Skoda-Fabia-Skoda-Rapid 2007-2009-2011 en Manual de Taller Caja de Transmision B929d3ee5a

Service
Workshop Manual
FABIA II 2007 ➤
Automatic 6-speed gearbox 09G
Edition 05.07
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
32 - Torque converter
37 - Control, housing
38 - Wheels, Control
39 - Final drive, differential gear

FABIA II 2007 ➤
Automatic 6-speed gearbox 09G - Edition 05.07
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical Data for the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification characters, aggregate assignment, ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Information and repair instructions for the automatic gearbox 09G . . . . . . . . . . . . . . . . . . 3
2.1 Information for the automatic gearbox 09G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Explanation of the terms used in this workshop manual . . . . . . . . . . . . . . . . . . . . . . . . . . 5
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Torque converter identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Draining the torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Removing and installing gasket ring for torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Checking the torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.5 Installing the torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
37 - Control, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Electric/Electronic components and fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Electric/Electronic components and fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Removing and installing automatic gearbox control unit J217 . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Repairing shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1 Inspecting the gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Inspecting and adjusting the selector lever control cable . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3 Dismantling and assembling the gearshift mechanism - Summary of components . . . . . . 24
2.4 Removing and Installing the cover for the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Removing and installing shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.6 Removing and installing the selector lever control cable . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.7 Removing and installing the Tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.8 Checking the plug connections at the gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . 34
3 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 Transporting an automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4 Inspecting ATF level and if necessary topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 Inspecting ATF level and if necessary topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2 Change ATF or top up after repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5 Removing and installing ATF radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1 ATF radiator - Overview of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2 Removing and installing ATF radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
38 - Wheels, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1 Removing and installing oil pan, oil filter, slide valve body and internal wiring looms . . . . 51
1.1 Oil pan, oil filter, slide valve body, internal wiring looms - Overview of components . . . . . . 52
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3 Removing and installing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.4 Removing and installing the slide valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.5 removing and installing wiring loom with 14-pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.6 Removing and installing wiring loom with 8-pin plug and integrated gearbox oil temperature
sender G93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Contents i
FABIA II 2007 ➤
1.7 Removing and installing the gearbox input r.p.m. sender G182 . . . . . . . . . . . . . . . . . . . . 72
1.8 Removing and installing the gearbox output r.p.m. sender G195 . . . . . . . . . . . . . . . . . . . . 73
2 Removing, installing and setting multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . 75
2.1 Removing and installing the multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.2 Setting multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
39 - Final drive, differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 Replace the flange shaft gasket rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Replacing the left flange shaft gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Replacing the right flange shaft seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2 Replacing the gasket ring for the gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.1 Replacing the gasket ring for the gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
ii Contents
FABIA II 2007 ➤
00 – Technical data
1 Technical Data for the Gearbox
1.1 Identification of the gearbox

The “Automatic 6-speed gearbox 09G” is installed in combination
with 4-cylinder engines. Assignment ⇒ page 1 .
Location of identification code letters on the gearbox
Identification characters and manufacturing data of the gearbox
-arrow 1- and -arrow 2-.
Example:
FXA Gearbox identification characters
02H2T0014 Serial number
4 02 : production year 2002
H : production month from A = January to M =
December
2T : identification of the gearbox from the manu‐
facturer, 2T = 09G
00144 : serial number for the production month,
this is the 144th gearbox for the month of August
09G 300 Part number
035G
AISIN AW Manufacturer: AISIN
Note
The gearbox identification characters also appear on the vehicle

data stickers.
1.2 Identification characters, aggregate assignment, ratios

Automatic gearbox 6-speed gearbox 09G
Identification characters JUF KGG
Manufac‐ from 05.07 06.08
tured through 05.08 07.10
Assignment Engine 1.6 ltr./77 kW
Torque con‐ Identification characters QAAA
verter
Ratio 1st gear 4,148
2nd gear 2,370
3rd gear 1,556
4th gear 1,155
5th gear 0,859
6th gear 0,686
Reverse gear 3,394
Intermediate Input gear 48
gear Output gear 53
Ratio 0,906
1. Technical Data for the Gearbox 1

FABIA II 2007 ➤

Final drive Drive pinion 15
Crown wheel 61
Ratio 4,067

Identification characters MFZ
Manufac‐ from 07.10
tured through
Torque con‐ Identification characters QAHA
verter
Ratio 1st gear 4,148
2nd gear 2,370
3rd gear 1,556
4th gear 1,155

5th gear 0,859
6th gear 0,686
Reverse gear 3,394
Intermediate Input gear 48
gear Output gear 53
Ratio 0,906
Final drive Drive pinion 15
Crown wheel 61
Ratio 4,067
1.3 Contents
Planetary gear
Contents Automatic gearbox 09G
New filling 6,0 - 6,1l
Top-up approx. 4.0 - 4.5 ltr 1)
Lubricant ⇒ Electronic Catalogue of Original
Parts
1) Filled for life: change the oil following repairs only.
Only ATF should be used as lubricant in the automatic gearbox
09G ⇒ Electronic Catalogue of Original Parts .
Checking ATF level, change ATF if necessary ⇒ page 43 .
2 Rep. Gr.00 - Technical data

FABIA II 2007 ➤
2 Information and repair instructions for

the automatic gearbox 09G
2.1 Information for the automatic gearbox

09G
Gearbox
The automatic 6 speed gearbox 09G is equipped with 6 hydraul‐
ically controlled forward gears. When the lockup clutch is closed,
these forward gears become mechanically driven gears by by‐
passing the converter slip.
Torque converter
The torque converter is equipped with a torque converter lockup
clutch. The closing of the lockup clutch is load and speed sensi‐
tive, and particularly low in vibrations, and without the converter
slip the lockup clutch drives all forward gears mechanically.
ATF

The ATF is filled for life. The ATF need not be changed within the
scope of servicing.
The ATF oil filling is for the planetary gear and final drive together.
Check and top up ⇒ page 43 .
♦ Only ATF available as spare part should be used in the auto‐
matic gearbox 09G. Other oils can lead to functional problems
or to failure of the gearbox, ATF spare part number ⇒ Elec‐
tronic catalogue of original parts .
Gear-change points change on upward and downward gradients
On upward or downward gradients, gear-changes are selected
automatically by additional gear-change mapping, according to
accelerator position and driving speed.
♦ On steep gradients, gear-change mapping is adapted to en‐
gine power output
♦ On steep gradients, gear-change mapping is adapted to the
braking effect of the engine.
♦ By directly selecting a gear via the Tiptronic, e.g. for a slope
during trailer operation, the motor braking effect is also fully
used.
2.2 Repair instructions

Scrupulous care and cleanliness as well as the proper tools are
essential requirements for carrying out proper and successful
gearbox repairs. 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. They apply to this
workshop manual.
Special tools
List of the special tools used in the workshop manual ⇒ Workshop
Equipment Electronic Catalogue .
Gearbox
♦ Each time a gearbox is installed, basic settings are required.
2. Information and repair instructions for the automatic gearbox 09G 3

FABIA II 2007 ➤
♦ Do not run the engine or tow the vehicle when the oil pan of
the gearbox has been removed or without ATF filling.
♦ If the automatic gearbox is replaced, check ATF level if nec‐
essary top up with ATF ⇒ page 43 . Capacity and specifica‐
tion ⇒ page 2 .
♦ Secure the torque converter against dropping out when the
gearbox is removed.
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Before installing the gearbox check the fitting position of the
torque converter ⇒ page 9 .
♦ When installing, take care with the correct positions of dowel
sleeves in the engine.
♦ Place removed parts on a clean surface and cover. Use foil
and paper. Do not use fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts. Remove spare parts from their wrap‐
ping immediately before fitting.

FABIA II 2007 ➤
O-rings, gasket rings, gaskets

♦ Always replace O-rings, gaskets and gasket rings.
♦ After removing gaskets, examine the contact surface in the
housing or on shafts for burrs or damage, and correct if nec‐
essary.
♦ Depending on location, before fitting a gasket ring, smear the
outer surface and sealing lip thinly with ATF or axle oil.
♦ Before inserting the O-rings coat with ATF to prevent the rings
being squashed during installation.
♦ The open side of the sealing rings is turned towards the oil.
♦ Never use other lubricants in the ATF area.
♦ Radial shaft seals - before mounting lightly oil at outside di‐
ameter and fill half the space between the sealing lips
-arrow- with sealing grease - G 052 128 A1- .
♦ After installation, inspect ATF level and if necessary top up
⇒ page 43 .
Locking elements

♦ Do not over-extend the circlips, if necessary replace.
♦ Circlips must be positioned in the base of the groove.
Screws, nuts
♦ Slacken and tighten nuts and bolts for attaching covers and
housings diagonally across.
♦ Do not twist particularly sensitive parts - e.g. the slide valve
body - and slacken and tighten diagonally across in stages.
♦ Tightening torques apply for non-oiled nuts and bolts.
♦ 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- .
♦ Clean all threaded holes into which self-locking bolts are in‐
serted, using a thread tap to remove locking agent residues.
Otherwise there is a risk that the bolts will shear at the next
disassembling.
♦ Replace the self-locking screws and nuts.
♦ Bolts that need to be turned at a certain angle after tightening
must always be replaced.
Targeted fault-finding
Before repairing the automatic gearbox 09G, try to determine the
origin of the damage as accurately as possible using the ⇒ Vehi‐
cle diagnosis, testing and information system VAS 5051 in the
“Targeted fault-finding” mode.
2.3 Explanation of the terms used in this

workshop manual
The following explanations are only related to this assembly: Au‐
tomatic gearbox 09G. They do not claim to be valid in all cases.
ATF (Automatic Transmission Fluid)
Gear oil for automatic gearbox.
ATF level
ATF level in the gearbox. To measure the ATF level, see the in‐
structions in the Workshop Repairs Manual.

FABIA II 2007 ➤
Brakes
They hold together the rotating components in the gearbox. As
opposed to the clutches the brakes are supported on the gearbox
housing.
Torque converter
Transfers the engine torque to the automatic gearbox and serves
as a hydraulic starting clutch. The torque converter also includes
the torque converter lockup clutch.
Self-diagnosis
The capability of the control unit for the automatic gearbox
-J217-:
♦ recognize faults,
♦ react to faults,
♦ store faults,
♦ Determine measured values and to display them in the meas‐
ured value block.
Perform self-diagnosis

– Connect ⇒ Vehicle diagnosis, testing and information system
VAS 5051 and perform “Targeted Fault Finding” or “Vehicle
self-diagnosis”.
Clutches
In combination with the brakes, the clutches switch between the
various forward and reverse gears of the planetary gears, thus
providing different forward gear ratios.
Wiring
Fitting locations of electrical cables and components in the gear‐
box.
Selector lever lock solenoid -N110-
Located in the gearshift mechanism close to the selector lever.
Prevents the (unintentional) shifting of the selector lever from po‐
sitions “P” and “N”, as long as the brake pedal is not pressed.
Solenoid valves
Open and shut the oil lines to the clutches and brakes.
Multi-function switch -F125-
The multi-function switch -F125- is screwed onto the top of the
gearbox housing to the gearshift shaft. It is an electrical switch,
which transfers the individual gears selected with the selector
lever to the gearbox control unit. It must be correctly set
⇒ page 77 .
Parking position
When the vehicle is parked, the selector lever locks the parking
gear in position “P” thereby preventing the vehicle from moving
off (unintentionally).
Planetary gear
The mechanical part of the automatic gearbox that is switched via
clutches and brakes without power flow interruption.
Slide valve body
Located below the gearbox and is surrounded by the oil pan of
the gearbox. Its valves regulate the hydraulic pressure and dis‐

FABIA II 2007 ➤
tribute it via the oil galleries to the gearshift elements (clutches

and brakes).
Automatic gearbox control unit -J217-
Control unit -J217- determines the shifting points. The function of
the gearbox is monitored via self-diagnosis. If components or
sensors fail, an emergency running programme is activated to
continuity of vehicle operation.
Torque converter lockup clutch
Mechanically transmits the engine torque to the gearbox.

FABIA II 2007 ➤
32 – Torque converter
1 Torque converter
Note
♦ Repair instructions ⇒ page 3 .

♦ Coat gasket rings with ATF. Other types of lubricant will cause
the gearbox hydraulic control system to malfunction.
1.1 Torque converter identification

There are different torque converters. Identification occurs with
identification characters -arrow-.
Assignment torque converter ⇒ page 1 .
Torque converter identification

(Gearbox installed)
1.2 Draining the torque converter

Special tools and workshop equipment required
♦ Oil aspirator unit -(z. B. V.A.G 1782) -
If the ATF has been contaminated or if the gearbox has had a
major repair, the torque converter should be drained as follows:
– Drain off the ATF from the torque converter using an oil aspi‐
ration unit -V.A.G 1782- .
1.3 Removing and installing gasket ring for

torque converter
♦ Ejection lever -MP3-418 (VW 681)-
♦ Thrust piece -T10175-
8 Rep. Gr.32 - Torque converter

FABIA II 2007 ➤
Removing gasket ring for torque converter

– Lever out gasket ring with ejection lever -MP3-418 (VW 681)- .
Install gasket ring for torque converter

– Insert the gasket ring for the torque converter using a pressure
plate - T10175- .
1.4 Checking the torque converter

– Check hub -arrow- of torque converter for traces of wear.
Note
The torque converter is welded and must be replaced completely

if damaged or faults.
1.5 Installing the torque converter

♦ Depth gauge
Work procedure
– Push the torque converter hub through the gasket ring up to
the first stop on the input shaft.
– Press the torque converter by hand into the converter housing
and turn it until the torque converter hub catches in the re‐
cesses of the inner gear of the ATF pump. The torque con‐
verter must be felt to slide in.
1. Torque converter 9
FABIA II 2007 ➤
– Measure the dimension -a- between the screw-on flange of the

gearbox housing and the contact surface of the threaded
bores of the torque converter using a depth gauge.
• The converter is correctly installed if the dimension -a- is at
least 19.5 mm.
– Absolutely ensure that the dimension -a- is maintained during
further assembly. The torque converter must not slide to the
front.
WARNING
If the converter is installed wrongly the driver of the torque

converter or the ATF pump will be destroyed when the gearbox
on the engine is connected at its flange.
When subsequently installing the gearbox, the following point

must be observed.
WARNING

Always check before and after tightening up the screws on the
flange of the engine/gearbox whether the torque converter be‐
hind the driver plate can be turned. In cases where the torque
converter cannot be turned one must assume that it is not
properly installed and that either the driver plate of the torque
converter or the ATF pump will be destroyed during final tight‐
ening of the bolted connections.
10 Rep. Gr.32 - Torque converter

FABIA II 2007 ➤
37 – Control, housing
1 Electric/Electronic components and
fitting locations
1.1 Electric/Electronic components and fitting locations
1 - Automatic gearbox control

unit -J217-
❑ Fitting location and re‐
moving and installing
⇒ page 16
❑ Control unit is checked
by self-diagnosis
2 - Diagnostic connection
❑ Fitting location: Cover in
driver's footwell
⇒ page 12
3 - Selector lever lock solenoid
-N110-
❑ Fitting location
⇒ page 13
❑ removing and installing
⇒ page 17
❑ is checked by self-diag‐
nosis
4 - Slide valve body
⇒ page 13
⇒ page 58
❑ Marking of solenoid
valves ⇒ page 55
5 - Wiring loom with 8-pin plug
and integrated gearbox oil
temperature sender -G93-
❑ Fitting location: Wiring
loom is fixed to the slide
valve body ⇒ page 13
❑ Gearbox oil tempera‐
ture sender -G93- is
checked by self-diagnosis
❑ removing and installing ⇒ page 71
❑ for solenoid valves and gearbox sensors
❑ Fitting location: Wiring loom is fixed to the slide valve body ⇒ page 13
❑ Identification of solenoid valves and wiring loom routing ⇒ page 55
7 - Multi-function switch -F125-
❑ Fitting location ⇒ page 14
❑ is checked by self-diagnosis
1. Electric/Electronic components and fitting locations 11

FABIA II 2007 ➤
8 - Cover for shift mechanism

❑ the Tiptronic switch -F189- ist integrated in the shift mechanism; Fitting location ⇒ page 14
9 - Relay for starter interlock switch
❑ Fitting location ⇒ Electrical System ⇒ Rep. Gr. 97
10 - Gearbox input r.p.m. sender -G182-
11 - Gearbox output r.p.m. sender -G195-
❑ measures the gearbox output speed
12 - Selector lever position indicator -Y6-
❑ a switched off gear display points to an emergency operation with deactivated gearbox control unit
❑ a fully lit gear display points to an emergency operation with activated gearbox control unit
❑ removing and installing ⇒ Electrical System ⇒ Rep. Gr. 90
13 - Kick-down switch -F8-
❑ Signal transfer from engine to gearbox control unit via CAN databus
❑ removing and installing accelerator pedal module ⇒ Engine ⇒ Rep. Gr. 20
14 - Brake light switch -F-
❑ removing and installing ⇒ Chassis ⇒ Rep. Gr. 46
Diagnostic connection
Fitting location: Cover in driver's footwell
12 Rep. Gr.37 - Control, housing

FABIA II 2007 ➤

Fitting location: Selector lever lock solenoid -N110- -A- is located
in the gearshift mechanism
Slide valve body

Fitting location: The slide valve body is bolted to the bottom of the
gearbox housing and covered with the gearbox oil pan.
Wiring loom with 8-pin plug and integrated gearbox oil tempera‐
ture sender -G93- -Arrow-
Fitting location: Wiring loom is fixed to the slide valve body
Wiring loom with 14-pin plug

Fitting location: Wiring loom is fixed to the slide valve body

FABIA II 2007 ➤
Multi-function switch -F125-
Fitting location: The multi-function switch is located at the top of

the gearbox. The plug connection -5- is directly placed onto the
multi-function switch.
Switch for Tiptronic -F189-

Fitting location: The Tiptronic switch -F189- is integrated into the
circuit board -A- of the gearshift mechanism.
The Tiptronic switch -F189- is installed firmly in the gearshift
mechanism and cannot be replaced individually. The removal and
installation procedure is only possible together with the gearshift
mechanism ⇒ page 27 .

FABIA II 2007 ➤
Gearbox output r.p.m. sender -G195-

Fitting location: The gearbox output r.p.m sender - G195-
-arrow 2- is fixed to the gearbox housing behind the slide valve
body.
Gearbox input r.p.m. sender -G182-

Fitting location: The gearbox input r.p.m sender -G182-
body.
Selector lever position indicator -Y6-

Fitting location: Integrated in the dash panel insert.
Note
The selector lever position indicator -Y6- can only be replaced

together with the dash panel insert.

FABIA II 2007 ➤
Kick-down switch -F8-
Brake light switch -F-

Fitting location: The brake light switch -F- -arrow- is located in the
foot controls.
Note
The switch may only be installed once to ensure that it has an

adequately tight fit.
1.2 Removing and installing automatic gear‐

box control unit -J217-
Fitting location: The control unit is located at the battery cover.
Removing the control unit
WARNING
Observe measures when disconnecting and connecting the

battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐

trical System ⇒ Rep. Gr. 27 .
– Unlock the plug connection from the gearbox control unit and
disconnect.

FABIA II 2007 ➤
– Press off locking tabs -arrows- from control unit holder.

– Remove control unit from the top.
Note
The adaptation values in the gearbox control unit are reset when
the plug connection of the gearbox control unit is separated. The
control unit must re-initialise these values after re-start. During
this “initialisation” the gearshift quality can be worse than usual.
Install
– Insert the control unit at the battery cover until it clicks into the
position of the locking tabs -arrows-.
– Mount the plug connection of the gearbox control unit.
WARNING

– Connect earth strap of battery ⇒ Electrical System ⇒ Rep.

Gr. 27 .
1.3 Removing and installing selector lever

lock solenoid -N110-
Removing
WARNING


– Removing the cover for the shift mechanism ⇒ page 26 .
– Remove centre console ⇒ Body Work ⇒ Rep. Gr. 68 .
– Pull out connector -A-.

FABIA II 2007 ➤
– Remove front exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26 with

bracket -1-.
– Remove underbody cover on right and left -arrows-.
– Remove tunnel bridge -arrows-.

– Unhook rear silencer in such a way that it does not come in
contact with the rear axle.
– Remove heat shield -arrows-.

FABIA II 2007 ➤
– Unscrew cover for bottom shift mechanism -arrows-.

– Carefully slide the cover with boot over the selector lever con‐
trol cable forward. At the same time do not damage the boot.
– Press off locking tabs -arrows A-.

– Slightly pull the solenoid out of the attachment.
– Pull solenoid control cable out of the catch -arrow B-.
Install
– Insert selector lever lock solenoid -N110- -A- into the gearshift
mechanism.
– Insert solenoid control cable into the catch -arrow B-.
The locking tabs -A- must click into place audibly.
– Position cover for bottom shift mechanism -arrows- and screw

on.

FABIA II 2007 ➤
– Attach front exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26 with bracket

-1-.
– Attach underbody cover on right and left -arrows-.
– Install tunnel bridge -arrows-.

FABIA II 2007 ➤
– Mount the plug connection -A-.

– Install centre console ⇒ Body Work ⇒ Rep. Gr. 68 .
– Installing the cover for the shift mechanism ⇒ page 26 .
WARNING


Gr. 27 .

