector -MP1-502-
t
t
Drift -MP3-403 (VW 295)Pressure washer -MP3-460 (VW 512)-
Pipe section -MP3-414 (VW 516)-
Separating device -Kukko 17/2-
Countersupport -Kukko 22/2Note
t When installing new pinions or a new output shaft observe the technical data Chapter.
t
Replace both tapered-roller bearings together.
t Do not over-tension the circlips. Always replace damaged or over-tensioned circlips.

t
If the clutch housing, output shaft (drive train) or tapered-roller bearing is replaced, it is
necessary to adjust the output shaft Chapter.
137
1-
2-
Circlip for 5th gear pinion
3-
Thrust washer
4-
5th gear pinion
5-
Gearbox housing
6-
Needle bearing
q
78q
9q

Circlip for 4th gear pinion
4th gear pinion
Circlip for 3rd gear pinion
Determining thickness again Chapter
138
10 -
3rd gear pinion
Set axial play Chapter
11 12 -
2nd gear sliding gear

Needle bearing for 2nd gear sliding gear
Pull off inner ring Chapter
Press on inner ring Chapter
13 q
14 q
q
15 -
2nd gear synchronizer ring

check for wear Fig.
Sliding sleeve with 1st and 2nd gear synchronizer body
Assembling sliding sleeve/synchronizer body Fig. and Fig.
1st gear synchronizer ring
check for wear Fig.
Identification Fig.
16 -
1st gear sliding gear
17 -
Spring
18 -
Sliding sleeve
19 -
Synchronizer body
20 q
21 q
22 q
Arresters
3 pieces
Needle bearing
for 1st gear
Thrust washer
23 -
Clutch housing
24 -
Adjusting washer
for output shaft
25 -
Outer ring/tapered-roller bearing small

139
removing Fig.
installing Fig.
26 -
Inner ring/tapered-roller bearing small
pressing off Fig.
pressing on Fig.
27 -
Output shaft
q is paired with the gear pinion of the final drive, when replacing they must both be replaced
q
adjust Chapter
28 -
Inner ring/tapered-roller bearing large
pressing off Fig.
pressing on Fig.
29 q
q
Bearing support
with outer ring/tapered-roller bearing large and stop for reverse gear
Always replace outer ring together with tapered-roller bearing large and bearing support
30 -
25 Nm and torque a further 90
Check 1st and 2nd gear snychronizer ring

for wear
Press the synchronizer ring on the cone

of the sliding gear and measure
clearance -a- with a feeler gauge.
Clearance -a-
Fitting dimension
Wear limit
1st and 2nd gear
1.11.7 mm
0.5 mm
140
Identification of the
1st gear synchronizer
ring
Identification: every 3
x 1 tooth missing
-arrow-.
This synchronizer ring
must only be installed
on the 1st gear.
Assemble sliding sleeve with synchronizer

body for 1st and 2nd gear
Fitting position of synchronizer body:
The groove marking on the front side
-arrow- points to the outer serration of the
sliding sleeve.

synchronizer body.

141
Assembly of the sliding sleeve/synchronizer

body for 1st and 2nd gear

Removing outer ring/tapered-roller

bearing small
A-
Interior extractor 37...46 mm, e.g.

-Kukko 21/6-
B - Countersupport, e.g. -Kukko 22/2-
142
Pressing in small outer ring/tapered-roller

bearing
Press off small inner ring/tapered-roller

bearing
A-

-Kukko 17/2Note
The inner ring can also be removed with

the tapered-roller bearing extractor
-V.A.G 1582- and the gripper
-V.A.G 1582/5-.
143
Pressing off large inner ring/tapered-roller

bearing
A-

-Kukko 17/2Note
The inner ring can also be removed with

the tapered-roller bearing extractor
-V.A.G 1582- and the gripper
-V.A.G 1582/7-.
Heat inner rings for small and large

tapered-roller bearings to approx. 100C,
place in position and press down.
Setting output shaft

