5 Speed Manual Gearbox 02K

Service
Workshop Manual
Octavia 1997 ➤
5 speed Manual gearbox 02K
Edition 08.96
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Control, housing
35 - Wheels, shafts
39 - Final drive, differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety Protected
precautions
by copyright.for working
Copying for privateon motor purposes,
or commercial vehicles
in partmust, asis not
or in whole, a permitted
matter of course, be observed. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 ŠKODA AUTO a. s. S0051150020

Octavia 1997 ➤
5 speed Manual gearbox 02K - Edition 08.96
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on the gearbox up to 06.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Location on the gearbox as of 07.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Identification characters, aggregate assignment, ratios, capacities . . . . . . . . . . . . . . . . . . 2
2 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 General repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Summary of components - Foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Removing and installing the over-centre helper spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Removing and installing the clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Summary of components - Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7 Check hydraulic clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.8 Removing and installing the master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.9 Removing and installing the slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.10 Bleeding
Protected by copyright. Copying theorclutch
for private commercial system
purposes, .in .part
. . or. .in .whole,
. . . .is .not. .permitted
.................................... 20
with respect2to the correctness
Repairing clutchin this. .document.
of information . . . . . Copyright
. . . . . .by. ŠKODA
. . . . .AUTO
. . . A. . .S.��
.................................. 22
2.1 Fault finding power transmission - problems with the clutch and clutch control . . . . . . . . . . 22
2.2 Summary of components - repairing the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
34 - Control, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1 Repairing the gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.1 Fitting location of shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2 Summary of components - shift housing / shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3 Removing and installing shift housing with shift lever and shift rod . . . . . . . . . . . . . . . . . . 34
1.4 Removing and installing shift lever from shift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.5 Summary of components - reverse-shift mechanism at the gearbox . . . . . . . . . . . . . . . . . . 38
1.6 Setting the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.1 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.2 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3 Inspect gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.1 Gearbox overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.2 Summary of components - disassembling and assembling the gearbox . . . . . . . . . . . . . . 56
4.3 Summary of components - Removing and installing gearbox housing cover and 5th gear
........................................................................ 57
4.4 Summary of components - removing and installing gearbox housing and shift mechanism
........................................................................ 58
4.5 Summary of components - Removing and installing the drive shaft, output shaft, differential
gear and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.6 Mounting sequence - disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . 61
5 Repairing gearbox housing and gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7 Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
35 - Wheels, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
Octavia 1997 ➤
1 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1.1 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.1 Disassembling and assembling the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.2 Setting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
39 - Final drive, differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1 Replacing the flange shaft gasket rings (gearbox assembled) . . . . . . . . . . . . . . . . . . . . . . 104
1.1 Replacing the left flange shaft gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.2 Replacing the right flange shaft seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2 Differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.1 Disassembling and assembling the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.2 Adjusting the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3 Setting overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
ii
Contents unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Octavia 1997 ➤
00 – Technical data
1 Identification of the gearbox
Assignment ⇒ page 2 .
Location on the gearbox as of 07.99
Identification characters and manufacturing data of the gearbox
on the top of the clutch housing -arrow 1-
Gearbox 02K -arrow 2-
1.1 Location on the gearbox up to 06.99

on the bottom of the clutch housing -arrow 1-

-arrow 1-
Example: CZD 27 08 6
I I I I
I I I I
Identification Day Month Manufacturing
characters year -1996-
Additional data depend on the manufacturing.
Note unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
The gearbox identification characters also appear on the vehicle
data stickers.
1. Identification of the gearbox 1

Octavia 1997 ➤
1.2 Location on the gearbox as of 07.99

on the top of the clutch housing -arrow 1-

-arrow 1-
Example: DUU 14 09 9
I I I I
I I I I
Identification Day Month Manufacturing
characters year (1999)
Additional data depend on the manufacturing.
Note
The gearbox identification characters also appear on the vehicle

data stickers.
1.3 Identification characters, aggregate assignment, ratios, capacities

Identification characters CZE DRY DUT
Assignment: Engine 1.6 ltr./55 kW
2 Rep. Gr.00 - Technical data

Octavia 1997 ➤
Identification characters CZE DRY DUT

Ratio: Final drive 67 : 15 = 4,467 67 : 15 = 4,467 67 : 15 = 4,467
Z2:Z1 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 38 : 12 = 3,167
Speedometer 2,08 2,14 2,14
Capacity 1.9 litres
Specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch disc diameter ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 90 mm
Identification characters CZD DLP DNZ

Assignment: Engine 1.6 ltr./74kW
Z2:Z1 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 38 : 12 = 3,167
Speedometer 2,08 2,14 2,14
Capacity 1.9 litres
Identification characters DUU DUV DUU

Assignment: Engine 1.6 ltr./74 kW 1.6 ltr./75 kW
Z2:Z1 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 unless authorised by ŠKODA AUTO A. S.38 : 12AUTO
ŠKODA = 3,167
A. S. does not guarantee or accept any liability
Speedometer 2,14
Capacity 1.9 litres
1. Identification of the gearbox 3

Octavia 1997 ➤
Identification characters DUU DUV DUU

Identification characters DUS DRZ DUW

Assignment: Engine 1.9 ltr./50 kW SDI 1.4 ltr./55 kW
Z2:Z1 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
Reverse gear 38 : 12 = 3,167
Speedometer 2,14
Capacity 1.9 litres
Clutch disc diameter ∅ with⇒ Electronic
respect Catalogue
to the correctness of Original
of information Parts
in this document. Copyright by ŠKODA AUTO A. S.��

Octavia 1997 ➤
2 Overview of Transmission System

Designation
Note
-Arrows- in direction of travel
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Drive shaft
5 - Output shaft
6 - Differential gear
-Arrows- in direction of travel
2. Overview of Transmission System 5

Octavia 1997 ➤
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
T - Speedometer drive

Octavia 1997 ➤
3 General repair information

To carry out gearbox repairs successfully and correctly, scrupu‐
lous care and cleanliness, as well as the proper tools, are essen‐
tial 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 several times at numerous points in
the workshop manual - are summarized here.
Gearbox
♦ When installing, ensure the dowel sleeves are correctly loca‐
ted between the engine and gearbox.
♦ When replacing the gearbox check the oil level and if neces‐
sary top up ⇒ page 54 .
♦ Filling capacity ⇒ page 1 .
♦ Specification ⇒ electronic catalogue of original parts .
O-rings, gasket rings, gaskets, sealant
On gearboxes with paper gaskets:
♦ 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 disassem‐
bly.
Lightly oil radial shaft seals at outside diameter before mounting
and fill half the space between the sealing lips -arrow- with sealing
grease -G 052 128 A1- .
The unless
openauthorised
side ofbythe ŠKODAsealing
AUTO A. rings is turned
S. ŠKODA AUTO A. towards the fluid
S. does not guarantee to any liability
or accept
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 replac‐
ing the gaskets and gasket rings ⇒ page 54 .
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 the groove.
3. General repair information 7

Octavia 1997 ➤
Replace roll pins. Fitting position: Slot -A- longitudinal to power

flow -arrow-.
Screws, nuts
♦ Slacken the bolts and nuts against the tightening sequence.
♦ Slacken and tighten nuts and bolts for attaching covers and
housings without tightening sequence diagonally across in
stages.
♦ Do not twist particularly sensitive parts - e.g. clutch pressure
plates - and slacken and tighten diagonally across in stages.
♦ 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 brush. Insert bolts with locking agent -
AMV 185 101 A1- .
♦ The threaded holes into which self-locking screws or screws
with locking agent were screwed in (e.g. with a screw-tap)
must be cleaned. Otherwise there is a risk that the screws will
shear at the next disassembly.
Bearings
♦ Position needleunless
bearing with the lettered side (thicker end) to‐
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
wards the drift pin.with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
♦ Fit all bearings to the gearbox with some gearbox fluid.
♦ Jointly replace tapered-roller bearings on 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 ,
e.g. -VAS 6414- , to approx. 100°C. When assembling, press
up to the stop until there is no axial play.
♦ Do not exchange the outer and inner rings of bearings of the
same size - bearings go in pairs.

Octavia 1997 ➤
Shims
♦ Gauge shims at several points with a micrometer. Different
tolerances allow to measure the required thickness for each
washer very precisely.
♦ Inspect for burrs and damage.
♦ Install only shims which are in perfect condition.
Synchronizer rings
♦ These are not interchangeable. If re-using, allocate synchron‐
izer rings to the same gear.
♦ 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 the induction heater
unit e.g. -VAS 6414- to approx. 100°C before pressing on.
♦ When assembling, press up to the stop until there is no axial
play.
♦ Check fitting position. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Sliding gears with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
♦ Inspect wheels 1st to 5th gear for small axial play or clearance
after installation.
Clutch control
♦ When removing gearbox, remove slave cylinder without open‐
ing the line system.
♦ If the slave cylinder with connected hydraulic line is removed,
do not depress the clutch pedal. Otherwise the piston is press‐
ed out of the slave cylinder.
♦ Do not tilt the clutch pressure plate, release or tighten in small
stages crosswise
♦ If the clutch pedal does not return to its initial position after the
coupling procedure - clutch pedal in home position - the clutch
system must be bled (further measures ⇒ page 15 ).
♦ In order to reduce unpleasant odours if the clutch is burnt,
thoroughly clean the clutch housing as well as the flywheel and
the engine on the side of the gearbox.
3. General repair information 9

Octavia 1997 ➤
30 – Clutch
1 Repairing clutch control
1.1 Overview
Note
♦ If the master or slave cylinder should be replaced due to a suspected defect, first check the clutch control
⇒ page 15 .
♦ 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.
♦ Grease all bearing and contact surfaces with Polycarbamide Grease -G 052 142 A2- .
♦ 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 ⇒ page 11
II - Summary of components -
Hydraulics ⇒ page 14
10 Rep. Gr.30 - Clutch