FABIA II 2007 ➤
2 Repairing shift mechanism
2.1 Inspecting the gearshift mechanism
WARNING
Before working on the engine when the engine is running, in‐

sert the selector lever in position “P” and apply handbrake.
♦ In selector lever positions “S”, “D”, “R” and Tiptronic position

it must not be possible to activate the starter.
♦ At speeds above 5 km/h and shifting in selector lever position
“N” the selector lever lock solenoid must not engage and block
the selector lever. Selector lever can be shifted in a driving
position.
♦ At speeds below 5 km/h (virtual standstill) and shifting in se‐
lector lever position “N” the selector lever lock solenoid must
only engage after approx. 1 s. The selector lever can only be
moved from position “N” by activating the brake pedal.
Selector lever in position “P” and ignition switched on:
• Brake pedal is not operated:
The selector lever is locked and cannot be moved out of position
“P”. The selector lever lock solenoid blocks the selector lever.
• Brake pedal is operated:
The selector lever lock solenoid releases the selector lever. It is
possible to engage a driving gear position. Slowly shift selector
lever from “P” through “R, N, D, S”; while doing so check whether
the selector lever position in the dash panel insert corresponds
with the actual selector lever position.
Selector lever in position “N” and ignition switched on:
“N”. The selector lever lock solenoid blocks the selector lever.
possible to engage a driving gear position.
Selector lever in position “D” ignition and light switched on:
• Selector lever in Tiptronic gear leads to:
The lighting up of the “D” symbol in the selector lever position
indicator should go out and the “+” and “-” symbols should light
up.
When the gear selector lever is put into the Tiptronic gate, the
selector lever position display in the dash panel insert should
change from “PRNDS” to “654321”.
– Move selector lever in the Tiptronic gear to “+” and “-”.
When the gear selector lever is put into a higher or a lower driving
position, the selector lever position display in the dash panel in‐
sert should change.
– Inspecting and adjusting the selector lever control cable
⇒ page 23 .

FABIA II 2007 ➤
2.2 Inspecting and adjusting the selector

lever control cable
Inspection
– Shift selector lever into position “P”.
– Remove engine cover.
– Disconnect plug from automatic gearbox control unit -J217- .
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
Gr. 27 .
– Remove intake hose ⇒ Engine ⇒ Rep. Gr. 24 .
– Lever off the selector lever control cable -1- from the gearshift
shaft lever -3- e.g using an open-end wrench -2-.
– Press together the catches at the cable support of the selector
lever control cable -arrows- and pull out the selector lever
control cable from the cable support/gearbox.
– Lever off selector lever control cable in such a way that the
extremity can move freely.

♦ Do not bend or buckle selector lever control cable.
– Shift selector lever from “P” to “S”.
– Check front boot on the selector lever cable control for dam‐
age, if necessary replace control cable.
• Gearshift mechanism and selector lever control cable must
move smoothly when shifting gears, if necessary replace se‐
lector lever control cable ⇒ page 30 or repair gearshift mech‐
anism.
– Carefully push the selector lever control cable onto the gear‐
shift lever and insert into the cable support/gearbox.
Setting
The selector lever control cable must be set, if:
♦ the selector lever control cable was removed from the gearbox
♦ the engine was removed and installed or the gearbox was re‐
moved and installed
♦ the selector lever control cable or the shift mechanism was
removed and installed
♦ the position of the engine/gearbox was changed, e.g. during
a stress-free assembly
2. Repairing shift mechanism 23

FABIA II 2007 ➤
– Release screw -2- at the front ball socket of the selector lever
control cable -1-.
– Tip selector lever in position “P” slightly to the front and to the
rear, however under no circumstances move out of “P” .
– Position the gearshift lever -3- at the gearbox in “P”, i.e. push
the gearshift lever fully backwards against the direction of
travel.
Note
The locking lever must engage in parking gear, both front wheels
are blocked (cannot be simultaneously turned in one direction).
– Tighten screw -2- (13 Nm).

– Inspect gearshift mechanism ⇒ page 22 .
2.3 Dismantling and assembling the gear‐

shift mechanism - Summary of compo‐
nents
Note
Grease bearing and friction surfaces with grease -G 000 450 02- .
There is no mechanical ignition key anti-removal lock, but an

electrical anti-removal lock.

FABIA II 2007 ➤

⇒ page 26
2 - Intermediate piece
3 - 25 Nm
❑ 4 pieces
❑ for attaching the gear‐
shift mechanism to body
4 - Gearshift mechanism
(bearing pot)
⇒ page 27
❑ with firmly integrated cir‐
cuit board for gearshift
mechanism, do not
touch
❑ with firmly integrated
Tiptronic switch -F189- ,
this can be checked in
the “Targeted fault find‐
ing” ⇒ Vehicle diagno‐
sis, testing and informa‐
tion system VAS 5051
❑ replace gearshift me‐
chansim if Tiptronic
switch -F189- defective
⇒ page 27
-N110-
⇒ page 17
nosis
6 - Retaining clip
❑ for selector lever control cable on bearing pot
❑ replace
7 - Cover for gearshift mechanism
❑ with affixed gasket
8 - 9 Nm
❑ self-locking
❑ for attaching the cover to the gearshift mechanism
❑ 4 pieces
❑ replace ⇒ Electronic Catalogue of Original Parts
9 - Selector lever control cable
❑ do not bend or buckle
❑ if the boot is damaged the selector lever control cable must be replaced
❑ testing and adjusting ⇒ page 23
❑ Do not grease drawbar eye and ball socket.
10 - 13 Nm
❑ for holder - Pos. 11 at gearbox
11 - Support
❑ for selector lever control cable

FABIA II 2007 ➤
12 - 23 Nm
❑ for cable support to gearbox
❑ 2 pieces
13 - Cable support
❑ for selector lever control cable on gearbox
2.4 Removing and Installing the cover for

the shift mechanism
Removing the cover for the shift mechanism
WARNING


– Pull out the unlocking button of the selector lever handle up to
the end stop, the button remains blocked.
– Lift cover in the -direction of the arrow-.
– Separate plug connection from circuit board.
– Release the retaining clip -arrows- and pull off the cover.
Installing the cover for the shift mechanism
Installation is performed in the reverse order, pay attention to the
following points:
– Insert the plug connection for the circuit board.

FABIA II 2007 ➤
Always replace retaining clip -arrow- ⇒ Electronic Catalogue of

Original Parts .
Note
When inserting the plug connection ensure that the contact pins
of the circuit board are not bent and that the retaining lugs of the
cover do not break off.
2.5 Removing and installing shift mecha‐

nism
Removing shift mechanism
WARNING


– Removing the cover for the shift mechanism ⇒ page 26 .
– Separate plug connections -A- and -B-.
Gr. 27 .

FABIA II 2007 ➤
– Unhook the selector lever control cable -1- from the clip
-arrow- at the gearbox.

bracket -1-.
– Detach tunnel bridge below the exhaust system ⇒ Engine ⇒

Rep. Gr. 26 .

FABIA II 2007 ➤
– Unscrew the nuts -arrows-.

– Remove the shift mechanism together with the selector lever
control to the bottom, ensuring the selector lever control cable
does not get bent and kinked.
Note
The shift mechanism can also be replaced without selector lever

control cable, to do so the selector lever control cable must be
separated from the shift mechanism. Removing selector lever
control cable ⇒ page 30 .
Installing shift mechanism

following points:
Tightening torques of screws or nuts as well as the instructions,
if the screws or nuts have to be replaced ⇒ page 24 .
– Insert the selector lever control cable in the cable support/
gearbox and carefully press onto the gearshift lever. Do not
bend the gearshift lever, otherwise it will no longer be possible
to adjust the gearshift operation exactly.
– Do not bend or buckle selector lever control cable.

FABIA II 2007 ➤
– Hang the selector lever control cable -1- in the clip -arrow- at
the gearbox. For the routing of the selector lever control cable
to the ATF cooler maintain a distance of at least 5 mm.
– Install exhaust system and align free of stress ⇒ Engine ⇒
Rep. Gr. 26 .
– Installing the cover for the shift mechanism ⇒ page 26 .
WARNING


Gr. 27 .
– Setting selector lever control cable ⇒ page 23 .
2.6 Removing and installing the selector

lever control cable
Removing selector lever control cable
WARNING


Gr. 27 .
– Remove intake hose ⇒ Engine; Rep. Gr. 24 .

FABIA II 2007 ➤
– Shift selector lever to position “Tiptronic”.

bracket -1-.
– Detach tunnel bridge below the exhaust system ⇒ Engine ⇒

Rep. Gr. 26 .

FABIA II 2007 ➤
– Unscrew cover for bottom shift mechanism -arrows-.

– Push away selector lever control cable -2- in

-direction of arrow- from the selector lever -3-.
– Pull out securing clasp -1-.
– Pull the selector lever control cable out of the protective cover.
Note
Do not bend or buckle selector lever control cable.
Installing selector lever control cable

following points:
Tightening torques of screws or nuts as well as the instructions,
if the screws or nuts have to be replaced ⇒ page 24 .

FABIA II 2007 ➤
– Press the selector lever control cable -2- onto the selector lev‐
er -3-.
– Fit new locking clasp -1- for selector lever control cable at the
gearshift mechanism.
– Screw on cover for bottom shift mechanism -arrows-.

– Push the gearshift lever -3- on the gearbox fully backwards

into position “P” (in the fig.: fully to the right), until the parking
lock engages. Both front wheels are blocked (cannot be si‐
multaneously turned in one direction).
the gearbox. For the routing of the selector lever control cable
to the ATF cooler maintain a distance of at least 5 mm.

FABIA II 2007 ➤
control cable -1-.
– Tighten screw -2- to 13 Nm.
– Shift selector lever from “P” to “S” and shift back again.
lector lever control cable or repair gearshift mechanism.
Rep. Gr. 26 .
WARNING


Gr. 27 .
2.7 Removing and installing the Tiptronic

switch -F189-
The Tiptronic switch is integrated firmly in the gearshift mecha‐
nism and cannot be replaced separately. To replace, the gearshift
mechanism must be replaced ⇒ page 27 .
2.8 Checking the plug connections at the

gearshift mechanism
• Before repairing or checking the plug connections, try to de‐
termine the origin of the damage as accurately as possible
using the ⇒ Vehicle diagnosis, testing and information system
VAS 5051 in the functions “Targeted fault finding”, “Vehicle
self-diagnosis” and “Measuring method”.
– Before checking the plug connections, all control units in the
vehicle should be checked for fault entries and if necessary
the faults must be rectified.
Plug connections at the gearshift mechanism
A - 2-pin plug connection to selector lever lock solenoid - N110-
B - 10-pin plug connection for connection lines from the gearshift
mechanism to the automatic gearbox control unit -J217-
C - 10-pin plug connection to cover for gearshift mechanism

FABIA II 2007 ➤
3 Removing and installing the gearbox

♦ Supporting device -MP9-200 (10-222A)-
♦ Cap -MP9-200/3 (10-222A/3)-
♦ Hook for MP9-200 and T30099 -MP9-200/10 (10-222A/10)-
♦ Engine/gearbox jack -V.A.G 1383 A-
♦ Gearbox mount -3282-
♦ Adjusting plate -3282/36-
♦ Wedge -T10161-
♦ Hose clamps -MP7-602 (3094)-
3.1 Removing the gearbox

Note
♦ If the battery earth strap is disconnected and connected, carry

out additional operations ⇒ Electrical System ⇒ Rep. Gr. 27 .
♦ All cable straps which are detached or cut open when remov‐
ing, should be fitted on again in the same place when installing.

Gr. 27 .
– Lever off the selector lever control cable -2- from gearshift
lever e.g. using an open-end wrench -1-.
– Disconnect plug connection -3-.
– Unscrew the cable support for the selector lever control cable
from the gearbox.
3. Removing and installing the gearbox 35

FABIA II 2007 ➤
– Unscrew earth strap -3-.

– Detach cables -1- and -2- at starter and expose.
– Mark hoses of ATF radiator to ATF radiator, in order to prevent
interchanging when installing.
Note
Depending on the as-built configuration a small plastic tube is lo‐

cated in the feed of the ATF radiator, which must be re-installed
during installation.
– Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Clamp off the ATF-radiator hoses with hose clamps -MP7-602

(3094)- and remove from ATF-radiator.
– Close ATF-radiator with a clean plug.
– Release all connecting screws of the engine/gearbox acces‐
sible from the top.

– Fit supporting device -MP9-200 (10-222A)- .

– Take up the weight of the engine/gearbox unit at the spindles.
– Remove gearbox console -A-, to this end release screws -1-

and -2-.
– Remove both front wheels.
– Remove the front left wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .

FABIA II 2007 ➤
– Separate plug connections -1- and -2- at automatic gearbox.

– Unscrew bracket for electrical cables from the gearbox.
– Tie up bracket with the electrical cables to the front.
– Remove the starter ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Remove pre-exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26 .
– Unscrew bolts -1-.

– Unbolt coupling rod -2- -arrow-.
– Swivel out the suspension strut, to do so press the drive shaft

out of the wheel bearing unit using the wedge -T10161- .
– Repeat procedure on the opposite side of the vehicle.
– Swivel out the wheel-bearing housing while guiding the drive
shaft into the wheelhouse and secure to the suspension strut
with e.g. wire.
– Tie up the right drive shaft as far as possible. Avoid damaging
the paintwork on the drive shaft during this operation.
– Unbolt the pendulum support -arrows-.

FABIA II 2007 ➤
Note
Unscrew bracket for AC pipe (if present) from the fan shroud.
– Screw out screws -arrows- and take out fan shroud down‐
wards.
– Remove the cap from the opening for the converter nuts.
– Unscrew the 6 nuts -arrow- from the torque converter. To do
so turn the crankshaft each time a further 60°.
Note
If not all 6 nuts are unscrewed from the torque converter, the tor‐
que converter is pulled out when removing the gearbox from the
engine!
– Lower the engine/gearbox assembly with the spindle approx.

50 mm.

FABIA II 2007 ➤
– Mount engine/gearbox mount -3282- onto engine/gearbox

jack -V.A.G 1383 A- .
– Position adjusting plate -3282/36 - onto the gearbox mount
-3282- (adjusting plate fits in only one position).
– Align arms of the gearbox mount with the holes in the adjusting
plate.
– Screw in the mounting elements as shown on the adjusting
plate.
– Position engine/gearbox jack -V.A.G 1383 A- below vehicle,
arrow symbol on adjusting plate points in the direction of travel.
– Align the adjusting plate parallel to the gearbox.
– Secure the gearbox on the gearbox support -3282- using
screw -1-.
– Position gearbox by lifting the gearbox mount from the bottom.
– Unscrew the remaining connecting screws of the engine/gear‐
box.
– Push gearbox off engine, simultaneously press off the torque
converter from the driver disc.
– Push torque converter against the ATF-pump -arrow-.

– Carefully swivel gearbox towards the assembly carrier.
– Carefully lower the gearbox and guide past the assembly car‐
rier downwards.
– Change the gearbox position at the spindles of the gearbox
mount -3282- when lowering.
– Secure torque converter against dropping out.
3.2 Installing the gearbox

Installation is carried out in the reverse order. Pay attention to the
following:
Note
♦ When performing installation work replace the self-locking

nuts and screws.
♦ Replace screws which have been tightened to a torquing angle
as well as gasket rings and seals.
♦ Check whether the dowel sleeves for centering the gearbox
are present in the cylinder block, insert if necessary.
♦ Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts .
♦ Before installing the gearbox one should ensure that the tor‐
que converter is correctly installed in the gearbox ⇒ page 9 .

FABIA II 2007 ➤
WARNING

– Inspecting ATF level, if necessary topping up ⇒ page 43 .

– Inspect setting of selector lever control cable and adjust if
necessary ⇒ page 23 .
3.2.1 Tightening torques

Vehicles with 1.6 ltr./77 kW engine
Gearbox to engine
Pos. Screw Piece Nm
s
1 M12 x 55 1 80
2 M12 x 55 1 80

3 M12 x 55 1 80
4 1) 2) M12 x 165 1 80
5 M12 x 80 1 80
6 M10 x 50 1 40
7 M10 x 50 1 40
8 M12 x 80 1 80
A Dowel sleeves for centering
Note
The second screw (80 Nm) M12 x 551) 2) to secure the starter to
the gearbox is not shown in the illustration.
1) Screw with threaded pin M8.

2) Starter fixing screw.
Gearbox console to gearbox and gearbox mount

Component Nm
Gearbox console -A- to gearbox, 40 + 90° 1) 2)
screws -1-
Gearbox console -A- to gearbox 60 + 90° 1) 2)
mount, screws -2-
1) Replace bolts.
2) 90° corresponds to a quarter turn.
Note
Install engine/gearbox mounting free of stress ⇒ Engine ⇒ Rep.

Gr. 10 .

FABIA II 2007 ➤
Torque converter on the driver plate

Component Nm
Torque converter to drive plate, 6 nuts 57 1)
-arrow-
1) Replace nuts.
All other bolted connections
Component Nm
Screws/nuts M6 10
M8 20
M10 45
M12 65
3.3 Transporting an automatic gearbox

♦ Shackle -10-222 A/12-
Work procedure
For transporting the automatic gearbox, the shackle -10-222 A/
12- can be used.
– Secure torque converter against dropping out when transport‐
ing.
– Attach shackle -10-222 A/12- to gearbox housing.
3.3.1 Attaching gearbox to assembly stand

♦ Engine and gearbox mount - MP1-202 (wie VW540, jedoch für
Montageständer MP9-101)-

FABIA II 2007 ➤
– Attach gearbox to engine and gearbox mount - MP1-202 (wie

VW540, jedoch für Montageständer MP9-101)- -arrows-.
– The workshop crane can be used
⇒ “3.3 Transporting an automatic gearbox”, page 41 for in‐
serting.
WARNING
The center of gravity of the gearbox is outside the turning cen‐

ter at the tensioning block. For turning the gearbox, a second
mechanic must hold the gearbox housing in order to avoid a
back-swing.
Note
If the filled gearbox on the assembly support is turned upwards

together with the oil pan, then the ventilation holes for the gearbox
housing must be closed off.


FABIA II 2007 ➤
4 Inspecting ATF level and if necessary

topping up
4.1 Inspecting ATF level and if necessary

topping up
♦ Vehicle diagnosis, measurement and information system -
VAS 5051-
♦ ATF filling system -V.A.G 1924-
♦ Adapter for oil filling -VAS 6262-
♦ Adapter for ATF oil filling -VAS 6262/2-
♦ Protective goggles
Test conditions
• Gearbox must not be in the emergency running mode.

• Vehicle on level ground.
• With selector lever in “P” position, let the engine idle.
• Air conditioning and heating switched off.
• ⇒ Vehicle diagnosis, testing and information system VAS 5051
connected, function vehicle self-diagnosis and vehicle system
“02 - gearbox electronics” selected.
• The ATF temperature must not be higher than 30 °C for be‐
ginning the test, if necessary first the gearbox must be cooled
down.
Note
♦ The ATF temperature is read off at the ⇒ Vehicle diagnosis,

testing and information system VAS 5051.
♦ The ATF level changes with ATF temperature.
♦ Checking ATF level when ATF temperature is too low may re‐
sult in over-filling.
♦ Checking ATF level when ATF temperature is too high may
result in under-filling.
♦ Both over-filling and under-filling affect gearbox operation.
or to failure of the gearbox, ATF spare part number ⇒ Elec‐
tronic catalogue of original parts .
4. Inspecting ATF level and if necessary topping up 43

FABIA II 2007 ➤
4.1.1 Inspection
Note
♦ The ATF level is checked at the ATF inspection plug.

♦ The ATF level is correct, if a small amount of fluid flows out at
the ATF inspection plug when the ATF temperature is between
35° and 45 °C (in hot countries 50 °C) (caused by the ïncrease
of the fluid level due to the heat).
– Fill ATF filling system with ATF for the automatic gearbox 09G.
WARNING
The ATF filling system must be clean and the ATF must not be
mixed with other ATF oils!
– Attach the reservoir of the ATF filling system as high as pos‐

sible to the vehicle.
– Run the vehicle on a four column lift platform or over a work‐
shop pit, so that it will be kept absolutely horizontal.
– Position the catch pan under the gearbox.
WARNING
♦ When working close to the radiator, always keep a dis‐

tance from the fan - risk of injury!
♦ The fan can switch on automatically.
– Start engine and run in idle.
WARNING
Wear safety goggles.
– If an ATF temperature of 35 °C is achieved, unscrew the ATF

inspection plug -A-.

FABIA II 2007 ➤
– Always replace gasket ring -arrows- for ATF inspection plug

⇒ Electronic Catalogue of Original Parts .
First of all the ATF in the overflow tube -arrow 2- drains off.
If more ATF drips out of the ATF inspection opening (approx. 1
drop per second) via the overflow tube before the ATF has
reached 40 °C, the ATF level is correct.
– Fit ATF inspection plug -arrow 1- with a new gasket ring and
tighten to tightening torque ⇒ page 54 . This completes the
ATF level inspection.

Note
At the latest at 45 °C (in hot countries 50 °C) the ATF inspection

plug must be closed again.
If no ATF flows out at the ATF inspection opening up to 45 °C, the

ATF must be filled up ⇒ page 45 .
– End function “08 - read measured value block”.
– Tip “06 - End output”.
– Switch off ignition and disconnect the diagnostic plug connec‐
tion.
4.1.2 Fill with ATF

Note
Pay attention to all the notes and test conditions ⇒ page 43 .

FABIA II 2007 ➤
– Screw in the adapter for ATF oil filling -VAS 6262/2- in the
location of the gearbox inspection plug -arrow 1- and connect
adapter for oil filling -VAS 6262- .
– Fill with 1 liter of ATF.

– Remove adapter for oil filling -VAS 6262- from adapter for ATF
oil filling -VAS 6262/2 - .
– Observe whether the ATF flows out of the opening of the
adapter for ATF oil filling -VAS 6262/2 - .
If ATF flows out of the opening of the adapter for ATF oil filling -
VAS 6262/2- , the ATF level is correct.

– Allow all excess ATF to drip out until it starts to drain off.
If no ATF flows out of the opening of the adapter for ATF oil filling
-VAS 6262/2- but only drips, the ATF level is not correct and the
ATF must be filled up.
– Unscrew adapter for ATF oil filling -VAS 6262/2- .
tighten to tightening torque ⇒ page 54 . This completes the
ATF level inspection.
Note

plug must be closed again, if necessary switch off the engine,
allow the gearbox to cool down and repeat the check.
– Install the noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .

– Switch off ignition and disconnect the diagnostic plug connec‐
tion.
4.2 Change ATF or top up after repair

• Engine switched off.

FABIA II 2007 ➤
Note

Note
♦ Observe the disposal instructions.

♦ The engine must not be started without ATF and the vehicle
must not be towed!
WARNING

♦ When working close to the radiator, always keep a dis‐

tance from the fan - risk of injury!
♦ The fan can switch on automatically.
4.2.1 Drain ATF

WARNING
– Unscrew the ATF inspection plug -A-.

– Unscrew the overflow tube -C- (5 mm Allen key) and drain the
ATF.
– Install overflow tube -C- with 5mm Allen key and tighten to
tightening torque ⇒ page 54 .
4.2.2 Fill with ATF


FABIA II 2007 ➤
Note
– Screw in the adapter for ATF oil filling -VAS 6262/2- in the
location of the gearbox inspection plug -arrow 1- and connect
adapter for oil filling -VAS 6262- .
– Pour in 4 liters of ATF.

– Remove adapter for oil filling -VAS 6262- from adapter for ATF
oil filling -VAS 6262/2 - .
– Unscrew adapter for ATF oil filling -VAS 6262/2- .

– Tighten ATF inspection plug by hand.
– Start engine.
– With the brake pedal actuated shift through all selector lever
positions “P, R, N, D, S” at idle speed, leaving the lever in each
position for about 10 seconds.
– Switch off ignition.
– Subsequently inspect ATF level and if necessary top up
⇒ page 43 .

FABIA II 2007 ➤
5 Removing and installing ATF radiator
5.1 ATF radiator - Overview of components
1 - Gearbox housing
2 - O-ring
❑ replace ⇒ Electronic
Catalogue of Original
Parts
3 - ATF radiator
⇒ page 49
4 - O-ring
Parts

5 - Washer
6 - Disc spring
❑ Fitting location: Must
rest on the washer Pos.
5; curved side of the disc
spring to the outside
must point upwards.
7 - 36 Nm
5.2 Removing and installing ATF radiator

♦ Hose clamps -MP7-602 (3094)-
Remove ATF radiator
WARNING

5. Removing and installing ATF radiator 49

FABIA II 2007 ➤

Gr. 27 .
Note

– Clamp off the ATF-radiator hoses with hose clamps -MP7-602

– Remove the ATF radiator -1- from the gearbox -arrow A-.
Install ATF radiator
following:
– Replace O-rings of ATF radiator ⇒ Electronic Catalogue of
Original Parts .
– The disc spring ⇒ Item 6 (page 49) must be installed in such
a way that it rests on the washer ⇒ Item 5 (page 49) and the
curved side of the disc spring points upwards.
– When installing the ATF radiator -1- position the peg
-arrow B- in the recess in the gearbox housing.
Component Nm
ATF radiator to gearbox 36
– Fit hoses of ATF radiator according to the markings onto the

ATF radiator.
Note

– Check coolant level in the cooling system ⇒ Engine ⇒ Rep.

Gr. 19 .
⇒ page 43 .

FABIA II 2007 ➤
38 – Wheels, Control
1 Removing and installing oil pan, oil
filter, slide valve body and internal
wiring looms
WARNING
Do not run the engine or tow the vehicle when the oil pan has
been removed or without filling with ATF.
Note
♦ Always replace soiled or faulty slide valve bodies.

♦ General repair information ⇒ page 3 .

♦ Coat O-rings and gasket rings with ATF. Other types of lubri‐
cant will cause the gearbox hydraulic control system to mal‐
function.
♦ The slide valve body and the wiring looms with 8-pin and 14-
pin plug can also be removed with the installed gearbox.
1. Removing and installing oil pan, oil filter, slide valve body and internal wiring looms 51
FABIA II 2007 ➤
1.1 Oil pan, oil filter, slide valve body, internal wiring looms - Overview of com‐
ponents
1 - ATF inspection plug M10 -

27 Nm
❑ Replace gasket ring -
Pos. 2
❑ Inspecting ATF level, if
necessary topping up
⇒ page 43
2 - Sealing ring
Parts
3 - Overflow tube - 2 Nm
❑ screw with 5 mm Allen
key into the oil pan
4 - Oil pan

⇒ page 56
5 - 7 Nm
❑ 8 pieces for attaching
the oil pan with the oil
pan gasket to the gear‐
box housing
6 - Gasket
7 - Magnet
❑ 2 magnets in the beads
of the oil pan
❑ clean before installation
8 - 11 Nm
ATF strainer to slide
valve body
9 - ATF strainer
10 - M6 screw
❑ 12 screws with different lengths for attaching the slide valve body to the gearbox
❑ Pay attention to assignment ⇒ page 58
❑ Marking of solenoid valves ⇒ page 55
12 - 6 Nm
13 - Gearbox input r.p.m. sender -G182-
❑ with cable and 2-pin plug connection
14 - 7 Nm
15 - Gearbox output r.p.m. sender -G195-
52 Rep. Gr.38 - Wheels, Control

FABIA II 2007 ➤
16 - Gearbox housing
17 - ATF bleeder
18 - ATF radiator
19 - Multi-function switch -F125-
❑ adjust ⇒ page 77
20 - Sealing ring
21 - ATF drain plug M18 - 40 Nm
22 - Lever
❑ for inside selector lever shaft at slide valve body
23 - Washer
24 - 10 Nm
❑ check fitting position ⇒ page 58
25 - Large spring
26 - Small spring
27 - Shock absorber piston
28 - Wiring loom with 8-pin plug and integrated gearbox oil temperature sender -G93-
❑ with O-ring to the plug connection
❑ Replace O-ring ⇒ Electronic Catalogue of Original Parts
❑ connected components ⇒ page 56
29 - 6 Nm
❑ with O-ring to the plug connection
❑ connected components ⇒ page 55
31 - 6 Nm
FABIA II 2007 ➤
Note
90° correspond to a quarter turn.

FABIA II 2007 ➤
1.1.2 Components at wiring loom of 14-pin plug
1 - Solenoid valve 1 -N88-

A - 14-pin plug
B - Wiring loom for 14-pin plug
FABIA II 2007 ➤
1.1.3 Components at wiring loom of 8-pin plug
1 - Hydraulic pressure sender

1 -G193-
❑ not available
2 - Plug connection for gearbox
input r.p.m sender -G182-
3 - Cables for gearbox input
r.p.m sender -G182-
2 -G194-
❑ not available
5 - Cables at gearbox input
r.p.m sender - G195-
6 - Plug connection for gearbox
output r.p.m sender - G195-
7 - Holder for the gearbox oil
temperature sender -G93-
8 - Gearbox oil temperature
sender -G93-
❑ is integrated in the wir‐
ing loom
⇒ Item B (page 56)
A - 8-pin plug
wiring loom for 8-pin
plug ⇒ page 71
C - Bracket for wiring loom
D - 7 Nm
E - 7 Nm
1.2 Removing and installing oil pan

Note
General repair information ⇒ page 3 .
Removing the oil pan

WARNING

FABIA II 2007 ➤

– Unscrew the overflow tube -C- (5 mm Allen key) and drain the
ATF.
– Loosen the 8 screws of the oil pan -arrows- crosswise.
WARNING
There is still ATF in the oil pan, because not all of it could be
drained via the opening -A-.

– Remove oil pan together with the oil pan gasket.
Installing the oil pan
following points:
– Clean the two magnets ⇒ Item 7 (page 52) in the oil pan beads.
Take care that the full surface of the magnets rests against the
oil pan.
Note
The magnets must be absolutely fitted on the provided points in

the oil pan.
– Clean gaskets and sealing surfaces and eliminate residues of

oil.
– Pay attention to correct fitting of oil pan gasket.
– When positioning the oil pan no cables must be trapped.
– Screw in the 8 screws of the oil pan -arrows- crosswise.
– Replace gasket ring of ATF drain plug ⇒ Electronic Catalogue
of Original Parts .
– Install overflow tube -C- (with 5 mm Allen key).

– Top up with ATF and inspect ATF level ⇒ page 43 .
• Gasket ring -B- of ATF inspection plug must be replaced after
the ATF level inspection ⇒ Electronic Catalogue of Original
Parts .
FABIA II 2007 ➤
Tightening torque
Component Nm
Overflow in oil pan ⇒ page 54
ATF inspection plug to oil pan ⇒ page 54
Oil pan to gearbox housing 1) ⇒ page 54
1) Tighten crosswise in stages.
1.3 Removing and installing the oil filter
Note
Removing oil filter

– Removing the oil pan ⇒ page 56 .

– Unscrew screws for oil filter -arrows-.
– Take the oil filter -A- out of the slide valve body.
Install oil filter
– Thinly coat gaskets on the intake collar of the oil filter (reverse
side) with ATF.
Note
If the gaskets on the reverse side of the oil filter for the slide valve
body are defective or no longer properly attached to the oil filter,
the oil filter must be replaced.
– Position oil filter on the slide valve body and tighten screws
-arrows- to tightening torque ⇒ page 54 .
– Installing the oil pan ⇒ page 57 .
1.4 Removing and installing the slide valve

body
Note


FABIA II 2007 ➤
Remove the slide valve body
WARNING


– Removing oil filter ⇒ page 58 .
– Make a sketch by hand in the same way as for the illustration

with all the solenoid valves and their plug connections and
mark all the plugs with the corresponding colour. Also mark
the related cables with the corresponding colours.
FABIA II 2007 ➤
Note
♦ This sketch is absolutely necessary, so that the plugs on the

solenoid valves are not inadvertently interchanged when re-
installing the slide valve body.
♦ Under certain circumstances an interchange of the plugs could
lead to a destruction of the gearbox.
– Carefully lever out the securing tabs of the plug connections

on the solenoid valves -Pos. 1 … 8- with a small screwdriver
and separate the plug connections.
Note
In case of damage of the plug connections, the wiring loom with

14-pin plug or the slide valve body with the solenoid valves must
be replaced.
– Unscrew the 3 screws -D- and -E-.

Carefully disconnect the following plug connections:

FABIA II 2007 ➤
Note
Plug connection -1- and plug connection -4- are not available.
– Plug connection -1- at hydraulic pressure sender -G193-

– Plug connection -2- for the gearbox input r.p.m. sender -
G182- .
– Plug connection -4- at hydraulic pressure sender 2 -G194-
– Plug connection -6- for the gearbox output r.p.m. sender -
G195- .
– Carefully pull the gearbox oil temperature sender -G93- -8-
together with the bracket -7- out of the slide valve body.
Note
When re-installing, pay attention to the attachment of the bracket

on the gearbox oil temperature sender -G93 - .

– Unhook wiring loom at bracket -C-.
Note
In case of damage of the plug connections (depending on the

defective plugs), the wiring loom with 8-pin plug or the gearbox
input r.p.m. sender -G182- or the gearbox output r.p.m. sender -
G195- must be replaced.
– Remove gearshift lever -A- on the gearshift shaft.
Note
♦ Carefully hold the gearshift lever -A- with combination pliers

-B-, so that the torque is not transmitted onto the multi-function
switch -F125 - .
♦ Pay attention to the slide valve on the slide valve body, in
which the gearshift lever is engaged, so that it is not damaged.
FABIA II 2007 ➤
– Loosen the fixing screws -arrows- of the slide valve body

crosswise and carefully remove the slide valve body.
– Remove the bracket -1- and -2-.
3 - Designation of slide valve body, here e.g. “A2”

Note
♦ Observe when installing that the screws have different lengths

and must be replaced.
♦ Only the marked fixing screws -arrows- must be released.
♦ When releasing other screws the function of the slide valve
body can be impaired or the slide valve body splits.
♦ When removing the slide valve body, the shock absorber pis‐
ton -E- must be secured against dropping out or removed
together with both springs.
Install slide valve body
Note
♦ The routing of the cables must be accurately observed, so that

when positioning the slide valve body they are not trapped or
damaged.
♦ Damaged or pinched cables must always be replaced.

FABIA II 2007 ➤
– Route the wiring loom -C- (with 8-pin plug) according to the
illustration in the specified recess in the slide valve body.
• The wiring loom -C- must not rest against the planetary gear‐
box. The clearance -a- must be maintained, so that the wiring
loom is not chafed in the driving mode.
– Route the wiring looms -A-, -B- and -D- according to the illus‐
tration over the gearbox border.
– Make sure that the shock absorber piston -E- is installed in the
illustrated location in the gearbox.
Note
♦ If the shock absorber -E- is removed, it must be cleaned to‐

gether with both springs and installed in the same way
⇒ Item 27 (page 53) , ⇒ Item 26 (page 53) ,
⇒ Item 25 (page 53) .
♦ To do so insert both springs into each other, coat the outer wall
of the shock absorber piston and the opening in the gearbox
with ATF and insert all parts in the gearbox.
♦ Press the shock absorber piston in the gearbox (secure
against falling out) until the slide valve body is positioned.
– Position the slide valve body without force.

• Wiring looms must not be trapped by the slide valve body,
pinched cables must always be replaced ⇒ Electronic Cata‐
logue of Original Parts .
– All fixing screws for slide valve body must be replaced ⇒
Electronic Catalogue of Original Parts .
– Screw on by hand the bracket for the wiring loom -1- and -2-
with the corresponding screw.
– Tighten remaining screws for slide valve body -arrows- by
hand.
– Pay attention to the screw lengths:
Arrow - screw M6 × 21
Arrow A - screw M6 × 16
Arrow B - screw M6 × 28
FABIA II 2007 ➤
Note
♦ If the cable -3- (for gearbox input rpm sender -G182- ) is too
short, in order to screw the plug connection -2- on the provided
point onto the slide valve body, it was wrongly routed or trap‐
ped by the slide valve body. Then the slide valve body must
be removed once again and the cable must be routed correct‐
ly.
♦ Pinched cables must be replaced ⇒ Electronic Catalogue of
Original Parts .
– Make sure that no cables are in fact trapped.

FABIA II 2007 ➤
– After this, tighten the screws -arrows- for the slide valve body
from the outside to the inside to a final torque ⇒ page 68 .
– Hang the wiring loom in the bracket -B-.

– Position the gearshift lever -2- on the gearshift shaft -5-.
Note
Make sure that the pin of the gearshift lever -2- engages in the
slide valve -1- -arrow A-. If necessary the slide valve must be
moved accordingly out or into the slide valve body.
– Fit washer -4- and nut -3- onto the gearshift shaft.
Note
♦ The centering collar of the nut must point to the washer and
when screwing on catch in the washer.
♦ The wiring loom must be routed below the gearshift lever.
– Tighten nut to tightening torque ⇒ page 54 .
Note

switch -F125 - .
♦ Pay attention to the slide valve on the slide valve body, in
which the gearshift lever is engaged, so that it is not damaged.
FABIA II 2007 ➤
– Connect plug connections -1 … 8- according to the sketches

made by hand on the solenoid valves. Absolutely pay attention
to the colours of the plug connections and cables.
– Route the wiring loom -B- in the same way as the ilustration.
Note
Under certain circumstances an interchange of the plugs could


FABIA II 2007 ➤
– Mount the plug connection -2-.

– Mount the plug connection -6-.
Note
The counterparts of the plugs must have the same colour as the
respective plugs.
– Position bracket -7- on the gearbox oil temperature sender -

G93- -8-.
– Insert gearbox oil temperature sender -G93- together with the
bracket in the slide valve body and tighten the screw (M6)
-E-.
– Fit plug connections -1- and -5- onto the pressure sender.
– Secure plug connections -2- and -6- with screws M5 -D- at
slide valve body.
FABIA II 2007 ➤
Note
♦ If the cable -3- (for gearbox input rpm sender -G182- ) is too
ped by the slide valve body. Then the slide valve body must
be removed once again and the cable must be routed correct‐
ly.
♦ Pinched cables must be replaced.
– Hang the wiring loom -B- in the bracket -C- and route in the
same way as the illlustration.
– Install oil filter ⇒ page 58 .
– Pay attention to the measures after connecting the battery ⇒
Electrical System ⇒ Rep. Gr. 27 .
Tightening torques
Component Nm
Slide valve body to gearbox housing (from out‐ ⇒ page 54
side to the inside)
M6 screws, pay attention to different screw
lengths1)
Gearshift lever on gearshift shaft (nut) ⇒ page 54
Gearbox oil temperature sender -G93- ⇒ page 54
(M6 screw with bracket to slide valve body)
2 x plug for the speed sender ⇒ page 54
(M5 screw with bracket to slide valve body)
1) Replace screws ⇒ Electronic Catalogue of Original Parts .

FABIA II 2007 ➤
1.5 removing and installing wiring loom with 14-pin plug
A - 14-pin plug
❑ Identification of solenoid
valves and wiring loom
routing ⇒ page 55
Note
Removing wiring loom with 14-pin plug

– Disconnect the battery-earth strap with the ignition off.
– Remove the slide valve body ⇒ page 58 .
FABIA II 2007 ➤
With gearbox installed:

– Unplug the 14 pin plug connection -A- from gearbox plug.
All:
– Unscrew fixing screw of 14-pin plug outside the gearbox hous‐
ing.
– Pull the plug out of the gearbox housing and carefully guide
through the wiring loom -D-.
Install wiring loom with 14-pin plug
following points:
– Replace O-ring at plug ⇒ Electronic Catalogue of Original
Parts .
– Moisten O-ring with ATF.
– Press plug with positioned O-ring up to the stop into the gear‐
box.
Tightening torque
Component Nm
Locking screw for 14-pin plug ⇒ page 54

FABIA II 2007 ➤
1.6 Removing and installing wiring loom with 8-pin plug and integrated gearbox
oil temperature sender -G93-
A - 8-pin plug
❑ Wiring loom compo‐
nents ⇒ page 56
Note
Removing wiring loom with 8-pin plug

– Disconnect the battery-earth strap with the ignition off.
FABIA II 2007 ➤
With gearbox installed:

– Unplug the 8 pin plug connection -B- from gearbox plug.
All:
ing.
through the wiring loom -C-.
Install wiring loom with 8-pin plug
following points:
Parts .
box.
Tightening torque
Component Nm
Locking screw for 8-pin plug ⇒ page 54
1.7 Removing and installing the gearbox in‐

put r.p.m. sender -G182-
Note
Removing gearbox input r.p.m. sender -G182-
WARNING



FABIA II 2007 ➤

– Release screw -1-.
– Pull gearbox input r.p.m. sender -G182- with cable -A- out of
the gearbox.
Installing gearbox input r.p.m. sender -G182-
following points:
– Carefully press gearbox input r.p.m. sender -G182- up to the
stop into the gearbox.

Tightening torque
Component Nm
Gearbox input r.p.m. sender -G182- to ⇒ page 54
gearbox, M6 screw
1.8 Removing and installing the gearbox

output r.p.m. sender - G195-
Note

♦ Observe measures when disconnecting the battery ⇒ Elec‐
Removing gearbox output r.p.m. sender -G195-
WARNING


FABIA II 2007 ➤

– Pull gearbox output r.p.m. sender -G195- with cable -B- out of
the gearbox.
Installing gearbox output r.p.m. sender -G195-
following points:
– Moisten O-ring at sender with ATF.
– Carefully press gearbox output r.p.m. sende -G195- up to the
Tightening torque

Component Nm
Gearbox input r.p.m. sender - G195- to ⇒ page 54
gearbox, M5 screw

FABIA II 2007 ➤
2 Removing, installing and setting mul‐

ti-function switch -F125-
2.1 Removing and installing the multi-func‐

tion switch -F125-
Removing
– Shift selector lever to position “N”.
– Remove air filter ⇒ Engine ⇒ Rep. Gr. 24 .
lever -6-, e.g using an open-end wrench, while ensuring that
the selector lever control cable does not get kinked.
Note

Do not release screw -2-.
– Unplug connector -5- at multi-function switch.
– Remove gearshift lever -1-.
2. Removing, installing and setting multi-function switch F125 75

FABIA II 2007 ➤
– Bend back the hooks of the circlip -2- using a screwdriver.
Note
If one or several hooks of the circlip break off by bending, the

circlip must be replaced ⇒ Electronic Catalogue of Original Parts .
– Remove nut -3- with washers -2- and -1-.

– Unscrew the 2 screws -B- and pull off the multi-function switch
-A- upwards over the gearshift shaft.
Install
following:
– Fit the multi-function switch -F125- onto the gearshift shaft.
– Tighten the fixing screws -B- for multi-function switch by hand.
– Fit washers -1-, -2- and nut -3- onto the gearshift shaft.
– Secure the nut by bending up the hooks to the circlip -2-.
Note

– Setting multi-function switch -F125- ⇒ page 77 .
– Install gearshift lever -1-.
Note
The gearbox must remain in the position “N”, if necessary shift

back into “N”.

FABIA II 2007 ➤
– The plug -5- is placed onto the multi-function switch.

– Push selector lever control cable -1- onto the gearshift lever
-6-, while ensuring that the selector lever control cable does
not get kinked.
Note
Under some circumstances the gearshift lever must be shifted in

the correct position, in order to be able to push on the selector
lever control cable.
– Inspect setting of selector lever control cable ⇒ page 23 .

Tightening torques
Component Nm
Multi-function switch -F125- to gearshift shaft 7
Gearbox shift lever to gearshift shaft 13
2.2 Setting multi-function switch -F125-

♦ Setting gauge -T10173-
lever -3-, e.g using an open-end wrench -2-, while ensuring
that the selector lever control cable does not get kinked.

FABIA II 2007 ➤

– Loosen both screws -B-.
Note
Do not release the screws.
– Fit the setting gauge -T10173 - onto the gearshift shaft.

– Turn the multi-function switch -A- until the peg of the plug
-arrow 1- engages in the groove of the setting gauge -
T10173- .
If the peg of the plug cannot engage into the groove of the setting
gauge, then the gearbox is no longer in the position “N”. In this
case, the gearbox must be shifted with the setting gauge into the
position “N”:
– To do so turn the setting gauge to the front or to the rear, until
the peg of the plug -arrow 1- can engage into the groove of the
setting gauge -T10173- (if necessary slightly turn the multi-
function switch -A-).
– Fix the setting gauge -T10173 - to the gearshift shaft using a
knurled screw -C-
– Screw on the two screws -B- (6 Nm).
– Remove setting gauge from gearshift shaft.
Further installation occurs in reverse order.
– Inspect setting of selector lever control cable ⇒ page 23 .