(Determine adjusting washer for output shaft)
t
Drift -MP3-403 (VW 295)-
Gauge block plate -MP3-405/17 (VW 385/17)-
Spindle of assembly device -MP3-434 (3066)144
Universal dial gauge holder -MP3-447 (VW 387)-
The output shaft must be re-set when the following components were changed:
t
Drive train
Clutch housing
or
t
Tapered-roller bearing
Setting overview Chapter.
Press in outer ring/tapered-roller bearing

small in the clutch housing with a 0.65
mm thick adjsuting washer up to the stop
Insert output shaft and tighten hexagon
screws nuts for the bearing support to 25
Nm and turn a further 90.
145
Insert dial gauge (3 mm measuring

range) and set to 0 with a 1 mm bias.
-A- Adjusting washer 0.65 mm thick
Move the output shaft up and down, read

off and write down the clearance on the
dial gauge. (Example: 0.35 mm).
Note
Do not turn the output shaft while

measuring as otherwise the bearings will
settle and the measuring result will be
inaccurate.
Determine the adjusting washer
The prescribed bearing preload is reached
by adding to the established measured
value (0.35 mm) and to the inserted
adjusting washer (0.65 mm) a constant
compression value (0.15 mm).
Example:
inserted washer
0.65 mm
+ measured value
0.35 mm
+ compression (constant value)
0.15 mm
Thickness of the adjusting washer
1.15 mm
146
Remove output shaft and pull out small

outer ring for tapered-roller bearing.
A-
Interior extractor 37...46 mm, e.g.

-Kukko 21/6-
B - Countersupport, e.g. -Kukko 22/2The following adjusting washers are

available:
Thickness (mm)
Spare part No.
0,65
0,70
020 311 391 P

020 311 391 Q
0,75
0,80
0,85
020 311 391

020 311 391 A
020 311 391 B
0,90
0,95
1,00
020 311 391 C

020 311 391 D
020 311 391 E
1,05
1,10
1,15
020 311 391 F

020 311 391 G
020 311 391 H
1,20
1,25
1,30
020 311 391 J

020 311 391 K
020 311 391 L
1,35
1,40
020 311 391 M

020 311 391 N
Different tolerances allow to measure the required thickness for each washer very precisely.
corresponding to the measured value may be fitted.
Press in outer ring/tapered-roller bearing with the determined adjusting washer (1.15 mm
147
in the example) Chapter and install output shaft.

Tighten hexagon screws for the bearing support in clutch housing to tightening torque.
148
Final drive, differential, differential lock

Replacing the flange shaft gasket rings (gearbox assembled)
Replacing the left flange shaft gasket ring Chapter.
Replacing the right flange shaft gasket ring Chapter.
Observe the general repair instructions Chapter.
Replacing the left flange shaft gasket ring

t
Extraction hook -MP3-419/37 (VW 771/37)t
Drive bushing -MP3-430 (2035)t
Inertia extractor -MP9-501t
Catch pan
t
Sealing grease -G 052 128 A1Removing
Remove front left wheel Chassis Rep. Gr.44 and raise vehicle.
If present, remove middle and left part of the noise insulation Body work Rep. Gr.50.
Turn steering to full left lock.

Remove left drive shaft Chassis Rep. Gr.40.
Position the catch pan under the gearbox.
Unscrew the fixing screw for the flange

shaft, to this end insert two screws in the
flange and using a tyre iron hold the
shaft.
Remove the flange shaft together with

the pressure spring.
149
Pull out gasket ring for flange shaft with

inertia extractor -MP9-501- and
extraction hook -MP3-419/37
(VW 771/37)-.
Install
Drive the new seal ring in up to the stop,

do not twist the seal ring.

and dust lip with sealing grease -G 052
128 A1-.
Insert the flange shaft.
Secure the flange shaft with the conical

screw and tighten with tightening torque.
Install left drive shaft Chassis Rep.

Gr.40.
Check gear oil level Chapter.

Install the noise insulation Body Work
Rep. Gr.50.
Install wheel Chassis Rep. Gr.44.