Octavia 1997 ➤
1.2 Summary of components - Foot controls
1 - Bulkhead
❑ with mount for bracket
and master cylinder
2 - Gasket
❑ always replace ⇒ Elec‐
tronic Catalogue of
Original Parts
3 - Bracket
❑ for support of clutch
pedal
4 - Screw
5 - Bracket
❑ for support of accelera‐
tor pedal and brake ped‐
al
6 - 25 Nm
❑ self-locking
tronic Catalogue of
Original Parts
7 - Connecting plate
8 - 25 Nm
❑ self-locking
tronic Catalogue of
Original Parts
9 - Bushing
10 - Bearing bolt
11 - Clutch pedal
❑ removing and installing
⇒ page 12
12 - Support
❑ removing and installing ⇒ page 14
13 - 25 Nm
❑ self-locking
❑ always replace ⇒ Electronic Catalogue of Original Parts
14 - Master cylinder
15 - Tubing
16 - Over-centre helper spring unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
17 - Bearing/over-helper centre spring
❑ insert in bracket
❑ to replace, remove and install the master cylinder ⇒ page 16
18 - Clutch pedal switch -F36-
1. Repairing clutch control 11

Octavia 1997 ➤
19 - Limit stop yoke

❑ for the clutch pedal
❑ Fitting position ⇒ page 16
20 - 25 Nm
❑ self-locking
1.3 Removing and installing the over-centre

helper spring
Special tools and workshop equipment required
♦ 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 -3317-
from 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 over-centre helper spring,
while doing so remove the assembly clamp -3317- .
1.4 Removing and installing the clutch pedal

Removing
– Remove clutch pedal switch -F36- (if present) ⇒ page 13 .
– Removing the with
over-centre helper spring ⇒ page 12 .
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
– Separate the clutch pedal from the master cylinder

⇒ page 16 .

Octavia 1997 ➤
– 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 over-centre helper spring ⇒ page 12 .
– If present, install clutch pedal switch -F36- ⇒ page 13 .
Tightening torque
Component Nm
Clutch pedal to bracket 251)
1) Always replace nut ⇒ Electronic Catalogue of Original Parts
1.5 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.
1.5.1 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.

Octavia 1997 ➤
1.5.2 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.
– Pull out the tappet -arrow- completely before assembly of the
clutch pedal switch.
– Insert the switch with the catch pegs -1- and -2- in 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 de‐
press).
• The clutch pedal must not be operated when installing it.
• The plunger is adjusted automatically when inserting the
clutch pedal switch.
1.6 Summary of components - Hydraulics
1 - Brake fluid reservoir

2 - Tubing
3 - Masterunless
cylinder
❑ removing and toinstalling
with respect the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
⇒ page 16
4 - Support
– only replace if the mas‐
ter cylinder has been re‐
moved
– removing ⇒ page 15
– installing ⇒ page 15
5 - Clutch pedal
⇒ page 12
6 - 25 Nm
❑ self-locking
tronic Catalogue of
Original Parts
7 - Support
❑ Mounted at the structure
8 - Release shaft
⇒ page 87
9 - Slave cylinder
⇒ page 19
10 - Collar screw, 25 Nm
11 - Support
❑ for tube-hose line pos. 12

Octavia 1997 ➤
12 - Tube-hose line
❑ assign according to ⇒ Electronic Catalogue of Original Parts
13 - Pipe connection/plug connection
14 - Dust cap
15 - Bleed valve
❑ Bleed the clutch system ⇒ page 20
16 - O-ring
❑ pull onto line connection
❑ insert with brake fluid
17 - Clamp
18 - Gearbox
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-.
1.7 Check hydraulic clutch control

• The pedal actuation must not be obstructed by moved or ad‐
ditional foot mats.
• Bleed the clutch system if necessary ⇒ page 20 .

Octavia 1997 ➤
– First of all check the brake fluid level in the brake fluid reser‐
voir.
Note
♦ The clutch hydraulic is connected to one of the chambers

-arrow 2- of the brake fluid reservoir by the return hose
-arrow 1-.
♦ 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 or below the gearbox, as well as on the noise
insulation under the gearbox.
♦ Check the correct routing of the tube-hose line between the
master and slave cylinder. The line must not be kinked or trap‐
ped.
– 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 ⇒ page 16 . At
the same time the first person must check if the clutch pedal
falls through on its own 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-.
1.8 Removing and installing the master cyl‐

inder
♦ Hose clamps up to 25 mm -MP7-602 (3094)-
♦ Pliers -T10005-

Octavia 1997 ➤
Removing
Note
♦ If the master cylinder must be replaced, first of all check the

hydraulic clutch control ⇒ page 15 .
♦ Unscrew the master cylinder from within the passenger com‐
partment.
♦ When performing the following work, make sure that no brake
fluid comes into contact with 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 .
– 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 -C- from the master
cylinder.
– Remove clutch pedal switch -F36- (if present) ⇒ page 13 .
Note
To remove the master cylinder completely remove the clutch con‐

trol. 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.

Octavia 1997 ➤
– 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.
– 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 unless
-direction of by
authorised arrow
ŠKODA3- outA.ofS. ŠKODA AUTO A. S. does not guarantee or accept any liability
AUTO
the bracket. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
Install
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.

Octavia 1997 ➤
– 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 ⇒ Chas‐
sis ⇒ Rep. Gr. 45 .
– After installing the master cylinder bleed the clutch system
⇒ page 20 .
– 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
1.9 Removing and installing the slave cylin‐

der
♦ Hose clamps up to 25 mm -MP7-602 (3094)-
Removing
– Remove noise insulation below engine/gearbox.

Octavia 1997 ➤
– Pull the tube-hose line out of the holder on the slave cylinder.
– Subsequently release the screws -arrows- and 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 17 (page 15) and subsequently the
tube-hose line from the slave cylinder. Close the line.
Install
following points:
– Press the clamp ⇒ Item 17 (page 15) 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
⇒ page 20 .
– Install noise insulation below engine/gearbox.
Tightening torque
Slave cylinder to gearbox 25 Nm
1.10 Bleeding the clutch system

♦ Brake filling and bleeding device e.g. -VAS 5234- or -ROM‐
ESS S15-
♦ Ventilation hose 670 mm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Note
♦ When performing the following work, make sure no brake fluid

comes into contact with the gearbox.
♦ 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 inter‐
mittently when bleeding the brake system.
Brake fluid specification ⇒ Chassis ⇒ Rep. Gr. 00 .

Use a bleeder hose (approx. 670 mm long) to bleed.

Octavia 1997 ➤
– 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.

Octavia 1997 ➤
2 Repairing clutch
2.1 Fault finding power transmission - prob‐

lems with the clutch and clutch control
Note
Check hydraulic clutch control ⇒ page 15 .
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 Measure
Clutch pedal does not return to ini‐ ♦ Air in line system. – Vent air from the line system;
tial position. top up with brake fluid.
♦ Line system, master cylinder or – Replace defective component,
slave cylinder leaking. vent air from the line system; top
up with brake fluid.
♦ Membrane spring of the pres‐ – Replace pressure plate.
sure plate broken.

Actuating force on the clutch pedal ♦ Over-centre helper spring de‐ – Replace over-centre helper
too high. fective. spring.
♦ Clutch release force increased – Inform customer (higher release

due to wear of clutch linings. force with increased wear).
– Replace clutch disc, when the

distance base/rivet is below 0.1
mm.
♦ Pressure plate with wrong – Assign pressure plate according
spring identification. to ⇒ Electronic Catalogue of
Original Parts .
♦ Mechanical fault at the pressure – Replace defective parts.
plate or the clutch disc.
Protected ♦ ClutchCopying
by copyright. disc on the serration
for private – inCheck
or commercial purposes, part or in serration of the hub for
whole, is not permitted
sluggish/jams.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not damage
guarantee or(burrs).
accept any Replace
liability the
clutch
with respect to the correctness of information in this document. Copyright disc ifAUTO
by ŠKODA necessary.
A. S.��
– Clean the hub and the drive

shaft serration from corrosion
and residues of lubricant and
grease with grease for plug ser‐
ration of clutch disc -G 000 100
- . Move clutch disc back and
forth, remove excess grease.
♦ Clutch push rod and release – Lightly grease contact points
plate (pressure plate) sluggish. with grease for plug serration of
clutch disc -G 000 100- .
– Lightly grease clutch push rod.

Octavia 1997 ➤

Clutch control noises. ♦ Release bearing defective. – Replace release bearing.
♦ Centre displacement of engine/ – Check dowel sleeves.

gearbox.
♦ Clutch disk incorrectly mounted. – Correct the fitting.
♦ Wrong clutch disc installed. – Use the ⇒ Electronic Catalogue

of Original Parts for the assign‐
ment of the clutch disc.