FABIA II 2007 ➤
39 – Final drive, differential gear

1 Replace the flange shaft gasket rings
Gasket rings can be replaced with the gearbox installed.
1.1 Replacing the left flange shaft gasket

ring
Gasket ring can be replaced with the gearbox installed.
♦ Extractor -T10055-
♦ Adapter -T10055/2-
Note


– Remove left drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Close opening for drive shaft at gearbox with a clean cloth
-A-.
– Drill a hole in the outer metal plate ring of the shaft seal with
a commercially available twist drill -B- (∅ 2 to 4 mm).
Note
♦ Only drill through the metal plate ring, otherwise the gearbox
may be damaged.
♦ Grease drill -B- in such a way that the drillings adhere.
1. Replace the flange shaft gasket rings 79

FABIA II 2007 ➤
– Screw a sheet metal screw with a diameter of approx. 4 mm

into the drilled hole of the gasket ring -arrow-.
Note
The sheet metal screw must not be screwed in too deep, so that
the bearing behind the screw is not damaged.
– Remove the gasket ring with the extractor -T10055- and

adapter -T10055/2- .
– Remove cloth -A- and thoroughly clean the gearbox.
WARNING
No metal swarfs must enter into the gearbox and into the open‐
ing for the drive shaft, if necessary suction off these swarfs.
When levering out, if only the the metal plate ring of the shaft seal
could be removed:

– Lever out the remaining shaft seal with a screwdriver -A-.
– Smear the outer surface and sealing lips of the gasket ring with
ATF.
• Fitting location: The open side of the gasket ring faces towards
the gearbox.
– Position new seal ring by hand and press in as far as possible,
so that the shaft seal is fixed in the gearbox housing.
– Position pressure plate -T10176- in the middle on the shaft

seal -A-.
– Drive the new gasket ring up to the stop in the pressure plate;
do not tilt the gasket ring.
– Install left drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Inspecting ATF level and if necessary topping up ⇒ page 43 .
Tightening torque
Flange shaft to gearbox ⇒ Chassis ⇒ Rep. Gr. 40
1.2 Replacing the right flange shaft seal ring

80 Rep. Gr.39 - Final drive, differential gear

FABIA II 2007 ➤
♦ Adapter -T10055/2-
Work procedure
Note

– Remove right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
-A-.
Note
may be damaged.
♦ Grease drill -B- in such a way that the drillings adhere.

Note
the bearing behind the screw is not damaged.
– Remove the gasket ring with the extractor -T10055- and

adapter -T10055/2- .
WARNING
When levering out, if only the the metal plate ring of the shaft seal
could be removed:

ATF.
the gearbox.

FABIA II 2007 ➤
– Position pressure plate -T10177- in the middle on the shaft

seal -A-.
– Install right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Inspecting ATF level and if necessary topping up ⇒ page 43 .
Tightening torque
Flange shaft to gearbox ⇒ Chassis ⇒ Rep. Gr. 40

FABIA II 2007 ➤
2 Replacing the gasket ring for the

gearshift shaft
2.1 Replacing the gasket ring for the gear‐

shift shaft
– Removing multi-function switch -F125- ⇒ page 75 .
– Remove gasket ring with screwdriver, do not damage the
gearshift shaft.
ATF.
the gearbox.
– Drive in the new seal ring with pressure plate -T10174- up to

the stop, do not twist the seal ring.
– Installing and setting multi-function switch -F125- ⇒ page 75 .
2. Replacing the gasket ring for the gearshift shaft 83

Service
Workshop Manual
FABIA II 2011 ➤
Automatic gearbox 0AM
Edition 02.10

Service
Repair Group
00 - Technical data
30 - Clutch
35 - Wheels, shafts

FABIA II 2011 ➤
Automatic gearbox 0AM - Edition 02.10
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical Data for the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Filling capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Transmission System - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Instructions for automatic gearbox DSG - 0AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Notes on tow starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 General repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Working with testing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Removing and installing the double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Remove double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Adjust the positions of the engaging bearing for clutch “K 1 and K 2” . . . . . . . . . . . . . . . . 15

1.3 Install double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
34 - Control, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1 Electric/electronic components and fitting locations of the automatic gearbox DSG - 0AM
........................................................................ 31
2 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3 Check operation of the ignition key anti-removal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4 Summary of components - Gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5 Removing and installing the handle and cover for the shift mechanism . . . . . . . . . . . . . . 39
2.6 Removing and installing gearshift mechanism with selector lever control cable . . . . . . . . 40
2.7 Emergency release of gearshift mechanism out of position “P” . . . . . . . . . . . . . . . . . . . . 43
2.10 Removing and installing selector lever switch locked in P F319 . . . . . . . . . . . . . . . . . . . . 44
2.11 Removing and installing the selector lever sensor control unit J587 . . . . . . . . . . . . . . . . . . 44
3 Mechatronics for double clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.1 Safety instruction for° mechatronics for double clutch gearbox J743 . . . . . . . . . . . . . . . . 45
3.2 Summary of components - mechatronics for double clutch gearbox J743 . . . . . . . . . . . . 47
3.3 Removing mechatronics for double clutch gearbox J743 ; gearbox removed. . . . . . . . . . . 47
3.4 Remove mechatronics for double clutch gearbox J743 ; gearbox installed. . . . . . . . . . . . . 52
3.5 Place the mechatronics for double clutch gearbox J743 by hand in the “removal position”
........................................................................ 60
3.6 Installing mechatronics for double clutch gearbox J743 ; gearbox removed. . . . . . . . . . . . . 62
3.7 Install mechatronics for double clutch gearbox J743 ; gearbox installed . . . . . . . . . . . . . . 66
5 Transport the gearbox and secure to the assembly support . . . . . . . . . . . . . . . . . . . . . . . . 83
6 Change gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
35 - Wheels, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1 Pinions and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Contents i
FABIA II 2011 ➤

ii Contents
FABIA II 2011 ➤
1 Technical Data for the Gearbox

The “7-speed automatic gearbox DSG - 0AM” is installed in com‐
bination with 4-cylinder engines. Assignment ⇒ page 1 .
Example for a gearbox:
The gearbox code letter -arrow- is located at the top and bottom
of the gearbox.
♦ MLN = gearbox identification character
♦ 09.12.09 = production date 9th December 2009
♦ 14 = manufacturer code

♦ 09:49 = time
♦ 0042 = serial number
data stickers.
Note
If these vehicle data stickers are not present and another gearbox
is installed than the one intended or you have no other possibility
to identify the installed gearbox in case of doubt, then read off the
identification characters directly from the gearbox.
1.2 Identification characters, aggregate assignment, ratios

Automatic gearbox DSG 0AM “front-wheel drive”
Gearbox Identification charac‐ MGV MLN MPU
ters
Manufactured from 03.10 05.10 11.10
throug 05.10 10.10
h
Assignment Engine 1.2 ltr./77 kW TFSI
Ratio: Z 2 : Z 1 Final drive for 1st gear 78 : 19 = 4,105
through 4th gear
Final drive for 5th 6th 78 : 25 = 3,120
and 7th gears
Final drive for reverse 78 : 20 = 3,900
gear
Ratios 1st gear 64 : 17 = 3,765
2nd gear 71 : 30 = 2,367
3rd gear 63 : 40 = 1,575
4th gear 60 : 54 = 1,111
5th gear 56 : 49 = 1,143
6th gear 51 : 54 = 0,944
7th gear 46 : 59 = 0,779
Reverse gear 63 : 30 x 53 : 26 = 4,281

FABIA II 2011 ➤

ters
itot. in the highest gear 2,430
Drive shaft flange ∅ 100 mm

Gearbox Identification charac‐ MLH MPP
ters
Manufactured from 05.10 11.10
throug 10.10
h
Ratio: Z 2 : Z 1 Final drive for 1st gear 71 : 16 = 4,438
through 4th gear
Final drive for 5th 6th 71 : 22 = 3,227
and 7th gears

Final drive for reverse 71 : 17 = 4,176
gear
Ratios 1st gear 63 : 18 = 3,5
2nd gear 50 : 22 = 2,273
3rd gear 49 : 32 = 1,531
4th gear 46 : 41 = 1,122
5th gear 40 : 34 = 1,176
6th gear 39 : 41 = 0,951
7th gear 35 : 44 = 0,795
Reverse gear 53 : 26 x 45 : 22 = 4,170
itot. in the highest gear 2,565
1.3 Filling capacity

The “7-speed automatic gearbox DSG - 0AM” has 2 separate,
different oil fillings. One for the area with gearbox oil -arrow A-
and the other one for the area with hydraulic oil -arrow B-.

FABIA II 2011 ➤
Gearbox capacity Area with gearbox oil

New filling 1.7 ltr.
Top-up no top-up
Lubricant Gearbox oil for double clutch gearbox 0AM
part number ⇒ Electronic Catalogue of Original Parts
Capacity in the mechatronics for Area with hydraulic oil

double clutch gearbox -J743-
Filling 1 ltr.
Top-up no top-up
♦ The mechatronics is allocated according to the gearbox code letters ⇒ Electronic Catalogue of Original
Parts .
♦ The “new” mechatronics for the gearbox is already precisely filled with oil at the factory.
Only spare part gear oils should be used for the “7-speed auto‐
matic gearbox DSG - 0AM”. Other oils can lead to functional
problems or to failure of the gearbox.

FABIA II 2011 ➤
1.4 Transmission System - Overview

The “7-speed automatic gearbox DSG - 0AM” has 2 drive shafts
and 3 output shafts.
A1 - 1st drive shaft

A2 - 2nd drive shaft
B1 - 1st output shaft
B2 - 2nd output shaft
B3 - 3rd output shaft
C - Front final drive
K1 - Clutch 1
K2 - Clutch 2
M - Engine
T1 - One part of the gearbox 1
❑ with 1st, 3rd, 5th and 7th
gear

❑ with 2nd, 4th, 6th gear
and reverse gear R

FABIA II 2011 ➤
2 Instructions for automatic gearbox

DSG - 0AM
The automatic gearbox DSG°-°0AM is also designated as double
clutch gearbox. The gearbox is built like a 7-speed manual gear‐
box.
2.1 Notes on tow starting and towing
Caution
When towing the vehicle, the selector lever must be in position

“N” and it must not be towed further than 50 km and faster than
50 km/h, otherwise the gearbox will be destroyed.
Note
It is not possible to tow start an engine, e.g. if the battery is weak

or the starter does not operate.
2.2 General repair information

workshop manual.
Special tools
List of the special tools used in the workshop manual is detailed
in the individual repair descriptions.
Summary of components of gearbox
1- Ventilation cap of the gearbox
2- Remove the cover “to the gearbox oil filling”
3- Lever/gearshift shaft
4- Ventilation cap of the mechatronics for double clutch gear‐
box -J743-
5- Mechatronics for double clutch gearbox -J743-
6- Double clutch
7- Flange shaft
8- Oil drain plug, 30 Nm
9- Automatic Gearbox DSG - 0AM
Gearbox
2. Instructions for automatic gearbox DSG - 0AM 5

FABIA II 2011 ➤
The gearbox has an opening in the housing -arrow-.
Note
♦ This opening is closed with a cap.

♦ When installing pay attention that nothing falls into this open‐
ing.
♦ If the covers are unscrewed from the gearbox or the gearbox

is without oil, do not let the engine run and do not tow the ve‐
hicle.
♦ Permanently ensure that no dirt can get into the “opened”
gearbox.
and then release.
♦ When installing the gearbox, ensure the dowel sleeves are
correctly located between the engine and gearbox.
Mechatronics

♦ The mechatronics is allocated according to the gearbox code
letters ⇒ Electronic Catalogue of Original Parts .
♦ The “new” mechatronics for the gearbox is already precisely
filled with oil at the factory, do not drain the oil.
♦ The “removed” mechatronics for the gearbox is sent back with
oil (close the ventilation opening with a suitable plug).
Gaskets, gasket rings, O-rings
♦ After removing gasket rings, examine the contact surface in

the housing or on shafts for burrs or damage, and correct if
necessary.
♦ Before a shaft seal is installed, fill half the space between the
sealing lip and dust lip with sealing grease -G 052 128-
-arrow-.
♦ The open side of the sealing rings is turned towards the oil.
♦ Replace O-rings, gasket rings and gaskets ⇒ Electronic Cata‐
♦ Before inserting the O-rings coat with oil to prevent the rings
being damaged during installation.
♦ After installing, check gear oil level ⇒ page 85 .
Gear oil

FABIA II 2011 ➤
The “7-speed automatic gearbox DSG - 0AM” has 2 separate,

The oil level cannot be checked. The adjustment of the gear oil
level can only be achieved by changing the gear oil, for example
if the gearbox leaks ⇒ page 85 .
Caution
Be careful when handling oil. Dispose of drained oil appropri‐

ately.
♦ Shake oil bottle before opening.

♦ Do not mix any additives in the oil, also do not fill in other oil.
♦ Drained oil must not be refilled.
Locking elements
Screws, nuts
housings diagonally across in stages.
agent with a wire brush. Insert bolts with locking agent -AMV
185 101 A1- .
♦ Clean all threaded holes into which self-locking screws are
screwed in, using a screw-tap to remove locking agent resi‐
dues. Otherwise there is a risk that the bolts will shear at the
next disassembling.
♦ Always replace the self-locking nuts and screws.
Electrical components
If you touch objects out of metal, it can happen that this can lead
to an electrostatic discharge. The reason for this is the electro‐
static charge of the human body. This electrostatic charge can
lead to operational problems when touching the electrical com‐
ponents of the gearbox and the shift mechanism.
– Touch an earthed object - e.g. a water pipe or a lift platform -
before working on the electrical components.
– Do not grab directly at the plug contacts.
Before repairing the gearbox try to determine the origin of the
damage as accurately as possible using “targeted fault finding”.

FABIA II 2011 ➤
The “targeted fault finding” is performed with the ⇒ Vehicle diag‐

nosis, testing and information system VAS 5051.
Rules of cleanliness
before releasing.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing.
♦ Place removed parts on a clean surface and cover, so that
they are not clogged up with dirt. Use foil and paper. Do not
use fuzzy cloths!
2.3 Working with testing devices

VAS 5052 A-
VAS 5051B-

Work in the operating modes targeted functions and tar-
geted fault finding .
2.3.1 Adapt information regarding lining

The mechatronics detects the other control units in the vehicle via
the signals in the CAN databus. If the key adapt information
regarding lining is pressed, the mechatronics receives a
command to forget all systems with which it can communicate.
However, after switching on the ignition all “active systems” with
which it can communicate are detected.
No faults can be “generated” with this function. The function
adapt information regarding lining is always carried out
after the following operations:
♦ After installing the mechatronics.
♦ After the gearbox has been fitted.
♦ After installing the selector lever.
♦ After installing a different control unit, for example of the en‐
gine, ABS or Gateway.
2.3.2 Perform basic setting

The mechatronics memorises important settings in the function
COMPLETE BASIC SETTING . The important settings are also
memorised, e.g reset to preprogrammed points. For example
among others, the synchronisation points and the “vertices” for
the engaging lever and the gear switch.
– Button COMPLETE BASIC SETTING only functions:
♦ after interrogating with “targeted fault finding”
♦ after rectifying the fault displayed in the fault memory
♦ or after installing the clutch

FABIA II 2011 ➤

workshop manual
These explanations are only related to the automatic gearbox
DSG - 0AM. They do not claim to be valid in all cases.
CAN databus
Data transfer. The electrical signals are therefore put into certain
forms (Bus). Further information on this can be found in ⇒ Self-
study programme No. 24 ; Škoda OCTAVIA; CAN databus;
Structure and Function .
DSG
Automatic gearbox DSG. Further information on this can be found
in ⇒ Self-study programme No. 75 ; Automatic gearbox DSG -
0AM .
Self-diagnosis
Engine control unit can:
– detect faults
– react to faults
– store faults
– Determine measured values and display them in the meas‐
ured value block
Gearbox input r.p.m. sender 3 -G641-
The sender determines the speed at the clutch and sends it to the
mechatronics.
Gearbox
clutch gearbox. The engine torque is initiated in the gearbox via
the two-mass flywheel. The flywheel and the double clutch are
interconnected via a serration. The gearbox is built like a 7-speed
manual gearbox. Due to the alternative hydraulic activation of the
2 dry clutches, it is operated like an automatic gearbox, i.e. the
gears are automatically or manually engaged via the Tiptronic
mode. A clutch pedal is not present.
Gear oil
The gearbox has separate oil fillings for mechatronics and manual
gearboxes. Oils are designed to be filled for life.
The selector lever lock solenoid is integrated into the shift mech‐
anism. Prevents the (unintentional) tipping of the selector lever
from the positions “P” and “N” for not-operated brake.
Emergency running mode
If individual or several components or sensors fail, the gearbox
control unit activates the corresponding backup functions or
emergency running programmes. This ensures a nondestructive
operation of the gearbox with the respective effect on the function
and quality of the shifting.
The emergency running mode is a “status of the control unit”,
which, if a fault of the control unit is detected, maintains driving
safety, protects the gearbox from damage, and ensures that ve‐
hicle running will be affected as little as possible.

FABIA II 2011 ➤
Parking position
When the vehicle is parked, the selector lever mechanically locks
the parking gear thereby preventing the vehicle from moving off
(unintentionally).
Shift mechanism
The selector lever position is no longer communicated mechani‐
cally, as for the other automatic gearboxes, via the selector lever
control cable and the multi-function switch (sensor for driving po‐
sition) to the gearbox. The selector lever postions or shifting are
transmitted via a separate control unit in the shift mechanism via
the CAN databus to the mechatronics. The shifting is then per‐
formed without control cable. Only in the selector lever position
“P” is the parking position engaged mechanically via the selector
• On steep gradients, gear-change mapping is adapted to en‐
gine power output.
• On steep gradients, gear-change mapping is adapted to the
• By directly selecting a gear via the Tiptronic, also with a con‐
crete gear, e.g. for a slope during trailer operation, the motor
braking effect is also used.
Tiptronic
Another one exists to the right of the normal selector lever gate.
In this selector lever gate, the selector lever can be tipped towards
the Plus sign (+) to change up the gears manually and vice versa
towards the Minus sign (-) to change down the gears manually.

FABIA II 2011 ➤
30 – Clutch
1 Removing and installing the double
clutch
Short description
Detach the clutch “upwards” when the gearbox is removed. The
mechatronics remains on the gearbox.
If a new clutch is installed, the positions of the engaging bearings
for “K 1” and “K 2” must be determined and adjusted. Then the
clutch is pressed onto the drive shaft.
When installing a clutch, “most” of the mechanics press the clutch
onto the drive shaft up to the stop. This is not the optimum position
of the clutch!
After the installation, the clutch is therefore slightly pulled “up‐
wards” against the circlip.
Overview

Transporting the gearbox and secure to the assembly support
⇒ page 83 .
Remove double clutch ⇒ page 11 .
Adjust the positions of the engaging bearing “K 1 and K 2”
⇒ page 15 .
Install double clutch ⇒ page 24 .
Note
The clutch is self-adjusting. Vibrations can have a negative effect

on the adjusting device. Therefore the clutch should not be drop‐
ped. The clutch should also not fall into the gearbox when instal‐
ling it. Even when the mechatronics is removed, the “removal” of
the special tool from below the engaging levers can have a neg‐
ative effect on the adjusting device.
1.1 Remove double clutch

♦ Assembly stand -MP9-101-
♦ Hook -3438-
♦ Supporting bridge -T10323-
♦ Gearbox mount -T30108-
♦ Gearbox mount -T30109 (VW 353)-
• Gearbox removed
• The mechatronics for double clutch gearbox -J743 - is installed
on the gearbox
1. Removing and installing the double clutch 11

FABIA II 2011 ➤
– Remove both ventilation caps -arrows- and close with suitable

screw plugs so that no oil can flow out.
The gearbox must be installed on the gearbox mount -T30109

(VW 353)- with the clutch pointing upwards.
The way in which the gearbox is transported and attached to the
assembly support can be seen here ⇒ page 83 .
– Remove the circlip for the hub -arrow-.
– Take out the hub with hook -3438- -A- and screwdriver -B-.
12 Rep. Gr.30 - Clutch

FABIA II 2011 ➤
– Remove the circlip for the clutch -arrow-.
Note
♦ It is possible that the clutch is resting at the circlip so close that

the circlip “fits very tightly”. In this case it is possible to press
the clutch slightly downwards as described in the following
work procedure. In doing so, the circlip is released. Do not
knock on the clutch or the shaft with a hammer!
♦ Always replace circlip -arrow- ⇒ Electronic Catalogue of Orig‐
inal Parts .
The circlip -arrow- for the clutch cannot be removed:
Note
In the following description the clutch is pressed slightly down‐

wards in the event that the circlip cannot be removed.

– Position the supporting bridge -T10323- parallel to the flange
of the clutch housing.
– Equalise distances, e.g using washers -B- with a total thick‐
ness of 15 mm.
– Attach the supporting bridge -T10323- with screws -A-.
Note
Fasten screws -A- with nuts.
– Carefully press the clutch downwards via the spindle.

– Remove supporting bridge -T10323- .

The circlip for the clutch -arrow- is removed:

FABIA II 2011 ➤
– Insert the extractor -T10373- in the clutch and remove the

clutch.
– Remove the clutch together with the extractor -T10373 - .
– Remove the small engaging bearing.

– Remove the large engaging lever.
– Remove the screws and the small engaging lever.

FABIA II 2011 ➤
– Remove the support for the engaging lever.