Tightening torque
Flange shaft on gearbox (conical screw)
25 Nm
Replacing the right flange shaft seal ring

t
Drive bushing -MP3-430 (2035)t
Assembly device -MP6-414 (3253)t
Catch pan
t
Sealing grease -G 052 128 A1150
Removing
If present, remove middle and right part of the noise insulation Body work Rep. Gr.50.
Turn steering to full right lock.

If present, remove heat shield for drive
shaft from the engine -arrows- Chassis
Rep. Gr.40.
Unscrew the drive shaft from the flange
shaft Chassis Rep. Gr.40.
Tie up the drive shaft as far as possible.
Avoid damaging the paintwork on the
drive shaft during this operation.
Position the catch pan under the gearbox
and the engine.
Unscrew the fixing screw for the flange

shaft; to do this, insert two screws in the
flange and hold the shaft using a tyre
iron.
Remove the flange shaft with pressure

spring.
Lever out gasket ring with screwdriver

-A-, while doing so support the
screwdriver on the cross member -3253/2
(MP6-414/2)-.
Note
t
Do not damage the bushing as this will

cause leaks.
t If damaged replace bushing Chapter.
Install
151
Drive in the new gasket ring up to the

stop using a drive bushing -MP3-430
(2035)-, while doing so do not twist the
gasket ring.
and dust lip with sealing grease -G 052
128 A1-.
Insert the flange shaft.
Secure the flange shaft with the conical

screw.
Install right drive shaft on gearbox

Chassis Rep. Gr.40.
If present, install heat shield for drive

shaft on the engine -arrows- Chassis
Rep. Gr.40.
Inspecting gear oil Chapter.
Install the noise insulation Body Work
Rep. Gr.50.
Tightening torque
Flange shaft on gearbox (conical screw)
25 Nm
152
Differential gear
Disassembling and assembling the differential gear
t
Drift -MP3-403 (VW 295)-
Press-on sleeve -MP3-412 (VW 455)-
Pressure plate -MP3-431 (3002)-
Thrust piece -MP3-448 (VW 408 A)-
Gearbox mount -MP3-501-
Drift -MP3-510-
Mandrel -MP3-511-
t
t
Tapered-roller bearing extractor -V.A.G 1582Gripper -V.A.G 1582/3Note
t Before installing heat the inner ring of the tapered-roller bearing to 100C.
t
t
Replace both tapered-roller bearings together.

When replacing the tapered-roller bearing of the differential housing, gearbox housing and
clutch housing adjust the differential Chapter.
153
1q
2q
q
screw to threaded connector Pos. 10 to attach the flange shaft
Flange shaft
with hole for conical screw
3-
Pressure spring for flange shaft
fitted behind flange shaft
4q
5q
q
6-
Thrust washer
Conical ring
Circlip
154
removed
7-
Gearbox housing
8-
Stop disc compound
insert with gear oil
9-
Differential bevel gear large
installing Fig.
10 -
Threaded part
installing Fig.
11 q
Differential bevel gear shaft
after removing the tensioning sleeve Pos. 12, drive out with drift pin -MP3-510-
installing Fig.
12 q
Tensioning sleeve
to secure the differential bevel gear shaft
removing and installing Fig.
13 -
Differential bevel gear small
installing Fig.
14 q
Rivet
only in the series; for attaching gear pinion/final drive Pos. 20 to differential gear housing
bore out Fig.

Note
Specifically on gearboxes up to gearbox manufacturing date 09 07 1 check the rivets for firm
seating, if necessary replace with fastening set Pos. 19.
15 q
16 q
q
17 q
Adjusting washer S2
always 1 mm thick
drive out Fig., to do so first remove sleeve Pos. 25
inserting Fig.
Inner ring/tapered-roller bearing
remove Fig.
155
pressing on Fig.
18 -
Clutch housing
19 -
Fastening set
only for customer service
installing Fig.
Nut, 65 Nm
20 q
q
Pinion for final drive

series riveted
is paired with the output shaft, replace together
pressing off Fig.
q
q
q
heat to 100 C before fitting

place on differential housing Fig.
screw Fig.
21 -
Differential gear housing
22 -
extracting Fig.
inserting Fig.
23 q
24 q
25 -
Adjusting washer S1
Determine thickness Chapter
Gasket ring
replace Chapter
Bushing
for gasket ring/right flange shaft
156
Driving outer ring/tapered-roller bearing

from clutch housing
First remove bushing for gasket ring/right
flange shaft.
Drive the outer ring/tapered-roller bearing

into the clutch housing
Remove inner rings/tapered-roller bearing
Before fitting the extractor, position the

pressure plate -MP3-431 (3002)- on the
differential gear housing.
Note
Both inner rings/tapered-roller bearings of

the differential gear housing are removed
in the same way.
157
Press on inner rings/tapered-roller bearing