Scratch noises when the forward or ♦ Air in the system, clutch does – Check and bleed system, top up
reverse gear is engaged, gearschift not separate fully. with brake fluid.
jams, hooks, is sluggish, shifting
not possible, clutch without opera‐
tion.
♦ Master cylinder or slave cylinder – Replace defective component,
is leaking, line is leaking. top up with brake fluid, vent air
from the system.
♦ The travel of the clutch pedal is – Inform customer.
not sufficent (carpet, foot mat
under the pedal), pedal is not
fully depressed.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. ♦ doesPressure
not guaranteeplate uneven
or accept due to in‐
any liability – Check components, if necessa‐
correctbyinstallation,
with respect to the correctness of information in this document. Copyright ŠKODA AUTO A.clutchS.�� disc ry replace, make sure the cen‐
warped due to improper han‐ tering pins are correctly fitted.
dling.
– If afterwards scratching still oc‐
curs, 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. – Use the ⇒ Electronic Catalogue
♦ Lining glued to the flywheel – Slightly rub down the friction sur‐
(long immobilization time, high faces of the clutch lining, if nec‐
humidity). essary when corrosion occurs in
a larger area, replace the com‐
ponent completely.
♦ Clutch disc on the serration – Check the hub for damage, if
sluggish/jams. Corroded hub, necessary replace the clutch
damaged during assembly. Hub disc.
profile knocked out on one side.
– Remove corrosion from the hub
and the shaft as well as residues
of lubricant. Lightly grease shaft
with grease for plug serration of
clutch disc -G 000 100 - .
– Move clutch disc back and forth,

remove excess grease.
– Check the position of the dowel

sleeves when the hub profile is
knocked out.
♦ The stroke of the pressure plate – Use the ⇒ Electronic Catalogue
is too low (wrong pressure plate of Original Parts for the assign‐
installed). ment of the pressure plate.
2. Repairing clutch 23
Octavia 1997 ➤

♦ Displacement of engine/gear‐ – Before installing the gearbox, in‐
box too large (dowel sleeves sert the dowel sleeves.
missing), support panel of clutch
plate bent through this. – Check clutch disc and pressure
plate for damage, if necessary
replace.
♦ The lining is spalled off because – Replace clutch disc. Inform cus‐
of too high revs (shift back into tomer.
lower gears during high
speeds).
♦ When starting, linings are spal‐
led off through slipping for too
long a time.
♦ Clutch push rod too short due to – Replace clutch push rod. Check
wear. release bearing, replace if nec‐
essary.
– Lightly grease contact points of

clutch push rod to release bear‐
ing with grease for plug serration
of clutch disc -G 000 100 - .

Load alteration shocks when push‐ ♦ Assembly bracket is too soft. – Inform customer. Use the ⇒
ing the accelerator pedal down Electronic Catalogue of Original
sharply and when the engine speed Parts for the assignment of the
drops suddenly. hanger.
♦ Irregular engine running. – Check engine setting, correct.
♦ Clutch disc with predamper is – Inform customer.

built in against gear rattling.
♦ Centre
unless authorised displacement
by ŠKODA AUTO A. S. ŠKODAof engine/
AUTO A. S. –
doesTest dowelor sleeves,
not guarantee replace
accept any liability if
gearbox.
with respect necessary.
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��

Clutch slips, no or poor acceleration ♦ Wrong clutch disc fitted, wrong – Use the ⇒ Electronic Catalogue
pressure plate installed. of Original Parts for the assign‐
ment of the clutch disc and the
pressure plate.
♦ Clutch disc worn out, burnt, – Replace clutch disc.
pressure plate overheated,
scoring, pressure plate warped – Replace pressure plate.
through incorrect assembly,
contact pressure of the pressure – Inform customer.
plate too low, driving error, nat‐
ural wear.
♦ Clutch disc, pressure plate, fly‐ – Replace clutch disc.

wheel - oily. Shaft seal of the
engine or the gearbox defective. – Clean contact surfaces of pres‐
Grease on the contact surface sure plate and flywheel.
through excess greasing of the
hub. – Replace shaft seal, remove ex‐
cess grease from the drive shaft.
♦ Clutch disk incorrectly mounted. – Correct the fitting, check clutch
disc, replace if necessary.

Octavia 1997 ➤

♦ Gasket ring for push rod in the – Replace gasket ring, clutch disc.
drive shaft leaks. Bearing bush‐
ing for push rod in the drive shaft – Check bearing bushing for
knocked out. clutch push rod, replace if nec‐
essary.
– Clean pressure plate, flywheel.

Clutch grabbing, ♦ Air in the system. – Bleed system, check brake fluid
unit shaking level, check system for leaks.
– Replace defective part.

♦ Engine does not run clean. – Check engine setting, correct.
♦ Driving error, speed too low – Inform customer.

when starting.
♦ Wrong clutch disc installed. – Use the ⇒ Electronic Catalogue

♦ Assembly bracket too soft, – Use the ⇒ Electronic Catalogue
knocked out. of Original Parts for the assign‐
ment of the assembly bracket.
♦ Clutch lining oily, contact sur‐ – Check shaft seal of the drive
face of pressure plate and fly‐ shaft for clutch or check crank‐
wheel oily (oil leakage from the shaft, if necessary replace.
clutch housing).
– Replace clutch disc, clean pres‐
sure plate and flywheel.
♦ Drive schaft too heavily greased – Clean pressure plate and fly‐
(traces of grease on the clutch wheel free of grease, replace in
disc, pressure plate and fly‐ the event of damage (traces of
wheel). wear, overheating, grooves).
– Remove traces of grease from

hub and shaft, grease shaft
lightly with grease for plug ser‐
ration of clutch disc -
G 000 100- .
– Move clutch disc back and forth,

remove excess grease.

Acoustic load alteration shock ♦ Carrier earth/drive shaft is ac‐ – Inform customer.
“clicking” when coupling (release celerated with sudden coupling.
clutch pedal). The drive shaft serration of the
pinions in mesh knocks; for
clutch
Protected by copyright. Copying discs
for private with predamper
or commercial theor in whole, is not permitted
purposes, in part
unless authorised by ŠKODAnoiseAUTO A.increases
S. ŠKODA AUTO as A.the predam‐
S. does not guarantee or accept any liability
per ofreaches
with respect to the correctness informationthe
in thisstop.
document. Copyright by ŠKODA AUTO A. S.��

Noises in idle. ♦ Torsional damper spring bro‐ – Replace clutch disc.
ken.
Octavia 1997 ➤

♦ Clutch disc fitted without pre‐– Use the ⇒ Electronic Catalogue
damper (idle rattling). of Original Parts for the assign‐
♦ Pressure plate warped, broken, – Replace pressure plate.
imbalance.
♦ Irregular engine running. – Check engine setting, correct if

necessary.
♦ The displacement of the engine – Before installing the gearbox, in‐
to the gearbox is too large (dow‐ sert the dowel sleeves.
el sleeves are missing).
♦ Intermediate plate rubs on the – Insert intermediate plate on

flywheel. sealing flange and push onto the
dowel sleeves.
2.2 Summary of components - repairing the

clutch
♦ Grease for the plug serration of the clutch disc -G 000 100-
Note
♦ Before replacing the clutch disc and pressure plate fault finding power transmission - observe complaints
of the clutch and clutch control ⇒ page 22 .
♦ If the dowel sleeves are not present, this can result in difficulties to shift, clutch problems and if necessary
noises from gearbox (gear rattling).
♦ Replace the clutch discs and pressure plates if the riveting is damaged or loose.
♦ 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 centering holes or the
centering slots in the pressure plate. Otherwise TDC is no longer correct on the flywheel.

Octavia 1997 ➤
1 - Screw, 20 Nm
❑ Release or tighten grad‐
ually and crosswise
2 - Flywheel
⇒ Engine ⇒ Rep. Gr.
13
❑ make sure the centering
pins are tight
❑ 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 hous‐
ing marked in different
colours. Assignment
⇒ page 82
3 - Clutch disc
❑ center ⇒ page 27
❑ Diameter ⇒ Electronic
Catalogue of Original
Parts
4 - Clutch push rod
❑ grease in the area of the
bearing bushing in the
drive shaft
5 - Retaining loop
6 - Release plate
❑ Apply a very thinProtected
layer of by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
grease for plug unless
serration of clutch
authorised by ŠKODA disc
AUTO-GA. 000 100-
S. ŠKODA to the
AUTO A. S.contact surface
does not guarantee and support
or accept any liability for the clutch push
rod. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
7 - Fixing screw of pressure plate at crankshaft

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

♦ Counterholder -MP1-221 (VW 558)-
♦ Locating disc -T10268-
♦ Centering device -MP2-400-
Octavia 1997 ➤
Removing
– Removing the gearbox ⇒ page 44 .
– Remove flywheel, to do so lock with counterholder -MP1-221
(VW 558)- .
– Remove clutch disc.
– Lever and remove the retaining ring -A- for 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.
– 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 remov‐
al.

Octavia 1997 ➤
– 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 ⇒ page 26 .
Note
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 -MP1-221 (VW 558)- as for the removal.
– Installing the gearbox ⇒ page 44 .
Octavia 1997 ➤
34 – Control, housing
1 Repairing the gearshift mechanism
1.1 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
30 Rep. Gr.34 - Control, housing

Octavia 1997 ➤
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 ⇒ Electrical System
⇒ Rep. Gr. 27 .
♦ Grease all bearing and contact surfaces with grease -G 000 450 02- .
shift housing / shift lever
⇒ page 32
reverse-shift mechanism at the
gearbox ⇒ page 38
Removing and installing shift
housing ⇒ page 34 .
Setting the shift mechanism

⇒ page 40 .
1. Repairing the gearshift mechanism 31

Octavia 1997 ➤
1.2 Summary of components - shift housing / shift lever
Note
Grease all bearing and contact surfaces with grease -G 000 450 02- .
1 - Gearshift knob
together with the collar
Pos. 2
❑ removing ⇒ page 33
and ⇒ page 33
2 - Collar
together with the gear‐
shift knob Pos. 1
and ⇒ page 33
❑ Separate collar from
gearshift knob
⇒ page 34
❑ before installing, as‐
semble with gearshift
knob ⇒ page 34
3 - Sound absorption
❑ only for vehiclesunless
fitted
with a 1.9 litre/50 kW en‐ to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
with respect
gine
4 - Clamping sleeve
❑ connects collar with
gearshift knob
⇒ page 34
5 - Open warm-type clamp
❑ for securing the gear‐
shift knob to the gear‐
shift lever
❑ open ⇒ page 33
tronic Catalogue of
Original Parts
❑ attach with hose binding claw -V.A.G 1275- onto the gearshift knob
6 - Shift lever
❑ removing and installing from shift housing ⇒ page 36
7 - Spacer bush
8 - Collar screw, 25 Nm
9 - Shift housing
10 - Gear shift rod
❑ after installing set shift mechanism ⇒ page 40

Octavia 1997 ➤
11 - 20 Nm
12 - 25 Nm
13 - Pressure spring
14 - Stop
❑ after installing set shift mechanism ⇒ page 40
15 - 25 Nm
❑ Coat thread with locking agent -D 000 600 A2-
16 - Ball socket
17 - Bushing
18 - Shock absorber
19 - 15 Nm
Remove gearshift knob and collar

– Pull out the collar for the shift lever towards the top -arrows-.
Open warm-type clamp

– Open the open warm-type clamp -arrow- and pull off gearshift
knob together with the collar.