Before installing the clutch, check if it must be adjusted or not
⇒ page 15 .
Install double clutch ⇒ page 24 .
1.2 Adjust the positions of the engaging

bearing for clutch “K 1 and K 2”
♦ Gauge block -T10374 -
♦ Straightedge -T40100-
♦ Adhesive -AMV 195 KD1 01-
♦ Digital depth gauge

The position of the engaging bearing must be adjusted after the
clutch and its controls were replaced.
♦ The support is also part of the control.
If all the mentioned parts are only removed and reinstalled, there
is nothing to adjust.
Conditions:
• Only use proper tools.
• The flange of the clutch housing must be free of “irregularities”.
This ensures a good position of the straightedge.
• The mechatronics is installed.
Short description
The position of the engaging bearing is comparable with the
clutch play of a mechanical manual gearbox. In the automatic
gearbox DSG - 0AM, tolerances are present in the engaging sys‐
tem of the gearbox and in the gearbox itself. The tolerances also
exist inside the double clutch. These tolerances must be consid‐
ered separately when adjusting.
In the following procedure is first shown how to establish all the
necessary dimensions on the “gearbox side” in order to determine
the suitable adjusting washer. The tolerances on the gearbox side
and the tolerances in the clutch determine the thickness of the
adjusting washer.
First a dimension “B” must be established. This dimension is re‐
quired for both clutches “K 1” and “K 2”.
In addition, a dimension “A” is established for each clutch. The
following figures N30-10291 and N30-10292 show where to
measure these dimensions.

FABIA II 2011 ➤
“K 1”
“K 2”

Note
Perform the following work steps accurately and “in sequence”.
Adjusting:
– Install the parts of the clutch up to the large engaging lever

⇒ page 24 .
Do not insert an adjusting washer.

FABIA II 2011 ➤
– Install the circlip of the outer drive shaft -arrow-.
– Place the ruler -T40100- upright on the flange of the clutch

housing.
Note
The ruler -T40100 - must remain in this position during the fol‐
lowing measurements. Do not turn or remove it.

– Place the digital depth gauge -A- on the outer drive shaft -B-.
– Reset the depth gauge to “zero”.
– Measure the distance to the circlip.

– Note the result and name it “B”.
As an example: “B” = 2.91 mm

FABIA II 2011 ➤
– Measure the dimension “B” once more at the opposite-facing

point.
Note
Do not measure on the joint of the ring. The ring could be pressed
off from the joint and thus the measuring result will be inaccurate.
– Remove the circlip again.

This ring must not be reinstalled!
– Determine the mean value from both measurement results.
As an example:
Dimension “B” = B1+B22 = 2,91+3,02 = 2.96
This dimension “B” is required for the following calculations.
In the following example calculations “B” should be = 2.96 mm.
The dimension “B” is for this example, there can be another value
“B” for different gearboxes.
As there are 2 clutches, 2 steps are performed for the adjustment.
Each measurement requires different preparatory measures, in‐

cluding a few calculations. Please observe the following work
procedures.
First determine the adjusting washer for the clutch “K 1”.
Do not insert an adjusting washer!
– Position the gauge block -T10374- on the “large” engaging

bearing.
– Press on the gauge block -T10374- once and turn it at the
same time.
In this way one can observe how the engaging bearing turns.
Thus, the “gauge block” is also positioned -T10374- correctly on
the bearing.
– Place the digital depth gauge at the “top” on the outer drive
shaft.
The ruler -T40100- is already positioned “upright” on the flange
of the clutch housing ⇒ page 17 .

FABIA II 2011 ➤
– Measure the distance from the “shaft end” to the gauge block
-T10374- .
– Position the digital depth gauge twice at opposite-facing points

for a precise measurement.
In this way, an even more precise value is determined as the in‐
accuracy resulting from the “wobbling” on the engaging bearing
is thus minimised.
– Note the mean value of both measurements to the gauge block
-T10374 - .

– Note this value and name it “A1”.
As an example:
Dimension “A1” = 2,61+2,812 = 2.71
As an example: “A1” = 2.71 mm
The following calculation:
“A1” minus “B” plus height of the gauge block -T10374- = depth
of the engaging bearing of clutch 1.
The height of the gauge block -T10374- is always the same. It is:
51.81 mm.
Example calculation:
2.71 mm minus 2.96 mm plus 51.81 mm = 51.56 mm.
You have now determined the value of how deep the engaging
bearing is actually positioned in the gearbox.
The depth of the bearing must be 50.08 mm on each gearbox.
The nominal dimension “50.08 mm” is deducted from the actual
dimension. Thus, the actual air passage of clutch 1 is determined.
– Continue the calculation:
The determined value (in the example: 51.56 mm) minus the
nominal value = the air passage of the clutch.
51.56 mm minus “50.08 mm” = air passage of clutch 1 = 1.48 mm.
Now the tolerances in the double clutch must be included in this
calculation. This is a very simple procedure:

FABIA II 2011 ➤
– Please read off the value of the clutch tolerance -arrow- from
the “new” clutch.
A value between minus 0.40 and plus 0.40 mm is attributed to the
new clutch.
– Note this value.
Example 1: “-0.40 mm” is given on your clutch.
The last calculation for “K 1”: “Its determined” air passage minus
the value of clutch 1 =
1.48 mm minus 0.40 = 1.08 mm.
Example 2: “+ 0.20 mm” is given on your clutch.
Then the last calculation for “K 1” is done as follows: 1.48 mm plus
0.20 = 1.68 mm.
– Select the correct washer from the table and install it.
Determined thickness of the Washer to be installed in mm
washer
from to
0,31 0,90 0,8
0,91 1,10 1,0
1,11 1,30 1,2
1,31 1,50 1,4
1,51 1,70 1,6
1,71 1,90 1,8
1,91 2,10 2,0
2,11 2,30 2,2
2,31 2,50 2,4
2,51 2,70 2,6
2,71 3,30 2,8
– From the delivered washers, determine the adjusting washer

which is required.
WARNING
At a later stage, just insert this 1 adjusting washer. Do not insert

2 washers.
Thus, the “correct” adjusting washer for “K 1” is determined.

Please install this adjusting washer when installing the clutch at
a later stage.
– Proceed with the adjustment for the clutch “K 2”.
Determine the adjusting washer for the “K 2”.

FABIA II 2011 ➤
– Only insert the small bearing.

Do not insert an adjusting washer!
The small engaging bearing fits in only one position due to the 4
grooves.
– While “turning”, check if the small engaging bearing is correctly

installed and the grooves are correctly positioned.
– Position the gauge block -T10374- “with the large opening up‐
wards” on the small bearing.

FABIA II 2011 ➤
– Place the digital depth gauge at the “top” on the outer drive
shaft.
– Reset the depth gauge to “zero”.
– Measure the distance from the “shaft end” to the gauge block
-T10374- .

FABIA II 2011 ➤

accuracy resulting from the “wobbling” on the engaging bearing
is thus minimised.
– Note the mean value of both measurements to the gauge block
-T10374 - .
– Note this value and name it “A2”.
As an example:
Dimension “A2” = 2,50+2,542 = 2.52
As an example: “A2” = 2.52 mm
The following calculation:
“A2” minus “B” plus height of the gauge block -T10374- = depth
of the engaging bearing of clutch 2.
The height of the gauge block -T10374- is always the same. On
the inside, it is: 36.20 mm.

2.52 mm minus 2.96 mm plus 36.20 mm = 35.76 mm.
You have now determined the value of how deep the engaging
bearing is actually positioned in the gearbox.
The depth of the bearing must be 34.35 mm on each gearbox.
The nominal dimension “34.35 mm” is deducted from the actual
dimension. Thus, the actual air passage of clutch 2 is determined.
– Continue the calculation:
The determined value (in the example: 35.76 mm) minus the
nominal value = the air passage of the clutch.
35.76 mm minus “34.35 mm” = air passage of clutch 2 = 1.41 mm.
Now the tolerances in the double clutch must be included in this
calculation. This is a very simple procedure:

FABIA II 2011 ➤
– Please read off the value of the clutch tolerance -arrow- from
the “new” clutch.
A value between minus 0.40 and plus 0.40 mm is attributed to the
new clutch.
– Note this value.
Example 1: “-0.40 mm” is given on your clutch.
The last calculation for “K 2”: “Its determined” air passage minus
the value of clutch 2 =
1.41 mm minus 0.40 = 1.01 mm.
Example 2: “+ 0.20 mm” is given on your clutch.
Then the last calculation for “K 2” is done as follows: 1.41 mm plus
0.20 = 1.61 mm.
– Select the correct washer from the table.
washer
from to
0,31 0,90 0,8
0,91 1,10 1,0
1,11 1,30 1,2
1,31 1,50 1,4
1,51 1,70 1,6
1,71 1,90 1,8
1,91 2,10 2,0
2,11 2,30 2,2
2,31 2,50 2,4
2,51 2,70 2,6
2,71 3,30 2,8
– From the delivered washers, determine the adjusting washer

which is required.
WARNING
At a later stage, just insert this 1 adjusting washer. Do not insert

2 washers.
Thus, the “correct” adjusting washer for “K 2” is also determined.

Please install this adjusting washer when installing the clutch at
a later stage. This washer belongs under the small engaging
bearing.
1.3 Install double clutch

♦ Supporting bridge -T10323-

FABIA II 2011 ➤
Do not oil or grease!

Before installing the clutch, the position of the engaging bearings
“K 1 and K 2” must be adjusted ⇒ page 15 .
– Insert the plastic support of the engaging levers and check for
correct fit.
– Install small engaging lever with clamp.

The sleeve with its retaining bracket fits only in one position.
– Check the correct fit of the engaging lever.

– Screw down the engaging lever with 2 new screws.
Tightening torque: 8 Nm + 90°
Note
The support of the engaging levers and the complete mechanism

for the engaging bearings must be dry and free of oil or grease.
If necessary, clean these component parts with a cloth.
– Insert the second “larger” engaging lever.

This “larger” lever is for the clutch “K 1”.
– Check the correct fit of both engaging levers.
Caution
Before performing any further assembly, check whether the

clutch must be adjusted.
Further assembly can only be performed once the clutch has
been adjusted!
Adjust the positions of the engaging bearings ⇒ page 15 .
– Insert the small engaging bearing -A- with the measured ad‐
justing washer -B-.
The adjusting washer -B- belongs under the small engaging bear‐
ing -A-. Therefore, insert the adjusting washer first.

FABIA II 2011 ➤
grooves.
If the clutch was replaced, the adjusting washer also belongs un‐
der the bearing.
– While “turning” the bearing, check if it is correctly installed and

the grooves are correctly positioned.
– Fix the adjusting washer -A- with 3 drops of glue -AMV 195
KD1 01- -arrows-.
This prevents that the washer slips out of its position when the
clutch is inserted.
The large adjusting washer is used for the clutch “K 1”, the small
one is used for the clutch “K 2”.
– Turn back the spindle of the extractor -T10373- .
– Insert the clutch.

– Insert the clutch into the gearbox using the extractor -T10373- .
– “Turn back” the spindle beforehand.
Note
The clutch is self-adjusting. Vibrations can have a negative effect

on the adjusting device. Therefore do not let the clutch fall. Do not
let the clutch fall into the gearbox when installing it.

FABIA II 2011 ➤
– Position the supporting bridge -T10323- parallel to the flange

– Equalise distances, e.g using washers -B- with a total thick‐
ness of 15 mm.
– Attach the supporting bridge -T10323- with screws -A-.
Note
Fasten screws -A- with nuts.
– Press the clutch downwards via the spindle.
Note
♦ During press-in procedure, place a hand onto the clutch. A

slight rattling can be felt. Rattling means that the clutch is
pressed into its fitting position. In this way, it can be “detected”
if the clutch is pressed in up to the stop.
♦ The clutch is pressed in up to the stop if the circlip can be
inserted.
Fitting position of the circlip: the joint of the circlip is “smaller at

the top”.
– Insert the new circlip -arrow-.

FABIA II 2011 ➤
– Turn the clutch against the extractor by hand so that the clutch
is thus located in its fitting position.
• Only turn the clutch by hand, do not use any tool.
Only turn by hand. In this way, the clutch slips against the circlip.
Do not use any further tool.
By pressing on the “clutch it is positioned at the bottom” on the
drive shaft. The clutch should only be pulled up as far as neces‐
sary until it touches the circlip.
Subsequently insert the hub:

The hub has a “large” tooth and therefore only fits in one position.
On the -engine side-, the “large” tooth has a marking -arrow-.
– Install the hub with the marking on the “large tooth” in such a
way that it is flush with the marking on the drive plate
-arrow-.

FABIA II 2011 ➤
– Insert the circlip for the hub -arrow-.

Fitting location: The joint of the ring must point to the “lug” on the
clutch.
– Turn the clutch by hand and while turning it pay attention to

the “small” engaging lever.
While doing so, the engaging levers must remain “still” in their
position. They must not move up and down.
If an engaging lever moves up and down, the adjusting washer is
not in its position.

FABIA II 2011 ➤
– In this case, remove the clutch again ⇒ page 11 .

– Have a close look at the adjusting washers -arrows-.
• The washers must be correctly positioned. They should not be
damaged.
– Remove the screw plugs and position both ventilation caps

-arrows- again.
Perform the basic setting after the gearbox has been fitted
with the ⇒ Vehicle diagnosis, testing and information system VAS
5051.

FABIA II 2011 ➤
1 Electric/electronic components and fitting locations of the automatic
gearbox DSG - 0AM
❑ Fitting location: dash
panel in the area of the
driver's footwell
2 - Selector lever position indi‐
cator -Y6-
❑ Fitting location: integra‐
ted in the dash panel in‐
sert
❑ a switched off gear dis‐
play points to an emer‐
gency operation with
deactivated gearbox
control unit
❑ a fully lit gear display
points to an emergency
operation with activated
gearbox control unit
❑ can only be replaced to‐
gether with the dash
panel insert ⇒ Electrical
System ⇒ Rep. Gr. 90
with lamp for selector lever
scale illumination -L101-
❑ the lamp for selector lev‐
er scale illumination -
L101- is integrated in
the cover for gearshift
mechanism -arrow-
L101- is checked by
self-diagnosis
⇒ page 39
4 - Gearbox input r.p.m. sender 3 -G641 -
❑ is an integral part of the mechatronics for double clutch gearbox -J743-
❑ can only be removed and installed with the° mechatronics for double clutch gearbox -J743-
⇒ page 47
5 - Mechatronics for double clutch gearbox -J743-
6 - Selector lever lock solenoid -N110-
❑ Fitting location: is integrated firmly in the gearshift mechanism and cannot be replaced separately
1. Electric/electronic components and fitting locations of the automatic gearbox DSG - 0AM 31
FABIA II 2011 ➤
❑ the removal and installation procedure is only possible together with the gearshift mechanism
⇒ page 40 .
7 - Selector lever -E313- with Tiptronic switch -F189- , selector lever sensor control unit -J587- and selector
lever switch locked in P -F319 -
❑ Tiptronic switch -F189- , selector lever sensor control unit -J587- and selector lever switch locked in P -
F319 - are integrated into the shift mechanism
❑ these components cannot be replaced separately; the removal and installation procedure is only possible
together with the gearshift mechanism ⇒ page 40
8 - Brake light switch -F- and brake pedal switch -F47-
❑ removing and installing ⇒ Chassis ⇒ Rep. Gr. 47
9 - Kick-down switch -F8-
❑ Signal transfer from engine control unit to gearbox control unit via CAN databus
❑ removing and installing ⇒ Engine ⇒ Rep. Gr. 20

Mechatronics for double clutch gearbox -J743-

Fitting location: The mechatronics for double clutch gearbox -
J743- is screwed onto the front of the gearbox housing.
The control unit is firmly integrated in the mechatronics for direct
manual gearbox -J743- .
♦ is checked by self-diagnosis
The sensors and the actuators are located in the mechatronics
for double clutch gearbox -J743- . Further information on this can
be found in ⇒ Self-study programme No. 75 ; Automatic gearbox
DSG - 0AM .
Removing and installing the mechatronics for double clutch gear‐
box -J743 - ⇒ page 47 .
Gearbox input r.p.m. sender 3 -G641-

Fitting location: The gearbox input r.p.m. sender 3 -G641- is clip‐
ped onto the front of the gearbox housing. Release the sender for
removal and pull out in -direction of arrow-.
The gearbox input r.p.m. sender 3 -G641- can only be replaced
together with the mechatronics for double clutch gearbox -J743-
⇒ page 47 .

FABIA II 2011 ➤
Brake light switch -F- and brake pedal switch -F47-

Fitting location: Brake light switch -F- and brake pedal switch -
F47- -Pos. 3- are located on the master brake cylinder.
Kick-down switch -F8-

An initialised value of the accelerator pedal position sender -
G79- / accelerator pedal position sender 2 -G185 - (intergrated in
the accelerator pedal module) is stored as a kick-down signal in
the engine control unit.
Fitting location: Accelerator pedal position sender -G79- / accel‐
erator pedal position sender 2 -G185- -arrow- are located on the
foot controls.
1. Electric/electronic components and fitting locations of the automatic gearbox DSG - 0AM 33
FABIA II 2011 ➤
2 Shift mechanism
WARNING


position.
only engage after approx. 1 second. The selector lever can
only be moved from position “N” by activating the brake pedal.
Selector lever in position “P”, push-button on selector lever press‐
ed and ignition switched on
• Brake pedal is not pressed:
The selector lever is locked when the push-button is pressed and
cannot be moved out of position “P”. The selector lever lock sol‐
enoid blocks the selector lever.
• Brake pedal is pressed:
lever from “P” to “S”; while doing so check whether the selector
lever position in the dash panel insert corresponds with the actual
selector lever position.
Selector lever in position “N”, push-button on selector lever press‐
ed and ignition switched on:
• Brake pedal is not pressed:
• Brake pedal is pressed:
Note
Shifting out of the position “N” to “D” by activating the brake pedal
is also possible without pressing the push-button on the selector
lever . From position “N” to “R” the push-button on the selector
lever must be additionally pressed.
Selector lever in position “D”, ignition switched on

The selector lever is locked and cannot be shifted from position
“D” to position “S”.
• The push-button pressed on the selector lever
The selector lever is released and can be shifted from position
“D” to position “S”.

FABIA II 2011 ➤
Selector lever in position “D”, ignition and light switched on

• Selector lever in the Tiptronic gear leads to
The lighting up of the “D” on the lamp for selector lever scale il‐
lumination -L101- should go out and the “+” and “–” symbols
should light up.
When the selector lever is put into the Tiptronic gate, the selector
lever position indicator -Y6- in the dash panel insert should
change from “P R N D S” to “7 6 5 4 3 2 1”.
• Move selector lever in the Tiptronic gear to “+” and “–”.
The display of the selector lever position “7 6 5 4 3 2 1” in the dash
panel insert must indicate (change) a higher or a lower gear when
shifting the selector lever to “+” or to “–”.
If the gearshift mechanism does not function as described:
⇒ page 35 .
– Checking the ignition key lock ⇒ page 37 .
Selector lever position indicator

If all parts of the selector lever position display are lit, it indicates
that the gearbox is in emergency operation mode.

lever control cable
2.2.1 Inspect setting of selector lever control

cable
• The gearshift mechanism is checked ⇒ page 34 .
– Pull selector lever out of position “P” with the push-button
pressed approx. 5 mm to the rear and hold, do not shift into
position “R”.
– Release the selector lever.
• The selector lever must automatically jump back again into the
position “P”.
– If this is not the case, then the gearshift mechanism must be
set ⇒ page 36 .
– Pull selector lever out of position “N” with the push-button
pressed approx. 5 mm to the rear and hold, do not shift into
position “D”.
position “N”.
set ⇒ page 36 .
– Pull selector lever out of position “N” with the push-button
pressed approx. 5 mm to the front and hold, do not shift into
position “R”.
position “N”.
2. Shift mechanism 35
FABIA II 2011 ➤

set ⇒ page 36 .
2.2.2 Adjusting selector lever control cable

The selector lever control cable must always be set, if:
♦ The selector lever control cable was removed from the gear‐
box
♦ Remove and install engine and (or) gearbox.
♦ Removed and installed parts of the unit mounting.
♦ The gearshift mechanism was removed and installed.
a stress-free assembly.
– The lock washer -arrow- must be correctly fitted.
Note
The lock washer -arrow- must be replaced after each removal ⇒


– Check the protective cover at the front gearshift mechanism
on the selector lever control cable for damage. The gearshift
mechanism must be replaced if damaged.
move smoothly when shifting gears.
Setting
– Shift selector lever in the vehicle into position “P”.
– Release screw -arrow-.
Note
If the clamping screw -arrow- is released, the selector lever of the

gearshift mechanism must remain in position “P”, otherwise the
setting is not correct.

FABIA II 2011 ➤
– Position gearshift shaft lever at gearbox in “P”. To do so, press

the gearshift shaft lever in -direction of arrow- in the direction
towards the cable support.
The figure shows the gearbox “from the rear”. -P- is in the direction
towards the cable support.
– Turn both front wheels in one direction, e.g. by rolling the ve‐
hicle forwards, until the parking lock in the gearbox engages
into the parking gear.
• Only if both front wheels cannot be simultaneously turned in
one direction, the parking lock is engaged.

– Slightly move the selector lever towards the front and rear,
without shifting into another selector lever position.
Note
In doing so, the selector lever control cable is slackened.
– Tighten screw -arrow- at selector lever cable without jolting to

tightening torque.
Tightening torque: 12 Nm
Note
Pay attention when tightening the screw -arrow- that the selector
lever control cable no longer shifts.
– Install air filter ⇒ Engine ⇒ Rep. Gr. 24 .
2.3 Check operation of the ignition key anti-

removal lock
– Turn the ignition key slightly to the right (do not start the en‐
gine) in order to set the position “ignition on”.
– Depress brake pedal and hold pressed.
• Shifting the selector lever out of the position “P” when the lock
button is pressed at the grip of the selector lever must be pos‐
sible without “jerking”.
• The ignition key should not be removable when the selector
lever position is out of “P”.
– Withdraw ignition key.
FABIA II 2011 ➤
• The ignition key should only be removable when the selector

lever is in “P”.
• The selector lever cannot be moved out of position “P” when
the lock button is pressed and the brake pedal is actuated.
If the ignition key removal lock does not function as described:
♦ Inspecting and adjusting the selector lever control cable
⇒ page 35 .
♦ Check the vehicle with the vehicle diagnosis, measurement
and information system -VAS 5051B- in the function “targeted
fault finding”.
2.4 Summary of components - Gearshift mechanism
Note
The gearshift mechanism and the selector lever control cable must not be separated from each other and are
replaced as one component part ⇒ Electronic Catalogue of Original Parts .