Note
The inner ring/tapered-roller bearing for

the gearbox housing side and clutch
housing side are pressed on with the same
pressure tools.
Drive outer ring/tapered-roller bearing out

of the gearbox housing
158
Drive outer ring/tapered-roller bearing into

the gearbox housing
Bore out rivet heads
Bore out the rivet heads on the sunken

side with a 12 mm drill and drive out
rivet with a drift.
Note
Clean differential gear before and after

drilling, protect tapered-roller bearing from
boring swarf.
159
Removing and
installing the
tensioning sleeve for
differential bevel gear
shaft
Removing
Cover inner
ring/tapered-roller
bearing and drive
wheel for
speedometer to
avoid any possible
damage and swarf.
Drive out tensioning
sleeve with a chisel,
position the chisel in
the circular slot.
Drive out differential
bevel gear shaft
with drift pin -MP3510-.
Install
Differential bevel
gears and
l differential bevel
gear shaft are
installed.
Drive in the new
tensioning sleeve
into the differential

gear housing up to
the stop.
160
Pressing off pinion/final drive
Fitting location of the pinion/final drive

The circular slot -arrow 1- points to the
l screw-on surface of the differential gear
housing -B-.
l
The chamfer -arrow 2- of the gear

pinion/final drive -A- points upwards.
Heat pinion/final drive to approx. 100C

and install
Guide the pinion/final drive during fitting

with screws -A- from the repair kit for the
for the gearbox 02K.
161
Screw pinion/final drive and differential

housing
Use special screws with shims and nuts
according to the Electronic Catalogue of
Original Parts.
Install the differential bevel gears
Install stop disc compound with gearbox

oil.
Insert both large differential bevel gears

and secure (e.g. with flange shafts).
Insert and swivel both small differential

bevel gears into position with a 180
offset.
Push in the differential bevel gear shaft

-arrow A- up to the first small bevel gear.
Insert the threaded parts -arrows B- in the

large differential bevel gears. Fitting
position: Heel of the differential bevel
gear.
Insert the differential bevel gear shaft up
to stop and secure with new tensioning
sleeve.
162
Fitting position of thrust washer for the

conical ring -1The collar -arrow- points towards the
pressure spring -B-.
The lands -A- are not present on certain
gearboxes.
The lands -A- point towards the conical ring
-1-.
Adjusting the differential gear

t
Drift -MP3-403 (VW 295)-
Gauge block plate -MP3-405/17-
t
t
t
Universal dial gauge holder -MP3-447 (VW 387)Gearbox mount -MP3-501Mandrel -MP3-511-
The differential gear must be re-set when the following components are replaced:
t
Gearbox housing
Clutch housing
or
t
differential gear tapered-roller bearing
Setting overview Chapter.

163
Drive outer ring/tapered-roller bearing

with adjusting washer S2 (always 1 mm
thick) into the clutch housing.
Note
The inner and outer ring of the taperedroller bearing are paired. Do not
interchange!
Insert outer ring/tapered-roller bearing

without adjusting washer into the
gearbox housing.
Insert the differential gear in the clutch

housing.
Position the clutch housing and tighten 5

screws to torque 25 Nm.
Set the dial gauge to 0 with 1 mm

preload on 0.
Move the differential gear up and down,

read off and write down the clearance on
the dial gauge.
(Example: 0.90 mm)
Note
Do not turn the differential while

measuring as otherwise the bearings will
settle and the measuring result will be
inaccurate.
Determine adjusting washer S1
The prescribed bearing preload is reached
164
by adding to the established measured