Octavia 1997 ➤
Separate gearshift knob from collar and assemble with collar

– Turn collar inside out.
– Lever off clamping sleeve -arrow- with 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.
1.3 Removing and installing shift housing

with shift lever and shift rod
♦ Hose binding claw -V.A.G 1275-
Removing
– 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 -arrow- and pull off gearshift
knob together with the collar.
– Remove sound absorption ⇒ Item 3 (page 32) , if present.

Octavia 1997 ➤
– 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-.
– 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
following points:
– 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 .
– Setting the shift mechanism ⇒ page 40 .

Octavia 1997 ➤
– Attach new warm-type clamp -arrow- with hose binding claw -

V.A.G 1275- onto the gearshift knob.
Tightening torques
Shift housing to body 25 Nm
screw M8
Shift housing to body 25 Nm
nut M8
Shift rod to selector lever 25 Nm
1.4 Removing and installing shift lever from

shift housing
Removing
– Remove shift housing ⇒ page 34 .
– Release screw -arrow- and remove shift rod from shift lever.
– Unscrew screw -1- and remove bushing -2- with shock ab‐
sorber -3-.
– Unscrew screws -arrows- for stop -4-.

Octavia 1997 ➤
– 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 ⇒ page 34 .

♦ Setting the shift mechanism ⇒ page 40 .
Tightening torques
Shift rod to shift lever 20 Nm
Stop for shift lever to shift housing 25 Nm

Octavia 1997 ➤
1.5 Summary of components - reverse-shift mechanism at the gearbox
Note
Grease bearing and friction surfaces with grease -G 000 450 02- .
1 - 20 Nm
❑ self-locking
tronic Catalogue of
Original Parts
❑ Shift lever on gearbox
2 - Gearbox shift lever
❑ only fits in one position
on the gearshift shaft
3 - Gasket ring
4 - Selector rod
5 - Shift rod - front
6 - Console
❑ with relay lever and in‐
termediate lever
❑ Removal and installa‐
tion of relay lever and in‐
termediate lever
⇒ page 39
❑ Modification as of 08.98
new console
⇒ page 39
❑ Installation of the new
console on the gearbox
up to 07.98
⇒ page 39
7 - Coupling rod
8 - Shift rod
unless with balancing
weight with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
9 - Shield
❑ is fitted on the selector
lever
10 - Screw
❑ for warm-type clamp Pos. 11 to shift rod Pos. 13
11 - Open warm-type clamp
12 - Plug
13 - Gear shift rod
14 - Collar nut, 20 Nm
❑ self-locking
❑ for warm-type clamp Pos. 11 to shift rod Pos. 13
15 - Selector lever
16 - Bracket
❑ with guide shaft
❑ Removal and installation of the guide shaft ⇒ page 40

Octavia 1997 ➤
17 - Shield
18 - 25 Nm
19 - 25 Nm
❑ Console to gearbox
20 - Gearbox
Removing and installing relay lever and intermediate lever

1- Lock washer; mount up to the stop
2- Intermediate lever
3- Bearing bushing; must lock in the intermediate lever
4- Console
5- Bearing bushing; must lock in the console
6- 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-.
1- Console with larger location holes for the rubber grommets
and the bearing bushings
2- Rubber grommet
3- Bushing
4- Hexagon screw M8 x 135
5- Hexagon nut M8; always replace ⇒ Electronic Catalogue of
Original Parts
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
Protected gear. Copying for private or commercial purposes, in part or in whole, is not permitted
by copyright.

Octavia 1997 ➤
Removing and installing guide shaft

1- Cap
2- Lock washer; mount up to the stop
3- Bushing
4- Ball; press off using a screwdriver; press out up to the stop
5- Bracket
6- Reversing lever
1.6 Setting the shift mechanism

♦ Shift lever gauge -3421-
Note
♦ The following are required for correct setting of the shift mech‐
anism:
♦ Operating and transmission elements of the shift mechanism
are in perfect condition.
♦ Shift mechanism operates freely.
♦ Gearbox, clutch and clutch control must be in perfect condi‐
tion.
• Gearbox in Neutral.
– Remove gearshift knob with collar ⇒ page 34 by
Protected . copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Loosen warm-type clamp -arrow-. The shift rod/selector
with respect leverof information in this document. Copyright by ŠKODA AUTO A. S.��
to the correctness
should move freely.

Octavia 1997 ➤
– Remove the bushing -3- from the shift lever ⇒ page 36 .

– Slacken screw -1- and -2- and on the right side press down‐
wards 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 by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless authorised
Make sure that no gear is engaged at the gearbox (neutral posi‐

tion).
– Tighten nut -arrow- for warm-type clamp to 20 Nm and take

out shift lever gauge -3421- .
– Install bushing for shift lever ⇒ page 36 .
– Depress clutch.
– Engage reverse gear.

Octavia 1997 ➤
– 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.
• The distance -a- must then be 2.0 mm

– If this is not the case, carry out fine adjustment.
Fine adjustment
• 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.

Octavia 1997 ➤
– 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 ⇒ page 34 .

Octavia 1997 ➤
2 Removing and installing the gearbox

♦ Alignment rails -MP3-457 (VW 457)- (change ⇒ page 44 )
♦ 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-
♦ Hexagon screw M8 x 25
Change
alignment rail -MP3-457 (VW 457)-
– The alignment rail -MP3-457 (VW 457)- is required when re‐
moving and installing the gearbox.
An additional hole -arrow- is necessary for attaching the align‐
ment 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)- .
2.1 Removing the gearbox
Note
All cable straps that have been loosened or cut open when the
gearbox was removed must be fitted again in the same location
when the gearbox
Protected is installed
by copyright. again.
Copying for private or commercial purposes, in part or in whole, is not permitted
– On models fitted with a coded radio set, pay attention to the
coding.
– Disconnect the earth strap from the battery with the ignition
off.

Octavia 1997 ➤
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.
– 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
– Unplug connector from reversing light switch -F4- -arrow-.

As of gearbox manufacturing date 03 08 8
– Unplug plug of the reversing
with respectlight switch -F4-
to the correctness -arrowin 3-.
of information this document. Copyright by ŠKODA AUTO A. S.��
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
2. Removing and installing the gearbox 45

Octavia 1997 ➤
– Lever off front shift rod -1- from shift lever -2- with screwdriver,
remove lock washer -3- and remove console -4- upwards.
– 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 the gearbox.
– Release screws -2- and remove control console -3- with cou‐
pling 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 acces‐
sible from the top.

Octavia 1997 ➤
– Install supporting device -MP9-200 (10-222A)- .
Note
When installing the lifting hooks of the supporting device, pay at‐
tention 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 2- from 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.
– 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.

Octavia 1997 ➤
– 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 .
– Release clamping sleeve -A- and separate the exhaust sys‐

tem.

– Separate front exhaust pipe from catalytic converter, to do so
unscrew nuts -arrows-.
– Unbolt pendulum support ⇒ page 48 , figure A34-0059.

Octavia 1997 ➤
– 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 threa‐

ded 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 -MP3-470 (3300 A)- and
tighten -arrows-.
– Carefully press engine/gearbox forward.
Note
Observe PAS line.

– Complete the gearbox jack with gearbox mount -3282- , ad‐
justing plate -3282/5- for “020” gearbox and mounting ele‐
ments 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 .
– Position gearbox jack below vehicle, arrow symbol -B-

( ⇒ page 49 , Fig. V34-2577) 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.

Octavia 1997 ➤
– Press gearbox off the engine and swivel towards the assembly
carrier.
– Change the gearbox position at the spindles of the gearbox
mount -3282- when lowering.
Note
Observe PAS line when lowering the gearbox.
2.1.1 Transporting the gearbox

– Screw down gearbox suspension device -MP3-478 (3336)-
onto clutch housing.
– 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.
2.2 Installing the gearbox

The installation of the gearbox occurs in reverse order. Install en‐
gine/gearbox mounting free of stress ⇒ Relevant Engine, Me‐
chanics; Rep.-Gr. 10 .

Octavia 1997 ➤
Note
♦ If the gearbox is replaced, if provided always refit the gearbox

shift lever and the console for the shift mechanism
⇒ page 38 .
♦ 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 cylinder block; insert if necessary.
If the dowel sleeves are not present, this can result in difficul‐
ties to shift, clutch problems and perhaps noises from the
gearbox (gear rattling).
♦ If the gearbox is inserted, ensure the intermediate plate is cor‐
rectly installed.
♦ Install the drive shafts on the gearbox ⇒ Chassis ⇒ Rep. Gr.
40 .
♦ Installing starter and cable ⇒ Electrical System ⇒ Rep. Gr.
27 .
♦ Check gear oil level ⇒ page 54 .
♦ Setting the shift mechanism ⇒ page 40 .
♦ Adjust assembly bracket ⇒ Engine ⇒ Rep. Gr. 10 .
♦ If the battery earth strap is disconnected and connected, carry
out additional operations ⇒ Electrical System ⇒ Rep. Gr. 27 .
2.2.1 Tightening torques

Gearbox to engine
Vehicles with 1.6 ltr./55 kW engine
Position Screw Qty Nm
1 M12 x 55 1 80
2,3 1) M12 x 55 1 80
4 1) M12 x 120 1 80
5 M12 x 55 1 80
6,7 M10 x 50 1 45
8 M12 x 35 1 20
9 M12 x 55 1 80
A Dowel sleeves for centering
1) Screw with threaded pin M8

Octavia 1997 ➤
Gearbox to engine
Vehicles with 1.6 ltr./74 kW and 1.6 ltr/75 kW engine
1 M12 x 65 1 80
2 1) M12 x 65 1 80
3,4 1) M12 x 140 1 80
5, 6, 7 M10 x 50 1 45
8 M12 x 80 1 80
Gearbox to engine
1 M12 x 55 1 80
2 1) M12 x 55 1 80
3,4 1) M12 x 140 1 80
5, 6, 7 M10 x 50 1 45
8 M12 x 55 1 80
Gearbox to engine
1 M12 x 65 1 80
2,3 1) M12 x 65 1 80
4 1) M12 x 140 1 80
5 M12 x 65 1 80
6,7 M10 x 50 1 45
8 M12 x 35 1 20
9 M12 x 65 1 80
Gearbox to body
– Replace screws -A- and -B-.
Screws -A- 60 Nm 90°1)
Screws -B- 40 Nm 90°1)
• 1) 90° corresponds to a quarter turn.