1 - Cover with handle
❑ Remove the cover
⇒ page 39
❑ for the emergency re‐
lease only the cover
needs to be unclipped
from the centre console
⇒ page 43
❑ the symbol insert and
the circuit board with the
lamp for selector lever
scale illumination -
L101- are integrated in
the cover
2 - Open warm-type clamp
❑ always replace ⇒ Elec‐
tronic Catalogue of
Original Parts
❑ tighten using hose bind‐
ing claw -V.A.G 1275-
3 - Centre console
❑ remove it for the remov‐
al and installation proce‐
dure of the gearshift
mechanism
4 - Noise insulation
❑ can only be removed af‐
ter the removal of the
centre console
5 - Gearshift mechanism with
selector lever and selector lev‐
er control cable
❑ with selector lever lock
solenoid -N110-
❑ Emergency release
⇒ page 43
❑ after the installation adjust the selector lever control cable ⇒ page 35

FABIA II 2011 ➤
❑ Remove the shift mechanism from the shift housing ⇒ page 39
6 - Screw, 8 Nm
❑ 4 pieces
7 - Shift housing with gasket
❑ Remove shift housing ⇒ page 39
8 - Nut M6 - 8 Nm; Nut M8 - 25 Nm
❑ 4 pieces
9 - Lever/gearshift shaft
10 - Cable support
11 - Lock washer
❑ always replace after removing ⇒ Electronic Catalogue of Original Parts
Note
❑ Do not grease selector lever control cable

❑ remove from the shift housing and install ⇒ page 39
❑ testing and adjusting ⇒ page 35
Remove the shift mechanism together with the selector lever con‐
trol cable from the shift housing
Remove the shift mechanism -A- together with the selector lever
control cable -C- from the shift housing -B- in
-direction of arrow-. To do so, unscrew 4 screws
⇒ Item 6 (page 39) from the shift housing.
2.5 Removing and installing the handle and

cover for the shift mechanism
♦ Hose binding claw -V.A.G 1275-
2.5.1 Removing
– Before removing the handle pull out lock button -1- over its
pressure point and secure it with a cable strap or a suitable
wire -2-. This can prevent that the lock button is inadvertently
pressed into the handle.
– Unclip the cover -3- from the centre console.
FABIA II 2011 ➤
– Pull the cover -B- upwards over the handle.

– Disconnect plug -A- for lamp for selector lever scale illumina‐
tion -L101- .
– Open the warm-type clamp -arrow- below the handle and pull
off handle with cover.
2.5.2 Install
following points:
Note
♦ The lock button must be fully pulled out for installing the se‐
lector lever grip. Then the lock button must be secured using
a cable strap or with the assembly aid which was factory-de‐
livered together with the new grip.
♦ If the lock button is not secured, it can no longer be pulled out
of the selector lever grip using mechanical auxiliary tools.
Press out the lock button if necessary by positioning a com‐
pressed air pistol on the underside of the grip.
– Press the selector lever grip completely onto the selector lever
with a new warm-type clamp - the lock button points to the
driver.
• During this procedure, the grip must latch in the annular
groove on the selector lever.
– Remove cable strap or assembly aid. After the removal, the
lock button actuator engages into the vertical groove on the
selector lever. If necessary, press the lock button into the se‐
lector lever grip.
– Tighten new warm-type clamp using the hose binding claw .
2.6 Removing and installing gearshift mech‐

anism with selector lever control cable
♦ Removal tool for the inner lining of the door panel -MP8-602/1-
2.6.1 Removing
– Removing the handle and cover for the shift mechanism
⇒ page 39 .
– Shift selector lever into position “S”.
– Remove the noise insulation from the gearshift mechanism.

FABIA II 2011 ➤
– Disconnect the plug connection -A- from the gearshift mech‐

anism.
– Unscrew the screws -arrows- from the shift housing.
– Raise vehicle.
– Unhook the pre-exhaust pipe from the retaining straps on the
assembly carrier.
– Disconnect the exhaust system at the clamping sleeve ⇒ En‐
gine ⇒ Rep. Gr. 26 .
– If present, slacken the underbody cover on right and left.
– Remove tunnel bridge -A- -arrows-.


– Lever off the selector lever control cable -A- from the gearshift
shaft lever with the removal tool for the inner lining of the door
panel -MP8-602/1- .
FABIA II 2011 ➤
– Remove lock washer.
Note
The lock washer -arrow- of the selector lever control cable must
always be replaced ⇒ Electronic Catalogue of Original Parts .
– Remove the gearshift mechanism.
Note
2.6.2 Install
following points:
Note
– Install the gearshift mechanism with selector lever control ca‐

ble and attach it to the shift housing with screws -arrows-.
– Mount the plug connection -A- and position the noise insula‐
tion on the gearshift mechanism.
– Installing the handle and cover for the shift mechanism
⇒ page 39 .

FABIA II 2011 ➤
– Carefully press the selector lever control cable -2- onto the
lever/gearshift shaft of the gearbox and secure in the cable
support with a new lock washer -1-.
– Check operation of the ignition key anti-removal lock
⇒ page 37
– Setting selector lever control cable ⇒ page 35 .
– Install air filter ⇒ Engine ⇒ Rep. Gr. 24 or ⇒ Rep. Gr. 23 .
– Install the heat shield below the shift mechanism and fasten
the trim panels for the underfloor on the body ⇒ Body Work
⇒ Rep. Gr. 50 .
Rep. Gr. 26 .
– Install tunnel bridges below the exhaust system ⇒ Engine ⇒
Rep. Gr. 26 .
2.7 Emergency release of gearshift mecha‐

nism out of position “P”
Selector lever lock solenoid -N110- locks the selector lever in po‐
sition “P”. The selector lever can only be moved out of “P” when
ignition is on or starting the engine, the brake pedal is actuated
and the button on the selector lever grip is pressed.
If there are faults in the voltage supply to the selector lever lock
solenoid (battery discharged or fuse defective) or in case of de‐
fective solenoids, the selector lever cannot be moved out of the
position “P”, i.e the vehicle cannot be moved because the parking
position is engaged.
If this is the case:
– Test fuse ⇒ Current flow diagrams and Fitting locations.
– Check battery voltage ⇒ Electrical System ⇒ Rep. Gr. 27 .
If the selector lever cannot be moved out of position “P” despite
the checks, the emergency release of the solenoids must be per‐
formed. If the selector lever is then shifted again into the position
“P”, it is blocked again in the position “P”.
2.7.1 Perform emergency release

Carefully unclip the selector lever cover from the centre console.
Note
Do not remove grip of selector lever.
FABIA II 2011 ➤
– Depress the brake pedal or pull on the handbrake.

– Press the yellow plastic wedge -A- in -direction of arrow 1-.
– Now press the button on the selector lever grip and move the
selector lever -B- in -direction of arrow 2- out of the position
“P”.
Note
If the selector lever is then shifted again into the position “P”, it is
blocked again in the position “P”.

switch -F189-
The Tiptronic switch -F189- is integrated firmly in the gearshift
mechanism and cannot be replaced separately. If the Tiptronic
switch -F189- is defective, the gearshift mechanism must be re‐
placed ⇒ page 40 .

lock solenoid -N110-
The selector lever lock solenoid -N110- is integrated firmly in the
gearshift mechanism and cannot be replaced separately. If the
selector lever lock solenoid -N110- is defective, the gearshift

switch locked in P -F319 -
The selector lever switch locked in P -F319- is integrated firmly in
the gearshift mechanism and cannot be replaced separately. If
the selector lever switch locked in P -F319 - is defective, the
gearshift mechanism must be replaced ⇒ page 40 .

lever sensor control unit -J587-
Selector lever sensor control unit -J587- is integrated firmly in the
gearshift mechanism and cannot be replaced separately. If the
selector lever sensor control unit -J587- is defective, the gearshift

FABIA II 2011 ➤
3 Mechatronics for double clutch gear‐

box -J743 -
3.1 Safety instruction for° mechatronics for double clutch gearbox -J743-
DANGER!
Do not remove the pressure tank. The pressure tank is under

pressure and should not be opened.
3. Mechatronics for double clutch gearbox J743 45

FABIA II 2011 ➤
Caution
♦ Do not slacken cover screws for mechatronics for double

clutch gearbox -J743- .
♦ Do not let the engine run and do not tow the vehicle if the
mechatronics for double clutch gearbox -J743- is removed
or without filling with gearbox oil.
♦ Only then touch or remove the mechatronics for double
clutch gearbox -J743- , after you have discharged yourself
electrostatically at an earthed object beforehand, e.g. skin
contact with mass.
♦ Under no circumstances must the plug contacts in the plug
of the gearbox be touched with the hands, because the
control unit can be destroyed through static discharge as
well as the mechatronics.

FABIA II 2011 ➤
3.2 Summary of components - mechatronics for double clutch gearbox -J743-
Note
♦ The “new” mechatronics for the gearbox is already precisely filled with oil at the factory, do not drain the oil.
♦ The “removed” mechatronics is sent back with oil (close the ventilation opening with a suitable plug).
♦ Pay attention to the ventilation when handling the mechatronics .
♦ During assembly work, remove the ventilation caps and close with a suitable screw plug.
1 - Screw, 10 Nm
❑ 3 pieces, M8 x 35
tronic Catalogue of
Original Parts
❑ for attaching the mecha‐
tronics for double clutch
gearbox -J743- at gear‐
box housing
2 - Screw, 10 Nm
tronic Catalogue of
Original Parts
gearbox -J743- at gear‐
box housing
3 - Mechatronics for double
clutch gearbox - J743-
❑ The mechatronics is al‐
located according to the
gearbox code letters ⇒
Electronic Catalogue of
Original Parts .
❑ Place the mechatronics
by hand in the “removal
position” ⇒ page 60 .
Gearbox installed:
❑ Remove mechatronics
⇒ page 52
❑ Install mechatronics
⇒ page 66
The gearbox is removed:
❑ Remove mechatronics ⇒ page 47
❑ Install mechatronics ⇒ page 62
3.3 Removing mechatronics for double

clutch gearbox -J743 - ; gearbox re‐
moved.
♦ Assembly lever -T10407-

FABIA II 2011 ➤
Note
♦ Observe safety instruction for the mechatronics for double

clutch gearbox -J743- ⇒ page 45 .
♦ Observe instructions for automatic gearbox DSG - 0AM
⇒ page 5 .
♦ The clutch is self-adjusting. Vibrations can have an effect on
this adjusting device. Also when the mechatronics is removed,
the “sudden removal” of the special tool below the engaging
levers can have a negative effect on the adjusting device.
♦ Turn the removed gearbox in such a way that the mechatron‐
ics for double clutch gearbox -J743- points to the top, if nec‐
essary drain gear oil.
♦ The “new” mechatronics for the gearbox is already precisely
filled with oil at the factory, do not drain the oil.

♦ The “removed” mechatronics is sent back with oil (close the
ventilation opening with a suitable plug).
– Remove the cap -arrow- from the ventilation and close with a
suitable screw plug so that no oil can flow out.
– Carefully unlock the gearbox input r.p.m. sender 3 -G641- with

a screwdriver and pull it out of the housing in
-direction of arrow-.

FABIA II 2011 ➤
– Slacken the long screws -B- (4 pieces, M8 x 90) of the me‐

chatronics for double clutch gearbox -J743- “crosswise” and
release them.
– Slacken the remaining screws -A- (3 pieces, M8 x 35) “cross‐

wise” and release them.
Note
♦ Do not remove more than 7 screws! “There are 4 long and 3

short screws”.
♦ Do not slacken the cover screws of the mechatronics .
Now both engaging levers of the clutch control must be pressed

off the tappets of the mechatronics . Otherwise the engaging lev‐
ers of the mechatronics clamp at the tappets and the mechatron‐
ics cannot be removed.

FABIA II 2011 ➤
– Insert the assembly lever -T10407- between the engaging lev‐

ers for the clutch control and the gearbox housing
The assembly lever -T10407- should rest with the complete sur‐
face of the “reverse side” against the gearbox housing and the
nut should form one level with the recess of the housing -arrow-.
Note
Do not insert the assembly lever -T10407- up to the stop.
– Turn the assembly lever -T10407- to the left in

-direction of arrow- and thus press the engaging lever away
from the tappets -arrows-.

FABIA II 2011 ➤
Note
♦ Exert a little force on the tip of the assembly lever -T10407-

when turning it.
♦ This prevents that the assembly lever -T10407 - slips out when
turning it.
♦ Do not remove the assembly lever -T10407- . It remains in‐
serted between the engaging levers and the gearbox housing
during the complete assembly.
If necessary, press the assembly lever -T10407- against the gear‐

box using a screwdriver.
– Grab with the hand (without gloves) e.g. a water pipe, in order
to discharge yourself electrostatically.
Caution

contact with mass.
– Remove mechatronics.
Note
♦ The mechatronics for double clutch gearbox -J743- remains

filled with oil.
♦ Make sure no oil runs out of the ventilation.
♦ The mechatronics for double clutch gearbox -J743- is filled
with recycled oil.

FABIA II 2011 ➤
If the mechatronics for double clutch gearbox -J743- “hooks” and

cannot be removed:
It can happen that the mechatronics cannot be removed. In this
case, the gear actuator “hooks” at the “top left” on the gearbox
housing.
In this case, the mechatronics should not be removed with in‐
creased force.
– First reposition the mechatronics on the gearbox housing and
secure it with a screw.
– In this case, the mechatronics must be put into the “removal
position” by hand ⇒ page 60 .
Install mechatronics on removed gearbox ⇒ page 62 .
3.4 Remove mechatronics for double clutch

gearbox -J743 - ; gearbox installed.

VAS 5051-
♦ Catch pan for workshop crane -VAS 6208-
Note
♦ Observe safety instruction for the mechatronics for double

clutch gearbox -J743- ⇒ page 45 .
⇒ page 5 .
♦ The clutch is self-adjusting. Vibrations can have an effect on
this adjusting device. Also when the mechatronics is removed,
the “sudden removal” of the special tool below the engaging
levers can have a negative effect on the adjusting device.
♦ Ensure adequate clearance in front of the gearbox in order to
remove the mechatronics . Components, which are not directly
connected with the gearbox, must be removed on some vehi‐
cles. The existing brackets, if applicable, must be removed at
the screws of the cover for mechatronics.
♦ After the battery earth strap is disconnected and reconnected,
carry out additional operations ⇒ Electrical System ⇒ Rep.
Gr. 27 .
The mechatronics remains filled with oil

– Connect vehicle diagnosis, measurement and information
system -VAS 5051- .
– Select Targeted functions .

FABIA II 2011 ➤
– Under “7-speed double clutch gearbox”, select bring gear

actuator into neutral position .

Gr. 27 .
Caution

– Grab with the hand (without gloves) at the mass, in order to

discharge yourself electrostatically.
– Unlock the cap for the plug of the mechatronics by pulling in

-direction of arrow- and disconnect the plug.
– Unclip the electrical cables from the top bracket at the front of
the gearbox.
– Remove the cap -arrow- from the ventilation and close with a
suitable screw plug so that no oil can flow out.
WARNING
Hot steam may escape after the compensation bottle is

opened. Cover the cap with a cloth and open carefully.
– When the engine is warm the cooling system is under pres‐

sure. Slowly open the cap of the compensation bottle, in order
to first reduce pressure before pulling off the coolant hoses.
– Raise vehicle.

FABIA II 2011 ➤
– Release oil drain plug -arrow- at the gearbox.
– Drain off oil.

– Install oil drain plug.
Vehicles with radiator fan control unit -J293-

– Unscrew the nuts -3- from the left frame side rail and tie up the
radiator fan control unit -J293- -4-.
Note
Do not disconnect the plugs -1- and -2-.
Continued for all vehicles
– Disconnect the plug connection -arrow-.

FABIA II 2011 ➤
– Release the fan shroud on the catch hook e.g. using a screw‐
driver and remove ⇒ Engine ⇒ Rep. Gr. 19 .
– Place a catch pan for workshop crane -VAS 6208- under the
radiator.
– Remove the bottom coolant hose from the radiator -arrow- and
drain the coolant ⇒ Engine ⇒ Rep. Gr. 19 .
– Remove the electrical lines from the bottom holder at the front
of the mechatronics and tie up.
– Remove all the front brackets from the gearbox.
– Carefully unlock the gearbox input r.p.m. sender 3 -G641- with

a screwdriver and pull it out of the housing in

FABIA II 2011 ➤
– Slacken the long screws -B- (4 pieces, M8 x 90) of the me‐

chatronics for double clutch gearbox -J743- “crosswise” and
release them.
– Slacken the remaining screws -A- (3 pieces, M8 x 35) “cross‐

wise” and release them.
Note
♦ Do not remove more than 7 screws! “There are 4 long and 3

short screws”.
♦ Do not slacken the cover screws of the mechatronics .
Now both engaging levers of the clutch control must be pressed

off the tappets of the mechatronics . Otherwise the engaging lev‐
ers of the mechatronics clamp at the tappets and the mechatron‐
ics cannot be removed.

FABIA II 2011 ➤
– Insert the assembly lever -T10407- between the engaging lev‐

ers for the clutch control and the gearbox housing
The assembly lever -T10407- should rest with the complete sur‐
face of the “reverse side” against the gearbox housing and the
nut should form one level with the recess of the housing -arrow-.
Note
Do not insert the assembly lever -T10407- up to the stop.
– Turn the assembly lever -T10407- to the left in

from the tappets -arrows-.

FABIA II 2011 ➤
Note
♦ Exert a little force on the tip of the assembly lever -T10407-

when turning it.
♦ This prevents that the assembly lever -T10407 - slips out when
turning it.
♦ Do not remove the assembly lever -T10407- . It remains in‐
serted between the engaging levers and the gearbox housing
during the complete assembly.
If necessary, press the assembly lever -T10407- against the gear‐

box using a screwdriver.
Caution

contact with mass.
Note
♦ The mechatronics for double clutch gearbox -J743- remains

filled with oil.
♦ Make sure no oil runs out of the ventilation.
♦ The mechatronics for double clutch gearbox -J743- is filled
with recycled oil.

FABIA II 2011 ➤
If the mechatronics for double clutch gearbox -J743- “hooks” and

cannot be removed:
It can happen that the mechatronics cannot be removed. In this
housing.
creased force.
– First reposition the mechatronics on the gearbox housing and
secure it with a screw.
– In this case, the mechatronics must be put into the “removal
position” by hand ⇒ page 60 .
Install mechatronics on installed gearbox ⇒ page 66 .

FABIA II 2011 ➤
3.5 Place the mechatronics for double clutch gearbox -J743 - by hand in the
“removal position”
It is possible that the mechatronics cannot be removed. In this
housing -arrow-.
• Only if the “removal position” could not be set with the vehicle
diagnosis system, measurement and information system -
VAS 5051B- , the mechatronics must be put into the “removal
position” by hand.
The “hooking” gear actuator -arrow- can be pressed into a “re‐
moval position” by hand. To do so, remove the cover for the
gearbox oil filling.
Gearbox installed:
The mechatronics is located on the gearbox housing and is se‐
cured with a screw.
– Remove air filter housing complete with air guide hose ⇒ En‐

FABIA II 2011 ➤
panel -MP8-602/1- .
– Detach the lock washer -arrow- of the selector lever control

cable.
– Then carefully push the selector lever control cable to the rear,
remove it from the cable support and tie up.
Note
♦ The lock washer -arrow- of the selector lever control cable

must always be replaced ⇒ Electronic Catalogue of Original
Parts .
The gearbox is removed:
– Position the gearshift shaft lever in “P”.

– To do so, press the lever by hand up to the stop in the direction
towards the cable support -arrow-.
The gearbox is installed or removed.
– Press the lever by hand up to the stop in the direction towards
the cable support.
– Remove the gearshift shaft lever.

– Unscrew the cover.
Note
The mechatronics will “no longer clamp” at the next work step.
This means it will fall out under certain circumstances. If not yet
performed, the mechatronics must be secured at the gearbox with
a screw against falling down.

FABIA II 2011 ➤
– Press the shift fork to the side through the opening in

By doing so, the “hooking” gear switch is also pressed back and
the mechatronics can be removed.
Note
Do not reinstall the cover yet, as the gear oil is filled up via this
opening after installing the mechatronics for double clutch gear‐
box -J743- ⇒ page 85 .
3.6 Installing mechatronics for double clutch

gearbox -J743 - ; gearbox removed.
♦ Guide bolt -T10406-
The mechatronics remains filled with oil
– If this is not yet the case: Close the ventilation with a suitable
screw plug so that no oil can flow out.
Note
♦ Make sure that all the shift forks are in the “centre position” before installing the mechatronics for double
♦ The “centre position” is shown in the illustration as position -N- (neutral).
♦ No gear is engaged in this position, i.e neutral (neutral position) is engaged.
– First check all 4 shift forks by hand.

All shift forks have 3 positions:
♦ Gear engaged
♦ Neutral -N-
♦ Gear engaged
– Consecutively bring all 4 shift forks once into each position
-arrows-, if necessary turn a little on the pinions.
– Then bring all the shift forks again into the “centre position”,
position -N-.