value for S1 (Example: 0.90 mm) a
constant compression value (0.25 mm).
Example:
measured value
0.90 mm
+ compression (constant value)
0.25 mm
Thickness of the adjusting washer S1=
1.15 mm
Remove the gearbox housing and drive

the outer ring/tapered-roller bearing out
of the gearbox housing.
The following adjusting washers are

available:
Thickness (mm)
Spare part No.
0,65
0,70
02K 409 210

02K 409 210 A
0,75
0,80
0,85
02K 409 210 B

02K 409 210 C
02K 409 210 D
0,90
0,95
1,00
02K 409 210 E

02K 409 210 F
02K 409 210 G
1,05
1,10
1,15
02K 409 210 H

02K 409 210 J
02K 409 210 K
1,20
1,25
02K 409 210 L

02K 409 210 M
165
Note
Assign the adjusting washers via the Electronic Catalogue of Original Parts.
Insert adjusting washer of the determined thickness, the thickest first.
Different tolerances allow to measure the required thickness for each washer very precisely.
If the measured washer thickness is greater than the one listed in the table, 2 washers
corresponding to the measured value may be fitted.
Drive the outer ring/tapered-roller

bearing with the determined adjusting
washer into the gearbox housing.
Setting overview
Note
When working on the gearbox it is only necessary to re-set the output shaft or differential
gear if parts were replaced that directly affect the setting of the gearbox. To avoid
unnecessary settings, refer to the following table:
Set:
Output shaft
Differential gear
Chapter (S1 and S2) Chapter
Replaced part: Gearbox housing
Clutch housing
Tapered-roller bearing for differential gear

Output shaft (drive train)
x
x
x
166
Tapered-roller bearing for output shaft
167

Skoda Octavia Mk1 - 06 - Power Transmission Gearbox 02K

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Skoda Octavia Mk1 - 06 - Power Transmission Gearbox 02K

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SKODA OCTAVIA

Summary of components - Hydraulics............................................................................................. 25

Installing the gearbox...................................................................................................................... 78

INSPECT GEAR OIL.................................................................................................................................... 84

Repairing gearbox housing and gearshift shaft.............................................................................122

Repairing clutch housing............................................................................................................... 127

Replacing the right flange shaft seal ring......................................................................................163

DIFFERENTIAL GEAR............................................................................................................................... 166

Location on the gearbox as of 07.99

Location on the gearbox up to 06.99

Identification characters and manufacturing data

Identification characters and manufacturing data

Additional data depend on the manufacturing.

Gearbox 02K -arrow 2-

Location on the gearbox as of 07.99

Identification characters and manufacturing data

Identification characters and manufacturing data

Additional data depend on the manufacturing.

Gearbox 02K -arrow 2-

Identification characters, aggregate assignment, ratios, capacities

Gear oil change interval

Filled for life

Clutch disc diameter

Electronic Catalogue of Original Parts

Drive shaft flange

Electronic Catalogue of Original Parts

Gear oil change interval

Filled for life

Clutch disc diameter

Electronic Catalogue of Original Parts

Drive shaft flange

Electronic Catalogue of Original Parts

Gear oil change interval

Filled for life

Clutch disc diameter

Electronic Catalogue of Original Parts

Drive shaft flange

1.9 ltr./50 kW SDI

Gear oil change interval

Filled for life

Drive shaft flange

Overview of Transmission System

-Arrows- in direction of travel

III III IV VRAT-

General repair information

Filling capacity Chapter.

O-rings, gasket rings, gaskets, sealant

Replace paper gaskets.

On gearboxes with sealants:

Slacken the bolts and nuts against the

Slacken and tighten nuts and bolts for

Tightening torques apply for non-oiled

Always replace the self-locking nuts and

Clean the thread of the screws that are

be cleaned. Otherwise there is a risk that

Position needle bearing with the lettered

Fit all bearings to the gearbox with some

Jointly replace tapered-roller bearings on

Inspect for burrs and damage.

Inspect for wear, replace if necessary

Gear pinions and synchronizer body

until there is no axial play.

Check fitting position.