Octavia 1997 ➤
Component Tightening torque

Cover plate for flywheel 10 Nm
Slave cylinder to gearbox 25 Nm
Console for shift mechanism on gear‐ 25 Nm
box up to 07.98
Console for shift mechanism on gear‐ 25 Nm
box as of 08.98 1)
Shift rod to gearbox 1) 20 Nm
Gearbox shift lever to gearbox 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
Octavia 1997 ➤
3 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 .

Octavia 1997 ➤
4 Disassembling and assembling the

gearbox
4.1 Gearbox overview
1 - Clutch housing
❑ repairing ⇒ page 82
❑ disassembling and as‐
sembling ⇒ page 107
3 - Output shaft
disassembling and assem‐
bling
4 - Drive shaft
5 - 1st gear
6 - Reverse gear
7 - 2nd gear
8 - Cover for gearbox housing
9 - 5th gear
10 - 4th gear
11 - 3rd gear
12 - Gearbox housing
4. Disassembling and assembling the gearbox 55

Octavia 1997 ➤
4.2 Summary of components - disassembling and assembling the gearbox

Mounting sequence - disassembling and assembling the gearbox
⇒ page 61
Removing and installing gear‐
box housing cover and 5th
gear ⇒ page 57
removing and installing gear‐
box housing and gearshift
shaft ⇒ page 58
III - Summary of components -
Removing and installing the
drive shaft, output shaft, differ‐
ential gear and shift forks
⇒ page 60

Octavia 1997 ➤
4.3 Summary of components - Removing and installing gearbox housing cover

and 5th gear
1 - 25 Nm
❑ M8 x 62
❑ 4 pieces
2 - Screw cap
tronic Catalogue of
Original Parts
❑ installing ⇒ page 76
3 - 25 Nm
❑ M8 x 85
❑ 2 pieces, one screw is
located under the screw
cap Pos. 2
5 - Sliding sleeve/synchronizer
body for 5th gear with stop ring
6 - Circlip
❑ always replace dam‐
aged or over-tensioned
circlips ⇒ Electronic
Parts
7 - Thrust washer
8 - Gear pinion for 5th gear
❑ Fitting position: groove Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
to the top with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
9 - Lock washer
tronic Catalogue of Original Parts
10 - 5th gear shift fork
❑ adjust ⇒ page 74
11 - 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 ⇒ page 61

Octavia 1997 ➤
4.4 Summary of components - removing and installing gearbox housing and

shift mechanism
1 - Oval-head countersunk
screw, 15 Nm
❑ M7 x 23
❑ 4 pieces
❑ for tensioning plate/
grooved ball bearing to
gearbox housing
2 - 20 Nm
❑ for shaft/reverse gear
3 - Gearbox housing
❑ as of gearbox manufac‐
turing date 03 08 8 with
additional threaded
bore for the reversing
light switch -F4 - Pos. 9
❑ Assembly of a gearbox
housing with an addi‐
tional threaded bore on
gearboxes up to gear‐
box manufacturing date
02 08 8 ⇒ page 59
4 - Screw cap, 50 Nm unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
5 - O-ring
tronic Catalogue of
Original Parts
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 - Locking screw, 40 Nm
❑ for gearshift shaft
11 - Reversing light switch -F4- and locking screw for gearshift shaft, 23 Nm
❑ installed up to gearbox manufacturing date 02 08 8
❑ as of gearbox manufacturing date 03 08 8, the reversing light switch -F4- Pos. 9 and the locking screw
Pos. 10 are two components ⇒ page 59

Octavia 1997 ➤
12 - Circlip
❑ holds the conical ring, stop disc and pressure spring in position when the flange shaft is removed
13 - Conical ring
❑ with slots for thrust washer catch
❑ Fitting position: Cone towards differential gear housing
14 - Thrust washer
❑ Fitting position: Collar to pressure spring, leg (if present) to conical ring
16 - Flange shaft left
17 - Conical screw, 25 Nm
18 - 25 Nm
❑ M8 x 52
❑ 12 pieces
19 - 5 Nm
❑ Fixing screw for speedometer drive Pos. 21
20 - Support
21 - Drive for speedometer
22 - 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:
♦ Reversing light switch -F4- -1-authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless
♦ Locking screw for the gearshift shaft -2-
Tightening torques
Reversing light switch -F4- -1- 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-.
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 -arrow- with 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
Reversing light switch -F4- -2- 23 Nm
Hexagon screw M12 x 1.5 -1- 25 Nm

Octavia 1997 ➤
4.5 Summary of components - Removing and installing the drive shaft, output
shaft, differential gear and shift forks
1 - Circlip
❑ always replace dam‐
aged or over-tensioned
circlips ⇒ Electronic
Parts
2 - 4th gear pinion
❑ Fitting position
⇒ page 71
3 - Circlip
❑ for 3rd gear pinion
❑ Determining thickness
again ⇒ page 71
4 - 3rd gear pinion
⇒ page 70
❑ Set axial play
⇒ page 71
5 - 2nd gear sliding gear
6 - Needle bearing
❑ for 2nd gear
❑ Pull off inner ring
⇒ page 61
❑ Press on inner ring
⇒ page 61
7 - Sliding sleeve with 1st and
2nd gear synchronizer body
8 - 1st gear sliding gear
9 - Thrust washer
⇒ page 61
10 - 25 Nm and torque a further 90°
11 - Bearing support
❑ with outer ring/tapered-roller bearing large and stop for reverse gear
12 - Output shaft complete
❑ disassembling and assembling ⇒ page 61
❑ Protected
disassembling and assembling
by copyright. Copying ⇒ page
for private or commercial 107 in part or in whole, is not permitted
purposes,
14 - Gasket ringto the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
with respect
❑ for right flange shaft
❑ do not remove for disassembling and assembling the gearbox
❑ replace ⇒ page 105
15 - Circlip
❑ holds the conical ring, stop disc and pressure spring in position when the flange shaft is removed
16 - Conical ring
❑ with slots for thrust washer catch

Octavia 1997 ➤
❑ Fitting position: Cone towards differential gear housing
17 - Thrust washer
❑ Fitting position: Collar to pressure spring, leg (if present) to conical ring
❑ for flange shaft
19 - Right flange shaft
❑ for attaching the flange shaft
21 - Clutch push rod
22 - Clutch housing
23 - Reverse gear wheel
24 - Reverse shaft support
25 - Drive shaft
❑ disassembling and assembling ⇒ page 90
❑ Press off grooved ball bearing -arrow- before installing ⇒ page 90
❑ Install grooved ball bearing in the gearbox housing ⇒ page 61
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 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.
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
33 - for reverse gear shift fork
4.6 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
♦ Drive bushing -MP3-402 (VW 244 B)-
♦ Pressure plate -MP3-410 (VW 434)-
♦ Press-on sleeve -MP3-412 (VW 455)-
♦ Assembly device for drive shaft -MP3-422 (VW 391)-
♦ Supporting bridge -MP3-425 (30-211 A)-
♦ Pressure plate -MP3-431 (3002)-
♦ Pipe wrench -MP3-433 (3059)-
♦ Extractor -MP3-432 (3042)-

Octavia 1997 ➤
♦ Driver -MP3-435 (3097)-

♦ Pressure washer -MP3-455 (VW 447 H)-
♦ Gearbox mount -MP3-501-
♦ Drive bushing -MP3-512-
♦ Press sleeve -MP6-504-
♦ Assembly stand -MP9-101-
♦ Drawing ring -T30036/3 (2003/3)-
♦ Pressing tool -T30087 (3367)-
♦ Two-arm extractor -Kukko 20/10-
♦ Extraction hook -Kukko 1-250-
♦ Extraction hook -Matra V 170-
♦ Sealant -AMV 188 200 03-
4.6.1 Disassembling gearbox

– Place catch pan underneath.
– Drain gear oil, to this end unscrew oil drain plug -arrow-.
– 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 be‐
low.

Octavia 1997 ➤
– 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
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.
– Mount supporting bridge -MP3-425 (30-211 A)- for drive shaft.

A - 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-.

Octavia 1997 ➤
– 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.

– Remove locking screw for gearshift shaft -A- with reversing
light switch -F4- -arrow-.

– 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.

Octavia 1997 ➤
– Unscrew torx screw to secure the reverse shaft support

-arrow-.
– Remove the left flange shaft.

– Remove the flange shaft with pressure spring, stop disc and
conical ring.
– Engage 5th gear -arrow 1-.

– Engage reverse gear -arrow 2- (front shift fork to the bottom).
–Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Unscrew screw for synchronizer body -arrow- using a 12 mm
polygon head wrench.

Octavia 1997 ➤
– Release lock washer for shift tube.
– 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 5thauthorised
unless gear sliding
by ŠKODAgear below
AUTO the syn‐
A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
chronizer body. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
– Remove circlip and thrust washer -A- for 5th gear pinion.