FABIA II 2011 ➤
N - Neutral
R - Reverse gear
Note
♦ When the reverse gear is engag‐

ed, the extended tappet of the
mechatronics is “hooked” on the
gearbox housing.
♦ Therefore, the mechatronics
must be put into the removal po‐
sition by hand ⇒ page 60 .
1 - first gear
2 - second gear
3 - third gear
4 - fourth gear
5 - fifth gear
6 - sixth gear
7 - seventh gear
– Screw in guide bolts -T10406- by hand.
Set gear switch:
Caution
Risk of damage mechatronics for double clutch gearbox -

J743- .
Do not support on the sensors when removing the tappets from
the mechatronics .

FABIA II 2011 ➤
– Set the 4 gear switches on the rear side of the mechatronics

for double clutch gearbox -J743- into the specified position.
Specified position: -a- = 25 mm
Note
♦ Clean the sealing surface on the gearbox housing on which

the mechatronics will rest at a later stage.
♦ Oil residues on the sealing surface can lead to the wrong di‐
agnosis “leaking” at a later stage.
♦ The seal for the mechatronics for double clutch gearbox -J743-
must be attached all around.
– Look at the sender. The clip must not be damaged.

– Position the mechatronics .
When handling and positioning, make sure that the shift forks are
not pressed out of their position. Also pay attention to the engag‐
ing lever and the tappet of the mechatronics .

FABIA II 2011 ➤
– Screw in the screws -A- (3 pieces, M8 x 35) and -B- (2 pieces,

M8 x 90) crosswise by hand.
– Remove guide bolts -T10406- .
– Screw in the remaining screws -B- (2 pieces, M8 x 90) by hand.
Make sure that the tappets are correctly positioned in the pans of
the engaging levers -arrow-. Pull out the tappets by hand until they
fit in the pans.
Note
The tappets can be put into position for example using a welded
wire hook.
– Now check the position of the tappets once again.
Note
Incorrectly mounted tappets will damage the mechatronics .

FABIA II 2011 ➤
– Tighten all the screws for the mechatronics for double clutch
gearbox -J743- crosswise to the tightening torque
⇒ page 47 .
– Carefully turn the assembly lever -T10407- to the right and
remove.
– Insert the gearbox input r.p.m. sender 3 -G641 - in

-direction of arrow- in the gearbox housing.
Note
♦ Look at the sender . The clip must not be damaged.

♦ The sender must be positioned completely and tightly with its
tab on the gearbox housing. If the sender is “loose”, the clip is
broken, replace the mechatronics.
– Remove the screw plug from the ventilation and position the
ventilation cap.
3.7 Install mechatronics for double clutch

gearbox -J743 - ; gearbox installed
♦ Assembly lever -T10407 -
♦ Catch pan for workshop crane -VAS 6208-

FABIA II 2011 ➤
– If this is not yet the case: Close the ventilation with a suitable
screw plug so that no oil can flow out.
Note
♦ Make sure that all the shift forks are in the “centre position” before installing the mechatronics for double
♦ The “centre position” is shown in the illustration as position -N- (neutral).
♦ No gear is engaged in this position, i.e neutral (neutral position) is engaged.

♦ Gear engaged
♦ Neutral -N-
♦ Gear engaged
– Then bring all the shift forks again into the “centre position”,
position -N-.

FABIA II 2011 ➤
N - Neutral
R - Reverse gear
Note
♦ When the reverse gear is engag‐

ed, the extended tappet of the
mechatronics is “hooked” on the
gearbox housing.
♦ Therefore, the mechatronics
must be put into the removal po‐
sition by hand ⇒ page 60 .
1 - first gear
2 - second gear
3 - third gear
4 - fourth gear
5 - fifth gear
6 - sixth gear
7 - seventh gear
– Screw in guide bolts -T10406- by hand.
Set gear switch:
Caution

J743- .
Do not support on the sensors when removing the tappets from
the mechatronics .

FABIA II 2011 ➤

for double clutch gearbox -J743- into the specified position.
Note
♦ Clean the sealing surface on the gearbox housing on which

♦ Oil residues on the sealing surface can lead to the wrong di‐
agnosis “leaking” at a later stage.
♦ The seal for the mechatronics for double clutch gearbox -J743-
– Look at the sender. The clip must not be damaged.

– Position the mechatronics .
When handling and positioning, make sure that the shift forks are
not pressed out of their position. Also pay attention to the engag‐
ing lever and the tappet of the mechatronics .

FABIA II 2011 ➤

– Remove guide bolts -T10406- .
Make sure that the tappets are correctly positioned in the pans of
the engaging levers -arrow-. Pull out the tappets by hand until they
fit in the pans.
Note
The tappets can be put into position for example using a welded
wire hook.
– Now check the position of the tappets once again.
Note
Incorrectly mounted tappets will damage the mechatronics .

FABIA II 2011 ➤
gearbox -J743- crosswise to the tightening torque
⇒ page 47 .
– Carefully turn the assembly lever -T10407- to the right and
remove.
– Insert the gearbox input r.p.m. sender 3 -G641 - in

-direction of arrow- in the gearbox housing.
Note
♦ Look at the sender . The clip must not be damaged.

♦ The sender must be positioned completely and tightly with its
tab on the gearbox housing. If the sender is “loose”, the clip is
broken, replace the mechatronics.
ventilation cap.
Caution

well as the mechatronics .

– Mount the plug of the mechatronics and lock.
– Attach all the holders and cables again on the gearbox.

– Install fan shroud ⇒ Engine ⇒ Rep. Gr. 19 .

FABIA II 2011 ➤
– Attach the bottom coolant hose at the radiator -arrow- and fill
up with coolant ⇒ Engine ⇒ Rep. Gr. 19 .
– If removed, install the radiator fan control unit -J293- on the
left frame side rail.
– Pour in gear oil ⇒ page 85 .
– Install the starter ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Install battery tray and battery ⇒ Electrical System ⇒ Rep.
Gr. 27 .
After the battery earth strap is disconnected and reconnected,
carry out additional operations ⇒ Electrical System ⇒ Rep. Gr.
27 .
– Inspect setting of selector lever control cable; adjust if neces‐
sary ⇒ page 35 .
After the installation of the mechatronics , perform a basic set-
ting with the ⇒ Vehicle diagnosis, testing and information system
VAS 5051.

FABIA II 2011 ➤

♦ Lifting device -MP9-200 (10-222A)-
♦ Adapter -MP9-200/3 (10-222A/3)-
♦ Adapter -MP9-200/18 (10-222A/18)-
♦ Bolt -3282/29-
♦ Tensioning strap -T10038-
♦ Engine and gearbox jack e.g. -V.A.G 1383 A-
♦ Socket insert e.g. -T10035 - or socket insert XZN 14 -T10061-
Note

⇒ page 5 .
♦ If the battery earth strap is disconnected and reconnected,
Gr. 27 .

Note
Do not take out ignition key.
– If present, remove engine cover ⇒ Engine ⇒ Rep. Gr. 10 .

– Remove battery ⇒ Electrical System ⇒ Rep. Gr. 27 .

FABIA II 2011 ➤
– Remove battery tray, to do so release the screw and the nuts

-arrows-.
lever with the removal tool for the inner lining of the door panel
-MP8-602/1- .
– Detach the lock washer -arrow- of the selector lever control

cable.
– Then carefully push the selector lever control cable to the rear,
remove it from the cable support and tie up.
Note

Parts .

When removing, it is recommended to begin with the bottom
starter screw.
– Release all the upper gearbox connecting screws to the en‐
gine. To this end, use if necessary socket insert -T10035- or
socket insert -T10061- .

FABIA II 2011 ➤
One of the screws is located in the opening for the starter

-arrow-.
– Screw out this screw.
Caution


– Unlock the cap of the plug on the mechatronics by pulling in

the gearbox.
For vehicles 1.2/77 kW

– Open the bracket -A- for the coolant hoses and unclip the
coolant hoses. Do not open the coolant lines.
– Then unlatch the bracket in the lower area -arrow 1- and de‐
tach it upwards from the timing case cover -B-
– Remove front wheels ⇒ Chassis ⇒ Rep. Gr. 44 and raise the
vehicle.
Gr. 66 .

FABIA II 2011 ➤
For vehicles 1.2/77 kW
– Remove lambda probe -G39- -1-.

– Disconnect the plug -2- from the alternator and remove the
heat shield -3- from the exhaust gas turbocharger -arrows-.
– Unhook the plug connections -1 … 3- from the bottom bracket

at the front of the gearbox and disconnect.
– Remove pre-exhaust pipe with catalytic converter -4- ⇒ En‐
Vehicles with radiator fan control unit -J293-

radiator fan control unit -J293- -4-.
Note
Vehicles with power steering

FABIA II 2011 ➤
– Open the spacer holder -1- and remove the cables -2- and
-3- for the power-assisted steering gear.
– Remove the engine pump aggregate for the power-assisted
steering with the bracket from the frame side rail and tie up to
the side ⇒ Chassis ⇒ Rep. Gr. 48 .
– Remove pendulum support from gearbox, to do so release

screws -1- and -2-.
– Release the screws -arrows- for the steering gear on the as‐
sembly carrier and tie up the steering gear in the right area,
e.g. on the bracket for the ABS control unit.
– Fix the assembly carrier before removing ⇒ Chassis ⇒ Rep.
Gr. 40 .
– Remove assembly carrier without steering gear ⇒ Chassis ⇒
Rep. Gr. 40 .
– Unscrew both drive shafts from the gearbox.
– Tie up right drive shaft as far as possible, e.g. with cord. Avoid
damaging the paintwork on the drive shaft during this opera‐
tion.
– Swivel the left drive shaft into the wheelhouse and secure it to
the suspension strut, e.g. with cord. Avoid damaging the paint‐
work on the drive shaft during this operation.
– Remove the right flange shaft.

– If hose and cable connections are located in the area of the
lifting eye of the engine for the supporting device -MP9-200
(10-222A)- , these must now be removed.

FABIA II 2011 ➤
– Install supporting device -MP9-200 (10-222A)- . For this pur‐

pose, position the supports -A- next to the screw -arrow 1- and
the support of the front flap -arrow 2- as shown.
– Slightly pre-tension the engine/gearbox unit via the spindles
(do not raise).
– Release screws -arrows- for engine mounting from engine

holder.
Note
Do not slacken the fixing nut for the engine mount.
– Unscrew the fixing screws -arrows 1- for the gearbox mount

at the console -A-.
– Screw out the rear fixing screw -arrow 2- for the console -A-
at the gearbox.
– Lower the engine/gearbox assembly via the spindles to the

dimension -a- by approx. 85 mm.
– In addition, slightly lower the engine.

FABIA II 2011 ➤
– Screw out the remaining fixing screws -arrows- of the console

at the gearbox, starting from the left wheelhouse.
– Remove console from gearbox.
For the removal of the gearbox 0AM the gearbox mount -3282- is
aligned with the adjusting plate -3282/59 - and placed on the en‐
gine/gearbox jack -V.A.G 1383 A- .
– Align arms of the gearbox mount to match the holes in the
adjusting plate -3282/59- .
– Screw in the mounting elements as shown on adjusting plate
-3282/59- .

– Position the engine and gearbox jack -V.A.G 1383 A- below
the vehicle.
• The arrow symbol on the adjusting plate -3282/59 - points in
the direction of travel.
– Align the gearbox mount -3282- parallel to the gearbox.
– Screw the bolt -3282/29- into the gearbox.
– Place both remaining mounting elements on the gearbox as
shown. To do so, place the panel of the drift under the gearbox
housing but not under the mechatronics.
– Secure the gearbox with the tensioning strap -T10038- .
– Support the gearbox by lifting the engine andgearbox jack -
V.A.G 1383 A- from the bottom.
– Remove the remaining connecting screws -4…8- engine to

gearbox.
Note
The 2 bottom screws -6- and -7- secure the cover plate for the
flywheel to the gearbox. Thereby, mark the fitting position of the
plate for reinstalling (on vehicles 1.2/77 kW).
– Press the gearbox off the engine and carefully swivel towards
the left assembly carrier.
Note
♦ The distance between the engine flange and the gearbox

flange must be approx. 50 mm before lowering the gearbox.
♦ Observe all lines and coolant hoses when lowering the gear‐
box.
– Carefully lower the gearbox.

FABIA II 2011 ➤
If necessary, remove the bracket at the front of the gearbox.
Note
If a “new” gearbox must be installed, the brackets must be fitted

to the “new” gearbox.
– Install the right flange shaft again ⇒ page 91 .

Tightening torque 30 Nm
Transporting the gearbox and secure to the assembly support
⇒ page 83 .
Installing the gearbox ⇒ page 80 .

following points:
Note
♦ When performing installation work replace the self-locking

nuts and screws ⇒ Electronic Catalogue of Original Parts .
♦ Replace screws which have been tightened to a torquing an‐
gle, as well as gasket rings and gaskets ⇒ Electronic Cata‐
Parts .
♦ The lock washer of the selector lever control cable must al‐
ways be replaced ⇒ Electronic Catalogue of Original Parts .
♦ Replace the needle bearing -arrow- in the crankshaft ⇒ En‐
♦ Remove the right flange shaft before installing the gearbox
⇒ page 91 .
♦ If the gearbox is inserted, ensure the intermediate plate be‐
tween the engine and gearbox is correctly installed.

FABIA II 2011 ➤
– Carefully raise gearbox with the engine/gearbox jack -V.A.G

1383 A- and put in its installation position with the gearbox
mount -3282- .
Note
Observe all lines and coolant hoses when raising the gearbox.
– Adjust the gearbox mount -3282- via the spindles in such a

way that the engine and the gearbox are “aligned”.
The engine and the gearbox must be guided together by hand
until the engine flange and the gearbox flange touch each other
all around!
– Screw the gearbox onto the engine, while doing so turn the
crankshaft if necessary.
– Install the console at the gearbox with the fixing screws -1-.

– Raise the engine/gearbox assembly via the spindles, align in
the installed position and install free of stress at the engine
mount and the gearbox mount.
– Install the right flange shaft after installing the gearbox
⇒ page 91 .
– Install the starter ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Fit the drive shafts to the flange shafts ⇒ Chassis ⇒ Rep. Gr.
40 .
– Install the assembly carrier ⇒ Chassis ⇒ Rep. Gr. 40 .
– Attach the steering gear to the assembly carrier and install the
engine pump aggregate with bracket on the frame side rail ⇒
Chassis ⇒ Rep. Gr. 48 .
– Install catalytic converter with exhaust pipe ⇒ Engine ⇒ Rep.
Gr. 26 .
– Install fan shroud ⇒ Engine ⇒ Rep. Gr. 19 .
Gr. 27 .
– Inspect setting of selector lever control cable and adjust
⇒ page 35 .
– Install the front left wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Install front wheels ⇒ Chassis ⇒ Rep. Gr. 44 .
with the ⇒ Vehicle diagnosis, testing and information system VAS
5051.

FABIA II 2011 ➤

Attachment of gearbox to engine (1.2 ltr./77 kW TFSI)
Pos. Screw Nm
1 M12 x 65 80
2 M12 x 65 80
31) M12 x 50 80
4 M12 x 65 80
5 M12 x 65 80
62) 3) M10 x 25 40
72) 3) M10 x 25 40
82) M12 x 65 80
A Dowel sleeves
1) Screw is located in the opening of the housing for the starter
2) screwed in from the engine side
3) Cover plate for flywheel to gearbox
Attachment of gearbox to engine (1.4 ltr./132 kW TFSI)

Pos. Screw Nm
1 M12 x 55 80
2 M12 x 55 80
31) M12 x 35 80
4 M12 x 65 80
5 M12 x 65 80
62) M10 x 50 40
72) M10 x 50 40
82) M12 x 65 80
A Dowel sleeves
1) Screw is located in the opening of the housing for the starter
2) Screwed in from the engine side
Console -A- to gearbox and gearbox mount to console
♦ Screw -arrow 2- (3 pieces) tightening torque 40 Nm + torque

a further 90° (1/4 turn)
♦ Screws -arrows 1- (2 pieces) tightening torque 40 Nm + torque
a further 90° (1/4 turn)
Always replace screws -1- and -2- ⇒ Electronic Catalogue of
Original Parts .

FABIA II 2011 ➤
5 Transport the gearbox and secure to

the assembly support
♦ Ring bolt -3368- (2 pieces)
♦ Shackle -10 - 222 A /12-
♦ Retaining plate -T30108-
♦ Lifting device -MP9-201 (2024 A)-
Transporting the gearbox.
– Screw the ring bolt -3368- into the threaded bore of the gear‐
box up to the stop and secure with nut M10. Then hang the
workshop crane in the shackle -10 - 222 A /12- .
Secure the gearbox in the gearbox mount -T30109 (VW 353)- .
Note
Before the gearbox can be turned vertically, both ventilation caps

-arrows- must be removed. The openings must be closed with
suitable screw plugs so that no oil can flow out.
5. Transport the gearbox and secure to the assembly support 83

FABIA II 2011 ➤
Raise the gearbox at the assembly stand -MP9-101 - .

The gearbox is raised together with the gearbox mount -T30109
(VW 353)- at the assembly stand .
Attach gearbox to assembly stand -MP9-101 - .

– The gearbox mount -T30109 (VW 353)- is screwed on the re‐
taining plate -T30108- with screws -arrows-.

FABIA II 2011 ➤
6 Change gearbox oil

♦ Sealing grease -G 052 128 A1-
♦ Catch pan
Note
♦ On the “7-speed automatic gearbox DSG - 0AM” the gear oil

is lifelong filled. For this reason the oil level is not checked and
an inspection plug is not present on this gearbox.
♦ Observe the general repair instructions ⇒ page 5 .
In case of leaks on the gearbox, the cause must be determined

and the faults rectified.
Then the gear oil must be completely drained and filled up with
new oil.
– Raise vehicle.
– Drain off oil.

6. Change gearbox oil 85

FABIA II 2011 ➤
panel -MP8-602/1- .
– Remove the lock washer -arrow- of the selector lever control

cable, the selector lever control cable must be left in the fitting
position.
– Shift gearbox in “P”. To do so, press the gearshift shaft lever

by hand up to the stop in the direction towards the cable sup‐
port -arrow-.
– Remove the gearshift shaft lever.

– Unscrew the cover.
Note
♦ The gear oil level cannot be checked.

♦ The prescribed filling capacity must be precisely respected.
♦ Only then the gearbox is correctly filled.
♦ An over-filling as well as an under-filling impair the proper
working of the gearbox.

FABIA II 2011 ➤
– Top up with 1.7 ltr. oil through the opening -arrow-.

– Clean the sealing surface on the gearbox and the cover.
Note
♦ Grease the shaft seal in the cover with sealing grease -G 052
128 A1- .
♦ Always replace the screw from the gearshift shaft lever ⇒
– Install the cover and the lever for the gearshift shaft again. For
this purpose, install the lever once again in the same position.
– Inspect setting of selector lever control cable and adjust
⇒ page 35 .

FABIA II 2011 ➤
35 – Wheels, shafts
1 Pinions and shafts
At present no repairs are carried out on the pinions and shafts.
88 Rep. Gr.35 - Wheels, shafts

FABIA II 2011 ➤


ring
♦ Multi-purpose tool -MP3-419 (VW 771)-
♦ Extraction hook -MP3-419/37 (VW 771/37)-
♦ Socket insert -T10107 A- or socket insert 6 mm, commercially
available
♦ Thrust piece -T30028 (3305)-
♦ Catch pan

1.1.1 Removing
Note

♦ Do not remove both flange shafts simultaneously from the
gearbox. If the differential bevel gears twist in the differential
gear, it will be difficult to reinstall the fixing screw for the flange
shaft.
– Loosen the front left wheel bolts.

– Raise vehicle.
– Remove front left wheel.
– Turn the sterring wheel to the left up to the stop and remove
the left drive shaft from the flange shaft ⇒ Chassis ⇒ Rep.
Gr. 40 .
– Unscrew nuts -arrows- for left steering joint ⇒ Chassis ⇒ Rep.
Gr. 40 .

FABIA II 2011 ➤
– Unscrew the nut -1- from the coupling rod -3- -arrow- ⇒ Chas‐
sis ⇒ Rep. Gr. 40 .
– Remove coupling rod and turn anti-roll bar -2- slightly up‐
wards.
– Swivel out left wheel-bearing housing.
– Swivel the left drive shaft into the wheelhouse and secure it to
the suspension strut, e.g. with cord. Avoid damaging the paint‐
– Unscrew screw for flange shaft with socket insert -T10107 A-

or commercially available socket insert 6 mm.
– Take out the flange shaft.
– Pull out gasket ring for flange shaft with multi-purpose tool -
MP3-419 (VW 771)- and extraction hook -MP3-419/37
(VW 771/37)- .
1.1.2 Install
– Lightly oil new gasket ring at outer surface.

FABIA II 2011 ➤
– Fill half the space between the sealing lip and dust lip with
sealing grease -G 052 128- -arrow-.
– Drive in new gasket ring with pressure plate -T30028 (3305)-

up to the stop. Do not tilt the new gasket ring during this
process.
– Insert the flange shaft.
– Tighten new conical screw to tightening torque.
– Attach the left drive shaft to the flange shaft ⇒ Chassis ⇒ Rep.
Gr. 40 .
– Change gearbox oil ⇒ page 85 .
Note
The gearbox oil must be changed, only in this way the correct gear
oil level can be ensured.
– Fit the left front wheel ⇒ Chassis ⇒ Rep. Gr. 44 .

Tightening torque
Component Nm
Flange shaft on gearbox (conical screw) 30
1)
1)Always replace conical screw ⇒ Electronic Catalogue of Orig‐

inal Parts .

♦ Socket insert -T10107 A- or socket insert 6 mm, commercially
available
♦ Extraction hook -T20143-
♦ Thrust piece -T30028 (3305)-
♦ Tensioning strap -T10038-
♦ Catch pan

FABIA II 2011 ➤
1.2.1 Removing
Note

♦ Do not remove both flange shafts simultaneously from the
gearbox. If the differential bevel gears twist in the differential
gear, it will be difficult to reinstall the fixing screw for the flange
shaft.