Octavia 1997 ➤
– Remove 5th gear pinion.

-A- Two-arm extractor , e.g. -Kukko 20/10- with 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.
– respect
with Attach assembly
to the device
correctness of -MP3-422
information (VWCopyright
in this document. 391)-bywith screw
ŠKODA AUTO(M8)A. S.��
-arrow- to gearbox housing. First remove dowel sleeve if nec‐
essary.
– 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 shaft.

Octavia 1997 ➤
– Remove 4th gear pinion.

-A- Two-arm extractor , e.g. -Kukko 20/10- with 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.
– Detach 3rd gear pinion with 2nd gear sliding gear.

-A- Two-arm extractor , e.g. -Kukko 20/10- with hook 250 mm
clamping depth.
– Remove synchronizer ring and needle bearing.
– Drive out reverse shaft support via screwed in bolt -arrow- us‐
ing a plastic hammer.
– Remove reverse gear from reverse lever.

Octavia 1997 ➤
– 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 20/10- with hook 250 mm
clamping depth.
– 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 ⇒ page 65 .

♦ Check the correct position of the rivets for the differential gear.
In the event that the riveted joints are loose, the fastening set
(screwed connection of pinion for final drive to differential gear
housing) must be installed ⇒ page 107 .
4.6.2 Assembling gearboxProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Insert the differential gear. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
– 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.

Octavia 1997 ➤
– Fitting position of the 1st and 2nd gear sliding sleeve/syn‐

chronizer body:
The groove marking on the front side -A- and 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 ap‐

prox. 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.
– 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)- .

Octavia 1997 ➤
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
♦ If the drive shaft was not disassembled:

♦ Press off grooved ball bearing for drive shaft ⇒ page 90 Pos.
10.
♦ Remove tensioning plate of ball bearing ⇒ page 90 Pos. 11.
– Insert drive shaft completely without grooved ball bearing.
– Mount supporting bridge -MP3-425 (30-211 A)- for drive shaft.

A - 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
unless -arrow- points
authorised by ŠKODAto 5thA.gear
AUTO sliding
S. ŠKODA AUTOgear -A-.not guarantee or accept any liability
A. S. does
– Position 4th gear sliding gear onto output shaft, drive in with
drive bushing -MP3-402 (VW 244 B)- and secure with circlip.

Octavia 1997 ➤
– 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 hous‐
ing cover on the gearbox housing do not get damaged, they must
be removed from the gearbox housing beforehand.
– 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.
Octavia 1997 ➤
– Align reverse shaft support. Distances -x- are the same.

– Apply sealant -AMV 188 200 03- uniformly on the sealing sur‐
face 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)- ⇒ page 63 .
– 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 ten‐
sioning plate for grooved ball bearing.
– Drive in 5th gear pinion
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 wash‐
er.
– Screw shift tube with pipe wrench -MP3-433 (3059)- towards
the right in the shift fork.

Octavia 1997 ➤
– 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 encapsulated. If not, coat the
screw with locking agent -D 000 600 A2- .
• Fitting position of the disc spring: the outside diameter (con‐
cave side) points to the 5th gear.
– 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-.
– Insert locking screw for gearshift shaft/ reversing light switch -
F4- -5- with sealant -AMV 188 200 03- .

– 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 “jump‐

ing out of gear” can be excluded.

Octavia 1997 ➤
– 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 dimension of “a” = 1.3 mm. Correct the di‐
mension 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 sur‐
face of the gearbox housing.
– Install cover -arrow- for gearbox housing (6 screws).
Note
One of the 6 screws is located inside the cover.

Octavia 1997 ➤
– 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.
– 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 A- for drive shaft.

Octavia 1997 ➤
– Insert the clutch push rod -A- in the drive shaft

-direction of arrow-.

Octavia 1997 ➤
5 Repairing gearbox housing and gear‐

shift shaft
♦ 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-
1 - Gearbox housing
❑ when replacing: adjust
the differential gear
⇒ page 113
❑ as of gearbox manufac‐
turing date 03 08 8 with
additional threaded
bore for the reversing
light switch -F4 -
⇒ page 58
2 - Fitting sleeve
❑ (2 pieces)
3 - Bushing
❑ remove with pliers
❑ drive in up to stop
4 - Cap
❑ for gearbox bleeder
5 - Gearshift shaft
⇒ page 61
6 - Stop cap
7 - Pressure spring
8 - Retaining bracket
❑ when removing the cir‐
clip Pos. 9 hold the re‐
taining bracket, then Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
carefully slacken the unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
pressure spring Pos. 7 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
9 - Circlip
tronic Catalogue of
Original Parts
10 - Needle bearing
❑ for output shaft

Octavia 1997 ➤
11 - Reversing light switch -F4- , 23 Nm

12 - Locking screw, 40 Nm
13 - Outer ring/tapered-roller bearing
❑ for differential
❑ when replacing: adjust the differential gear ⇒ page 113
14 - Adjusting washer “S1”
❑ Setting overview ⇒ page 116
15 - Reversing light switch -F4- and locking screw for gearshift shaft, 23 Nm
❑ installed up to gearbox manufacturing date 02 08 8
❑ as of gearbox manufacturing date 03 08 8, the reversing light switch -F4- and the locking screw are two
components ⇒ page 58
16 - Gasket ring
❑ for left flange shaft
17 - Ball sleeve
18 - Gasket ring
❑ can be replaced on an installed gearbox
Removing gasket ring for gearshift shaft

– Lever out using a by
Protected screwdriver in for
copyright. Copying -direction of the arrow-.
private or commercial purposes, in part or in whole, is not permitted
5. Repairing gearbox housing and gearshift shaft 79

Octavia 1997 ➤
Install gasket for gearshift shaft

– Insert up to the stop.
– Drive in with -MP3-462/8- when the gearbox is removed.
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 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

Octavia 1997 ➤
Drive in needle bearing up to stop
5. Repairing gearbox housing and gearshift shaft 81

Octavia 1997 ➤
6 Repairing clutch housing

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

❑ without magnet
2 - Fitting sleeve
❑ (2 pieces)
❑ always 1 mm thick
4 - Outer ring/tapered-roller
bearing
❑ for differential
❑ extracting and inserting
⇒ page 107
❑ when replacing: adjust
the differential gear
⇒ page 113Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
5 - Magnet with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
❑ is held in position by the

separator surface of the
housing
❑ insert with the sealant -
AMV 188 200 03-
❑ Setting overview
⇒ page 116
7 - Outer ring/tapered-roller
bearing
❑ extracting and inserting
⇒ page 97
❑ when replacing: set the
output shaft
⇒ page 102
8 - Needle bearing
❑ for drive shaft
❑ inserting ⇒ page 84

Octavia 1997 ➤
9 - 25 Nm
❑ with locking teeth below the screw head
10 - Reverse lever
12 - Support for reverse lever
13 - Sliding block
14 - Bushing for starter
❑ not present on all gearboxes
❑ assign according to ⇒ Electronic Catalogue of Original Parts
❑ can be replaced on an installed gearbox
15 - Screw plug
❑ green - clutch diameter 210 mm
❑ white - clutch diameter 190 and 200 mm
Note
Consequences when interchanging the screw plugs:
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 - Cap
17 - Clutch housing
❑ Insert oil strainer ⇒ page 84
❑ when replacing: Set output shaft and differential gear ⇒ page 116
18 - Gasket ring for drive shaft
19 - Bushing
❑ for gasket ring Pos.20
20 - Gasket ring
❑ for right flange shaft
6. Repairing clutch housing 83

Octavia 1997 ➤
Insert oil strainer -A- in the clutch housing
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

Octavia 1997 ➤
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 by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless authorised
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)- .
Levering out the bushing with a screwdriver -arrow-
6. Repairing clutch housing 85

Octavia 1997 ➤
Drive in the bushing

Octavia 1997 ➤
7 Repairing gearbox housing cover

♦ Ejector -MP1-502-
♦ Insertion tool -MP1-174-
♦ Driver -MP3-504-
♦ Pipe section -MP3-409 (VW 418 A)-
♦ Inserting device -MP3-436 (3128)-
1 - Screw cap
tronic Catalogue of
Original Parts
⇒ page 61
2 - Release bearing
❑ can be replaced on in‐
stalled gearbox, after re‐
moval of the screw cap
Pos. 1 and removal of
the slave cylinder
3 - Clutch
Protectedlever
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑unless
remove
authorisedlocking
by ŠKODA clip Pos.
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
5 for removing
❑ fits in one position only

4 - Bushing, small
5 - Locking clip
6 - Needle bearing
7 - Bushing, large
❑ pressing out
⇒ page 88
8 - Gasket ring
❑ can be replaced on in‐
stalled gearbox, to do so
remove release shaft
Pos. 9
9 - Release shaft
❑ 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
❑ as spare part only version with bearing bushings Pos. 7 and Pos. 4
11 - Oil filler plug, 25 Nm
7. Repairing gearbox housing cover 87

Octavia 1997 ➤
Press on large bushing -A-
Note
Instead of the driver -MP3-504- it is also possible to use the pres‐

sure spindle -MP6-405 (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)- .
Pull out small bushing

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

Octavia 1997 ➤
Insert gasket ring for release shaft

– Secure the cap for the gearbox housing in a vice fitted with
protective jaws.
7. Repairing gearbox housing cover 89

Octavia 1997 ➤
35 – Wheels, shafts
1 Disassembling and assembling the
drive shaft
1.1 Disassembling and assembling the

drive shaft
♦ 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-
Note
♦ When installing new pinions observe the technical data ⇒ page 2 .

♦ Do not over-tension the circlip Pos. 14. Always replace damaged or over-tensioned circlips.
90 Rep. Gr.35 - Wheels, shafts

Octavia 1997 ➤
1 - M17, 150 Nm
❑ self-locking
❑ always replace
❑ new screw is micro en‐
capsulated (thread with
locking agent)
⇒ page 61
2 - Disc spring
❑ Fitting position: the out‐
side diameter (concave
side) points to the 5th
gear
3 - Sliding sleeve/5th gear syn‐
chronizer body
⇒ page 61
4 - Stop ring
❑ prevents the arresters
from wandering
5 - 5th gear sliding sleeve
⇒ page 95
6 - 5th gear synchronizer body
7 - Arresters
❑ 3 pieces
8 - Spring
❑ by(2
Protected pieces)
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
9 - respect
with Oval-head countersunk
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.��
screw, 15 Nm
❑ M7 x 23
❑ 4 pieces
10 - Grooved ball bearing
❑ pressing off ⇒ page 94
❑ is pressed in when installing the drive shaft into the gearbox housing ⇒ page 61
11 - Tensioning plate
❑ secures the grooved ball bearing
12 - 4th gear sliding gear
13 - 4th gear synchronizer ring
❑ check for wear ⇒ page 94
14 - Circlip
15 - Sliding sleeve with 3rd and 4th gear synchronizer body
❑ press off with 3rd gear sliding gear ⇒ page 94
❑ Fitting position of synchronizer body ⇒ page 95
❑ assembling ⇒ page 95
❑ pressing on ⇒ page 95
1. Disassembling and assembling the drive shaft 91

Octavia 1997 ➤
16 - Sliding sleeve
17 - Synchronizer body
18 - Arresters
❑ 3 pieces
19 - Spring
❑ (2 pieces)
20 - Drive shaft
21 - Clutch housing
22 - Needle bearing
❑ for drive shaft
23 - Gasket ring for clutch push rod
❑ can be replaced on removed (not disassenbling) gearbox
❑ release with a screwdriver ⇒ page 93
24 - Bushing for clutch push rod
❑unless
canauthorised
be replaced
by ŠKODAon removed
AUTO A. S. ŠKODA(notAUTOdisassenbling) gearbox
A. S. does not guarantee or accept any liability
25 - Needle bearing
❑ for 3rd gear sliding gear
26 - 3rd gear sliding gear
27 - 3rd gear synchronizer ring
28 - Needle bearing
❑ for 4th gear sliding gear
29 - Gearbox housing
❑ 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 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 - Thrust washer
❑ after mounting the 5th gear needle bearing Pos. 32, press the 5th gear synchronizer ring Pos. 34 and
the 5th gear sliding gear Pos. 33 onto the 5th gear synchronizer body
32 - Needle bearing
❑ for 5th gear sliding gear
33 - 5th gear sliding gear
34 - 5th gear synchronizer ring

Octavia 1997 ➤
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
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 21/01-
– Use thread adapter of countersupport
unless authorised by ŠKODA AUTO A. ,S.e.g. ŠKODA-Kukko
AUTO A.22/1-
S. does for
not guarantee or accept any liability
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)- .

Octavia 1997 ➤
Drive in bearing bushing for clutch push rod

– Drive the bearing bushing into the drive shaft approx. 7 mm.
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
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 1.15 ... 1.75 mm 0.5 mm
4th gear 1.3 ... 1.9 mm
5th gear 1.3 ... 1.9 mm

Octavia 1997 ➤
Fitting position of the 3rd and 4th gear synchronizer body

The shorter serration below the round slot -arrow A- points to‐
wards the 3rd gear.
The groove on the front side -arrow B- points towards the 4th gear.
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 an‐
gled end of the spring must grip into the hollow arrester.
Press on the synchronizer body with the 3rd and 4th gear sliding
sleeve Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Fitting position of the 5th gear sliding sleeve

The chamfer at the rigid serration -arrow 1- points at the same
time towards the shaft -arrow 2- of the 5th gear synchronizer
body.
gled end of the spring must grip into the hollow arrester.

Octavia 1997 ➤
Fitting position of thrust washer for 5th gear sliding gear

The chamfer -arrowin 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)- ⇒ page 96 .
– 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.

Octavia 1997 ➤
2 Output shaft
2.1 Disassembling and assembling the out‐

put shaft
♦ Drift -MP1-178-
♦ Ejector -MP1-502-
♦ Drift -MP3-403 (VW 295)-
♦ Pipe section -MP3-414 (VW 516)-
♦ Separating device -Kukko 17/2-
Note
♦ When installing new pinions or a new output shaft observe the technical data ⇒ page 2 .
♦ Replace both tapered-roller bearings together.
♦ Do not over-tension the circlips. Always replace damaged or over-tensioned circlips.
♦ If the clutch housing, output shaft (drive train) or tapered-roller bearing is replaced, it is necessary to adjust
the output shaft ⇒ page 102 .
2. Output shaft 97
Octavia 1997 ➤

2 - Circlip for 5th gear pinion
3 - Thrust washer
4 - 5th gear pinion
⇒ page 61
5 - Gearbox housing
6 - Needle bearing
⇒ page 78
7 - Circlip for 4th gear pinion
8 - 4th gear pinion
⇒ page 69
9 - Circlip for 3rd gear pinion
❑ Determining thickness
again ⇒ page 69
10 - 3rd gear pinion
⇒ page 69
❑ Set axial
Protected play Copying for private or commercial purposes, in part or in whole, is not permitted
by copyright.
⇒ page
unless 69 by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
authorised
11 - 2nd gear sliding gear
12 - Needle bearing for 2nd
gear sliding gear
❑ Pull off inner ring
⇒ page 62
❑ Press on inner ring
⇒ page 69
13 - 2nd gear synchronizer ring
14 - Sliding sleeve with 1st and 2nd gear synchronizer body
❑ Assembling sliding sleeve/synchronizer body ⇒ page 100 and ⇒ page 100
15 - 1st gear synchronizer ring
❑ Identification ⇒ page 99
16 - 1st gear sliding gear
17 - Spring
18 - Sliding sleeve
19 - Synchronizer body
20 - Arresters
❑ 3 pieces
21 - Needle bearing
❑ for 1st gear
22 - Thrust washer

Octavia 1997 ➤
23 - Clutch housing
❑ Setting overview ⇒ page 116
25 - Outer ring/tapered-roller bearing small
26 - Inner ring/tapered-roller bearing small
27 - Output shaft
❑ is paired with the gear pinion of the final drive, when replacing they must both be replaced
❑ adjust ⇒ page 102
28 - Inner ring/tapered-roller bearing large
29 - 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 1.1…1.7 mm 0.5 mm
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.
2. Output shaft 99
Octavia 1997 ➤
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.
Assembly of the sliding sleeve/synchronizer body for 1st and 2nd

gear
gled end of with
therespect
spring must
to the grip ofinto
correctness the hollow
information arrester.
in this document. Copyright by ŠKODA AUTO A. S.��
Removing outer ring/tapered-roller bearing small

A - Interior extractor 37...46 mm , e.g. -Kukko 21/6-

Octavia 1997 ➤
Pressing in small outer ring/tapered-roller bearing
Press off small inner ring/tapered-roller bearing

Note
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- .
Pressing off large inner ring/tapered-roller bearing

Note
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 ap‐
prox. 100°C, place in position and press down.
2. Output shaft 101

Octavia 1997 ➤
2.2 Setting output shaft

(Determine adjusting washer for output shaft)
♦ Drift -MP3-403 (VW 295)-
♦ Gauge block plate -MP3-405/17 (VW 385/17)-
♦ Spindle of assembly device -MP3-434 (3066)-
♦ Universal dial gauge holder -MP3-447 (VW 387)-
The output shaft must be re-set when the following components
were changed:
♦ Drive train
♦ Clutch housing
or
♦ Tapered-roller bearing
Setting overview ⇒ page 116 .
– 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°.

Octavia 1997 ➤
– 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 es‐
tablished 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
– Remove output shaft and pull out small outer ring for tapered-
roller bearing.
A - Interior extractor 37...46 mm , e.g. -Kukko 21/6-
The following adjusting washers are available:
Thickness (mm) Spare part No.
0,65 020 311 391 P
0,70 020 311 391 Q
0,75 020 311 391
0,80 020 311 391 A
0,85 020 311 391 B
0,90 020 311 391 C
0,95 020 311 391 D
1,00 020 311 391 E
1,05 020 311 391 F
1,10 020 311 391 G
1,15 020 311 391 H
1,20 020 311 391 J
1,25 020 311 391 K
1,30 020 311 391 L
1,35 020
Protected by copyright. 311 for
Copying 391 M or commercial purposes, in part or in whole, is not permitted
private
1,40 unless authorised by020
ŠKODA 311 391
AUTO A. S.NŠKODA AUTO A. S. does not guarantee or accept any liability
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.
– Press in outer ring/tapered-roller bearing with the determined
adjusting washer (1.15 mm in the example) ⇒ page 97 and
install output shaft.
– Tighten hexagon screws for the bearing support in clutch
housing to tightening torque.
2. Output shaft 103

Octavia 1997 ➤
39 – Final drive, differential

1 Replacing the flange shaft gasket
rings (gearbox assembled)
Replacing the left flange shaft gasket ring ⇒ page 104 .
Replacing the right flange shaft gasket ring ⇒ page 105 .
Observe the general repair instructions ⇒ page 7 .
1.1 Replacing the left flange shaft gasket

ring
♦ Extraction hook -MP3-419/37 (VW 771/37)-
♦ Drive bushing -MP3-430 (2035)-
♦ Inertia extractor -MP9-501-
♦ Catch pan
♦ Sealing grease -G 052 128 A1-
1.1.1 Removing
– 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
Protectedshaft, to this
by copyright. endforinsert
Copying private or commercial purposes, in part or in whole, is not permitted
two screws in the flange and using a tyre iron hold the shaft.
– Remove the flange shaft together with the pressure spring.
– Pull out gasket ring for flange shaft with inertia extractor -
MP9-501- and extraction hook -MP3-419/37 (VW 771/37)- .
104 Rep. Gr.39 - Final drive, differential

Octavia 1997 ➤
1.1.2 Install
– Drive the new seal ring in up to the stop, do not twist the seal
ring.
– Fill half the space between the sealing lip 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 ⇒ page 54 .
– 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
1.2 Replacing the right flange shaft seal ring

♦ Drive bushing -MP3-430 (2035)-
♦ Assembly device -MP6-414 (3253)-
♦ Catch pan
♦ Sealing grease -G 052 128 A1-
1.2.1 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.
1. Replacing the flange shaft gasket rings (gearbox assembled) 105

Octavia 1997 ➤
– Lever out gasket ring with screwdriver -A-, while doing so sup‐
port the screwdriver on the cross member -3253/2
(MP6-414/2)- .
Note
♦ Do not damage the bushing as this will cause leaks.

♦ If damaged replace bushing ⇒ page 82 .
1.2.2 Install
– Drive in the new gasket ring up to the stop using a drive bush‐
ing -MP3-430 (2035)- , while doing so do not twist the gasket
ring.
– Fill half the space between the sealing lip 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 ⇒ page 54 .
– Install the noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
Tightening torque
Flange shaft on gearbox (conical screw) 25 Nm

Octavia 1997 ➤
2 Differential gear
2.1 Disassembling and assembling the dif‐

ferential gear
♦ Drift -MP3-403 (VW 295)-
♦ Press-on sleeve -MP3-412 (VW 455)-
♦ Pressure plate -MP3-431 (3002)-
♦ Thrust piece -MP3-448 (VW 408 A)-
♦ Drift -MP3-510-
♦ Mandrel -MP3-511-
♦ Tapered-roller bearing extractor -V.A.G 1582-
♦ Gripper -V.A.G 1582/3-
Note
♦ Before installing heat the inner ring of the tapered-roller bearing to 100°C.
♦ Replace both tapered-roller bearings together.
♦ When replacing the tapered-roller bearing of the differential housing, gearbox housing and clutch housing
adjust the differential ⇒ page 113 .
2. Differential gear 107

Octavia 1997 ➤
❑ screw to threaded con‐
nector Pos. 10 to attach
the flange shaft
2 - Flange shaft
❑ with hole for conical
screw
⇒ page 104
3 - Pressure spring for flange
shaft
❑ fitted behind flange
shaft
4 - Thrust washer
⇒ page 113
5 - Conical ring
❑ with slots for thrust
washer catch
❑ Fitting position: Cone to‐
wards differential gear
housing
6 - Circlip
❑ holds the conical ring,
stop disc and pressure
spring in position when
the flange shaft is re‐
moved
7 - Gearbox housing
8 - Stop disc compound
❑ insert with gear oil
9 - Differential bevel gear large
10 - Threaded part
11 - Differential bevel gear shaft
❑ after removing the tensioning sleeve Pos. 12, drive out with drift pin -MP3-510-
12 - Tensioning sleeve
❑ to secure the differential bevel gear shaft
13 - Differential bevel gear small
14 - Rivet
❑ only in the series; for attaching gear pinion/final drive Pos. 20 to differential gear housing
❑ bore out ⇒ page 111
Note

❑ always 1 mm thickby copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Protected

Octavia 1997 ➤

❑ drive out ⇒ page 109 , to do so first remove sleeve Pos. 25
17 - Inner ring/tapered-roller bearing
❑ remove ⇒ page 110
18 - Clutch housing
19 - Fastening set
❑ only for customer service
❑ Nut, 65 Nm
20 - Pinion for final drive
❑ series riveted
❑ is paired with the output shaft, replace together
❑ heat to 100 °C before fitting
❑ place on differential housing ⇒ page 112
❑ screw ⇒ page 112
21 - Differential gear housing
❑ extracting
unless authorised by ŠKODA AUTO ⇒ A.page 110AUTO A. S. does not guarantee or accept any liability
S. ŠKODA
❑ Determine thickness ⇒ page 113
24 - Gasket ring
25 - Bushing
❑ for gasket ring/right flange shaft
Driving outer ring/tapered-roller bearing from clutch housing

First remove bushing for gasket ring/right flange shaft.

Octavia 1997 ➤
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.
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

Octavia 1997 ➤
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.
Removing and installing the tensioning sleeve for differential bev‐

el 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 -MP3-510- .
Install
• Differential bevel gears and differential bevel gear shaft are
installed.
– Drive in the new tensioning sleeve into the differential gear
housing up to the stop.
with Pressing
respect to the off pinion/final
correctness drive
of information in this document. Copyright by ŠKODA AUTO A. S.��

Octavia 1997 ➤
Fitting location of the pinion/final drive

• The circular slot -arrow 1- points to the screw-on surface of the
differential gear housing -B-.
• The chamfer -arrow 2- of the gear pinion/final drive -A- points
upwards.
Heat pinion/final drive to approx. 100°C and install

– Guide the pinion/final drive during fitting with screws -A- from
the repair kit for the for the gearbox 02K.
Screw pinion/final drive and differential housing

Use special screws with shims and nuts according to the ⇒ Elec‐
tronic 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 posi‐
tion 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.

Octavia 1997 ➤
Fitting position of thrust washer for the conical ring -1-

The 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-.
2.2 Adjusting the differential gear

♦ Drift -MP3-403 (VW 295)-
♦ Gauge block plate -MP3-405/17-
♦ Universal dial gauge holder -MP3-447 (VW 387)-
♦ Mandrel -MP3-511-
The differential gear must be re-set when the following compo‐
nents are replaced:
♦ Gearbox housing
♦ Clutch housing
♦ Differential gear housing
or
♦ differential gear tapered-roller bearing
Setting overview ⇒ page 116 .

– 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 tapered-roller bearing are paired.
Do not interchange!

Octavia 1997 ➤
– Insert outer ring/tapered-roller bearing without adjusting wash‐

er 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 by adding to the es‐
tablished measured value for “S1” (Example: 0.90 mm) a constant
compression value (0.25 mm).
Example:
measured value 0.90 mm
+ compression (constant value)
Protected by copyright. Copying for private or 0.25 mmpurposes, in part or in whole, is not permitted
commercial
Thickness of the adjusting washer
with respect “S1”= of information1.15
to the correctness in thismm
document. Copyright by ŠKODA AUTO A. S.��

Octavia 1997 ➤
– 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 02K 409 210
0,70 02K 409 210 A
0,75 02K 409 210 B
0,80 02K 409 210 C
0,85 02K 409 210 D
0,90 02K 409 210 E
0,95 02K 409 210 F
1,00 02K 409 210 G
1,05 02K 409 210 H
1,10 02K 409 210 J
1,15 02K 409 210 K
1,20 02K 409 210 L
1,25 02K 409 210 M
Note
Assign the adjusting washers via the ⇒ Electronic Catalogue of

Original Parts .
– Insert adjusting washer of the determined thickness, the thick‐

est 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.

Octavia 1997 ➤
3 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
⇒ page 102 (S1 and S2)
⇒ page 113
Replaced part: Gearbox housing x
Clutch housing x x
Tapered-roller bearing for differential gear x
Output shaft (drive train) x
Differential gear housing x
Tapered-roller bearing for output shaft x

5 Speed Manual Gearbox 02K

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Service

Service Department. Technical Information

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Copyright © 2010 ŠKODA AUTO a. s. S0051150020

1 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

39 - Final drive, differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1.1 Location on the gearbox up to 06.99

Identification characters and manufacturing data of the gearbox

1. Identification of the gearbox 1

Gearbox 02K -arrow 2-

1.2 Location on the gearbox as of 07.99

Identification characters and manufacturing data of the gearbox

The gearbox identification characters also appear on the vehicle

Gearbox 02K -arrow 2-

1.3 Identification characters, aggregate assignment, ratios, capacities

2 Rep. Gr.00 - Technical data

Identification characters CZE DRY DUT

Identification characters CZD DLP DNZ

Identification characters DUU DUV DUU

1. Identification of the gearbox 3

Identification characters DUU DUV DUU

Identification characters DUS DRZ DUW

4 Rep. Gr.00 - Technical data

2 Overview of Transmission System

-Arrows- in direction of travel

-Arrows- in direction of travel

2. Overview of Transmission System 5

6 Rep. Gr.00 - Technical data

3 General repair information

3. General repair information 7

Replace roll pins. Fitting position: Slot -A- longitudinal to power

8 Rep. Gr.00 - Technical data

3. General repair information 9

10 Rep. Gr.30 - Clutch

1.2 Summary of components - Foot controls

1. Repairing clutch control 11

19 - Limit stop yoke

1.3 Removing and installing the over-centre

The bore hole -arrow- points towards the clutch pedal.

– Position the clutch pedal in home position and remove the

– First position the over-centre helper spring in the over-centre

1.4 Removing and installing the clutch pedal

– Separate the clutch pedal from the master cylinder

12 Rep. Gr.30 - Clutch

– The support -A- must be located on the actuating rod -B- of

1.5 Removing and installing clutch pedal

1.5.1 Removing and installing the clutch pedal

1. Repairing clutch control 13

1.5.2 Removing and installing the clutch pedal

1.6 Summary of components - Hydraulics

1 - Brake fluid reservoir

14 Rep. Gr.30 - Clutch

Lift off the support -A- in -the direction of the arrow-.

Push the actuator rod/master cylinder in the support -A- in

1.7 Check hydraulic clutch control

1. Repairing clutch control 15

♦ The clutch hydraulic is connected to one of the chambers

– Subsequently check the following components of the hydraulic

♦ Symptoms of an external leak are, amongst others, traces of

– Subsequently depress the clutch pedal carefully, at the same

1.8 Removing and installing the master cyl‐

16 Rep. Gr.30 - Clutch

♦ If the master cylinder must be replaced, first of all check the