– Remove right drive shaft from 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.
– Unscrew screw for flange shaft with socket insert -T10107 A-

– Remove the gasket ring of the flange shaft e.g with extraction
hook -T20143- or tyre iron.
1.2.2 Install
sealing grease -G 052 128- -arrow-.

FABIA II 2011 ➤
– Drive the new seal ring in up to the stop, do not twist the seal
ring.
– Tighten new conical screw to tightening torque.
– Fit the right drive shaft to the flange shaft ⇒ Chassis ⇒ Rep.
Gr. 40 .
– Change gearbox oil ⇒ page 85 .
Note
Tightening torque
Component Nm
Flange shaft on gearbox (conical screw) 30
1)
1)Always replace conical screw ⇒ Electronic Catalogue of Orig‐

inal Parts .

Service
Workshop Manual
Fabia II 2007 ➤ , Fabia II 2009 ➤ ,
Fabia II 2011 ➤ , Rapid 2011 ➤ ,
Rapid India 2011 ➤ , Rapid NH 2013 ➤ ,
Roomster 2006 ➤
Gearbox 02R
Edition 08.2014

Service
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...
Gearbox 02R - Edition 08.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Identification characters, aggregate assignment (Fabia II) . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Identification characters, aggregate assignment (Roomster) . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Identification characters, aggregate assignment (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Identification characters, aggregate assignment (Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Designation of components and transmission ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Summary of components - foot controls (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . 10
1.2 Removing and installing the crash strut for the clutch pedal (Fabia II 2007 ►; Roomster 2006
►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Removing and installing the over-centre helper spring (Fabia II 2007 ►; Roomster 2006 ►)
........................................................................ 14
1.4 Removing and installing the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . 16
1.5 Summary of components - foot controls (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH) . . 17
1.6 Summary of components - Foot controls (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.7 Removing and installing the bracket with the master cylinder (Fabia II 2011 ►; Roomster 2011
►; Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.8 Removing and installing the bracket with the master cylinder (Rapid) . . . . . . . . . . . . . . . . 30
1.9 Removing and installing the bracket without the master cylinder (Fabia II 2011 ►; Roomster
2011 ►; Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.10 Removing and installing the bracket without the master cylinder (Rapid) . . . . . . . . . . . . . . 34
1.11 Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.12 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) . . . . 38
1.13 Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster
2011 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) . . . . . . . . . . . . 41
1.15 Summary of components - Hydraulic (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.16 Check hydraulic clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.17 Removing and installing the master cylinder (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . 48
1.18 Removing and installing the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid 2011
►; Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.19 Removing and installing the slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.20 Bleeding the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2 Repairing the clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.1 Fault finding power transmission - problems with the clutch and clutch control . . . . . . . . . . 60
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Fitting location of shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Summary of components of the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.3 Summary of components - gearshift knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Separating collar from gearshift lever (Fabia II, Roomster) . . . . . . . . . . . . . . . . . . . . . . . . 69
1.5 Separating collar from gearshift lever (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Contents i
1.6 Remove and install gearshift knob and shift lever collar (Rapid NH) . . . . . . . . . . . . . . . . . . 72
1.7 Summary of components - Shift lever and shift housing . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.8 Summary of components - Control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH) . . . . . . . . . . . . . . . . . . . . . . 77
1.10 Remove and install shift mechanism (Fabia II, Roomster, Rapid NH) . . . . . . . . . . . . . . . . 79
1.11 Removing and installing shift mechanism (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.12 Setting the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.1 Removing gearbox (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Removing gearbox (Fabia II 2011 ►; Roomster 2011 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.3 Removing gearbox (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.4 Removing gearbox (Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.6 Tightening torques (Rapid NH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.7 Transporting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3 Check gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.1 Gearbox overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.3 Removing and installing gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . . . 130
4.4 Removing and installing gearbox housing and shift mechanism . . . . . . . . . . . . . . . . . . . . 131
4.5 Removing and installing the drive shaft, output shaft, differential gear and shift forks . . . . 133
4.6 Mounting sequence - Removing and installing gearbox housing cover and 5th gear . . . . 134
4.7 Mounting sequence - completely disassembling and assembling the gearbox . . . . . . . . . . 139
5 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
6 Repairing the gearshift mechanism on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.1 Disassembling and assembling the gearshift mechanism on the gearbox side (gearshift shaft
can be removed from gearshift cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
cannot be removed from gearshift cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7 Disassembling and assembling the gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.1 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.2 Setting drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.1 Disassembling and assembling the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.2 Setting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.1 Disassembling and assembling the reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

1 Replacing the flange shaft gasket rings (gearbox assembled) . . . . . . . . . . . . . . . . . . . . . . 191
1.2 Replace gasket ring for right flange shaft (gasket ring and bushing are one component) . . 193
2 Differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.1 Disassembling and assembling differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.2 Adjusting the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3 Setting overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
ii Contents
1 Identification of the gearbox
(SRL000728; Edition 08.2014)
⇒ “1.1 Identification of the gearbox”, page 1

Location on the gearbox
Identification characters and production date -arrow 1-.
Identification of gearbox 02R -arrow 2-.
Identification characters and production date of the gearbox

Example: JDE 18 02 7
I I I I
Identifica‐ Day Month Manufacturing
tion char‐ year (2007)
acters
1. Identification of the gearbox 1

2 Technical data
⇒ “2.1 Identification characters, aggregate assignment (Fabia II)”,
page 2
⇒ “2.2 Identification characters, aggregate assignment (Room‐
ster)”, page 3
⇒ “2.3 Identification characters, aggregate assignment (Rapid)”,
page 3
⇒ “2.4 Identification characters, aggregate assignment (Rapid
NH)”, page 3
⇒ “2.5 Filling capacity”, page 4
⇒ “2.6 Calculation of gear ratios”, page 4
2.1 Identification characters, aggregate assignment (Fabia II)

Manual gearbox 5 speed 02R
through 03.10 03.10 03.10
Identification characters JCZ JDE JDD
Assignment: Engine 1.4 ltr./59 kW TDI

through 04.07 03.10
Identification characters JDA JXY
Assignment: Engine 1.9 ltr./77 kW TDI 1.9 ltr./77 kW TDI

through 10.10 10.10
Identification characters KFK, MZL MAL MNY
Assignment: Engine 1.6 ltr./55 kW TDI CR 1.2 ltr./55 kW TDI CR
1.6 ltr./66 kW TDI CR

through 10.10
Identification characters MUW MZR
Assignment: Engine 1.2 ltr./55 kW TDI CR

through
Identification characters MZK MZN MZM
2 Rep. gr.00 - Technical data

2.2 Identification characters, aggregate assignment (Roomster)

Identification characters HZP JEP
Assignment Engine 1.9 ltr./77 kW TDI

Identification characters JXZ JDE
Assignment Engine 1.9 ltr./77 kW TDI 1.4 ltr./59 kW TDI

Identification characters MQC MQD
Assignment Engine 1.2 ltr./55 kW TDI CR

Identification characters MZP MZQ
tured through

Identification characters KFK, MZL
tured through
2.3 Identification characters, aggregate assignment (Rapid)

Identification characters MZS MZS QXQ
through 08.15
2.4 Identification characters, aggregate assignment (Rapid NH)

2. Technical data 3

Identification characters MZL MZM MZS
through

Filling capacity 2.0 litre
Gearbox oil specification ⇒ Electronic Catalogue of Original Parts
Gear oil change interval Filled for life
2.6 Calculation of gear ratios

Example
5th gear Final drive
Drive wheel ZG1 = 46 ZA1 = 24
Output gear ZG2 = 33 ZA2 = 70
i = ZG2 : ZG1 1)
iG = Ratio of a gear = ZG2 : ZG1 = 33 : 46 = 0,717
iA = Ratio of the final drive = ZA2 : ZA1 = 70 : 24 = 2,917
itotal = Total ratio = iG x iA = 0.717 x 2.917 = 2.091
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

3 Overview of Transmission System

⇒ “3.1 Designation of components and transmission ratio”,
page 5
3.1 Designation of components and transmission ratio
Note
The -arrows- point in the direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Drive shaft
5 - Output shaft
6 - Differential gear
I - 1. gear
II - 2. gear
III - 3. gear
IV - 4. gear
V - 5. gear
R - Reverse gear
A - Final drive
T - Speedometer drive
❑ for vehicles without ABS
3. Overview of Transmission System 5

4 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
the workshop manual - are summarised here. They apply for this
particular workshop manual.
Gearbox
before releasing.
♦ Bolts and other attachments should have a classification in the
♦ When installing the manual gearbox, ensure the dowel
sleeves are correctly located between the engine and gear‐
box.
♦ When installing mounts as well as waxed components, the
contact surfaces must be cleaned. Contact surfaces must be
free of wax and grease.
♦ When replacing the gearbox, inspect the gearbox oil level and
top up with oil if necessary
⇒ “3 Check gear oil level”, page 127 .
♦ Filling capacity, Fabia II
⇒ “2.1 Identification characters, aggregate assignment (Fabia
II)”, page 2
♦ Filling capacity, Roomster
⇒ “2.2 Identification characters, aggregate assignment
(Roomster)”, page 3
♦ Filling capacity, Rapid
⇒ “2.3 Identification characters, aggregate assignment (Rap‐
id)”, page 3
♦ Filling capacity, Rapid NH
⇒ “2.4 Identification characters, aggregate assignment (Rapid
NH)”, page 3
♦ Oil specification ⇒ Electronic Catalogue of Original Parts .
Sealant
♦ Thoroughly clean the contact surfaces of the housing before
applying the silicone sealant.
♦ Apply sealant AMV 188 200 03 evenly and not too thick.


♦ After removing gaskets, check the contact surface in the hous‐
ing or shaft for burrs or damage which occured during the
assembly.
♦ Shaft seals - before mounting lightly oil at outside diameter
and fill half the space between the sealing lips -arrow- with
sealing grease - G 052 128 A1- .
♦ The open side of the shaft seals is turned towards the fluid to
be sealed.
♦ Press in new shaft seal in such a way that the sealing lip is not
located on the same point as the sealing lip of the old seal (use
tolerance for insertion depth).
♦ Before inserting lightly oil the O-rings, in order to prevent the
rings being squashed during installation.
♦ Inspect the oil level after replacing the gaskets and gasket
rings, top up oil if necessary
⇒ “3 Check gear oil level”, page 127 .

Locking elements
♦ Do not over-tension the circlips.

♦ Always replace damaged or over-tensioned circlips ⇒ Elec‐
tronic Catalogue of Original Parts .
♦ Replace roll pins. Fitting position: Slot -A- longitudinal to power
flow -arrow-.
4. General repair instructions 7

Nuts and bolts

♦ Slacken the bolts and nuts against the tightening sequence.
housings without tightening sequence diagonally across in
stages.
♦ Specified torques given are for unlubricated nuts, bolts and
screws.
♦ Clean the threaded holes into which self-locking screws or
screws with locking agent were screwed in (using e.g. a screw-
tap). Otherwise there is a danger of bolts shearing when
subsequently being removed.
♦ It is important to ensure at all bolted connections that the con‐
tact surfaces as well as the nuts and bolts are waxed only after
being installed, should this be necessary.
Bearings
♦ Insert moist all bearings into the gearbox with gear oil.
♦ Before installing, heat the inner rings of the bearing on a heat‐
ing plate or with the induction heater unit - VAS 6414- to
approx. 100°C, when installing press in axial and play-free up
to the stop.
♦ The temperature can be checked with a temperature measur‐
ing instrument.
♦ Do not mix up the outer and inner races of bearings of the
same size.
♦ Always jointly replace tapered-roller bearings on the same
shaft and use products of the same manufacturer.
♦ Position needle bearing with the lettered side (thicker end) to‐
wards the drift pin.
Shims
♦ Measure shims at several points with a micrometer. Different

tolerances allow to measure the required thickness for each
washer very precisely.
♦ Check for burrs and damage.
♦ Install only adjusting washers which are in perfect condition.
Synchronizer rings

♦ These are not interchangeable. If re-using, allocate synchron‐

izer rings to the same sliding gear.
♦ Inspect for wear, replace if necessary ⇒ Electronic Catalogue
of Original Parts .
♦ Check grooves -arrow 1- on synchronizer ring -A-, or check
the inside of the ring for flattened parts (grooves worn).
♦ When installing the intermediate ring -B-, check outer contact
surface -arrow 2- and inner contact surface -arrow 3- for
grooves, blue coloring (caused by overheating) and other
damages.
♦ Insert with some gearbox fluid.
Pinions
♦ Clean and heat on a heating plate or with the induction heater
unit - VAS 6414- to approx. 100°C before pressing on.
ing instrument.
♦ Check fitting position.
Sliding gears
♦ Check 1st to 5th gear sliding gears after assembly for low axial
play or smooth operation.
Clutch control
♦ When removing gearbox, remove slave cylinder, do not de‐
tach the tube-hose line.
♦ If the slave cylinder with connected hydraulic line is removed,
do not depress the clutch pedal. Otherwise the tappet is press‐
ed out of the slave cylinder.
♦ Do not tilt the clutch pressure plate; release and tighten cross‐
wise in small stages.
♦ If the clutch pedal does not return to its initial position after the
coupling procedure - clutch pedal in home position - the clutch
control must be bled (further measures
⇒ “1.16 Check hydraulic clutch control”, page 47 ).
♦ 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.
Safety precautions for vehicles with start-stop system
WARNING
On vehicles with start-stop system, there is the risk of injury

from automatic engine start.
♦ On vehicles with activated start-stop system (recogniza‐
ble by a message in the dash panel insert), the engine can
start automatically if required.
♦ It is therefore necessary to ensure that the start-stop sys‐
tem is deactivated when carrying out work on the vehicle
(ignition switched off; if required switch ignition on again).

30 – Clutch
1 Clutch control
⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;
Roomster 2006 ►)”, page 10
⇒ “1.2 Removing and installing the crash strut for the clutch pedal
(Fabia II 2007 ►; Roomster 2006 ►)”, page 14
⇒ “1.3 Removing and installing the over-centre helper spring (Fa‐
bia II 2007 ►; Roomster 2006 ►)”, page 14
⇒ “1.4 Removing and installing the clutch pedal (Fabia II 2007 ►;
Roomster 2006 ►)”, page 16
⇒ “1.5 Summary of components - foot controls (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH)”, page 17
⇒ “1.6 Summary of components - Foot controls (Rapid) ”,
page 25
⇒ “1.7 Removing and installing the bracket with the master cylin‐
der (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”, page 27
der (Rapid) ”, page 30
⇒ “1.9 Removing and installing the bracket without the master
cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”,
page 32
cylinder (Rapid) ”, page 34
⇒ “1.11 Removing and installing the clutch pedal with the over-
centre helper spring (Fabia II 2011 ►; Roomster 2011 ►; Rapid
NH)”, page 36
⇒ “1.12 Removing and installing the clutch pedal with the over-
centre helper spring (Rapid) ”, page 38
⇒ “1.13 Removing and installing the clutch pedal with the tension
spring (Fabia II 2011 ►; Roomster 2011 ►)”, page 39
⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Room‐
ster ►; Rapid NH) ”, page 41
⇒ “1.15 Summary of components - Hydraulic (Rapid) ”,
page 44
⇒ “1.16 Check hydraulic clutch control”, page 47
⇒ “1.17 Removing and installing the master cylinder (Fabia II 2007
►; Roomster 2006 ►)”, page 48
⇒ “1.18 Removing and installing the master cylinder (Fabia II 2011
►; Roomster 2011 ►; Rapid 2011 ►; Rapid NH)”, page 50
⇒ “1.19 Removing and installing the slave cylinder”, page 51
⇒ “1.20 Bleeding the clutch control ”, page 54
1.1 Summary of components - foot controls

(Fabia II 2007 ►; Roomster 2006 ►)
♦ Polycarbamide grease - G 052 142 A2-
10 Rep. gr.30 - Clutch

Note
♦ Summary of components - Hydraulics

⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) ”, page 41 .
♦ After the battery earth strap is disconnected and re-connected, carry out additional operations ⇒ Electrical
System; Rep. gr. 27 .
♦ Grease all bearing points 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 .
1 - Front wall
❑ with mount for bearing
bracket and master cyl‐
inder
2 - Gasket
tronic Catalogue of
Original Parts
3 - Bearing bracket
❑ for attaching clutch ped‐
al
4 - Screw
5 - Gas/brake foot controls
6 - 25 Nm
❑ self-locking
❑ for bracket on front wall
tronic Catalogue of
Original Parts
7 - Clutch pedal switch - F36-
❑ Difference between
clutch pedal switch
⇒ page 13
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ Removing and installing
⇒ “1.1.1 removing and
installing, setting angu‐
lar clutch pedal switch
F36 ”, page 13 angular
clutch pedal switch
⇒ “1.1.2 removing and installing, setting cylindrical clutch pedal switch F36 ”, page 13 cylindrical clutch
pedal switch
8 - Over-centre helper spring
⇒ “1.3 Removing and installing the over-centre helper spring (Fabia II 2007 ►; Roomster 2006 ►)”, page
14
1. Clutch control 11
9 - Bushing
10 - Bearing bolt
11 - Clutch pedal
⇒ “1.4 Removing and installing the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►)”, page 16
12 - Support
❑ only replace if the master cylinder has been removed
⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) ”, page 41
13 - 25 Nm
❑ self-locking
❑ for master cylinder to front wall
❑ always replace ⇒ Electronic Catalogue of Original Parts
14 - Master cylinder
⇒ “1.17 Removing and installing the master cylinder (Fabia II 2007 ►; Roomster 2006 ►)”, page 48
15 - Clamp

❑ to remove and install the tube-hose line pull out retaining clip up to the stop
16 - Supply hose
❑ out of plastic ⇒ page 12
17 - Bearing
❑ for over-centre helper spring
❑ insert in bearing bracket
❑ Fitting position: Peg -arrow- clips into the recess on the master cylinder
18 - Screw
❑ for pedal stop on bracket
19 - Pedal stop
❑ screw onto bracket with screw Pos.18 with the master cylinder installed
20 - 25 Nm
❑ self-locking
Plastic return hose -1-

• The gaskets -2- must be located in the return hose.

Difference between clutch pedal switches - F36-

♦ -A- Clutch pedal switch with angular housing
Removing and installing
⇒ “1.1.1 removing and installing, setting angular clutch pedal
switch F36 ”, page 13 .
♦ -B- Clutch pedal switch with cylindrical housing
Removing and installing
⇒ “1.1.2 removing and installing, setting cylindrical clutch pedal
switch F36 ”, page 13 .
1.1.1 removing and installing, setting angular

clutch pedal switch - F36-
Note
The clutch pedal switch - F36- may only be installed once to en‐
sure that it has an adequately tight fit in the bracket for clutch
pedal.
Removing
– Remove the storage area on the driver's side ⇒ Body Work;
Rep. gr. 70 .
– Unplug connector from the clutch pedal switch - F36- .
– Turn clutch pedal switch - F36- 90° to the left and remove it
from the support.
Installing and setting
– Pull out the tappet of the clutch pedal switch up to the stop.
– Press down the clutch pedal as far as possible.
– Insert clutch pedal switch into the support and turn switch by
90° to the right.
– Insert connector for the clutch pedal switch - F36- .
– Install the storage area on the driver's side ⇒ Body Work; Rep.
gr. 70 .
1.1.2 removing and installing, setting cylindri‐

cal clutch pedal switch - F36-
Note
pedal.

Rep. gr. 70 .
– Unplug connector -1- from the clutch pedal switch - F36- .

– Turn clutch pedal switch - F36- -2- in the bracket 45° to the left
and remove it from the support.
Note
Clutch pedal always remains in the off position in this case (do
not depress the clutch pedal).
– Before installing the clutch pedal switch - F36- pull out tappet
-3- fully.
• Clutch pedal -4- in the off position.
– Fit the clutch pedal switch - F36- through the assembly open‐
ing, press against the clutch pedal and attach by turning it 45°
to the right.

gr. 70 .
1.2 Removing and installing the crash strut

for the clutch pedal (Fabia II 2007 ►;
Roomster 2006 ►)
Removing
Rep. gr. 70 .
– Release screws -arrows- and remove crash strut.
Install
Installation is carried out in the reverse order.
Tightening torque
Crash strut to steering column 9 Nm
1.3 Removing and installing the over-centre

helper spring (Fabia II 2007 ►; Roomster
2006 ►)
♦ Pliers - T10005-

Removing
Rep. gr. 70 .
– Remove crash strut (if present)
⇒ “1.2 Removing and installing the crash strut for the clutch
pedal (Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .
– Remove clutch pedal switch - F36-
⇒ “1.1 Summary of components - foot controls (Fabia II 2007
►; Roomster 2006 ►)”, page 10 -Pos. 7-, if provided.
Unlock the actuating rod/master cylinder from the clutch pedal as
follows:
– Pull clutch pedal slightly into the passenger compartment.
– Insert pliers - T10005- in the clutch pedal recesses.
– Press together both sides of the support inwards using the pli‐
ers - T10005- -arrows- and separate the clutch pedal from the
master cylinder.
– Press the over-centre helper spring towards the front wall

-in direction of arrow- and remove it downwards.
Install
• Check whether the bearing -arrow 1- for the over-centre helper

spring is inserted in the bracket.
Fitting position:
The peg of the bearing is located in the recess of the master cyl‐
inder -arrow 2-.
– First of all, insert the over-centre helper spring in the rear
bearing.
– Then press the over-centre helper spring onto the centering

pin of the clutch pedal -arrow-.
– Position the clutch pedal with the master cylinder
⇒ “1.4 Removing and installing the clutch pedal (Fabia II 2007
►; Roomster 2006 ►)”, page 16 .
– Install clutch pedal switch - F36-
►; Roomster 2006 ►)”, page 10 -Pos. 7-.
– Install crash strut (if present)
gr. 70 .
1.4 Removing and installing the clutch pedal

♦ Pliers - T10005-

Removing
Rep. gr. 70 .
follows:
master cylinder.
– Removing the over-centre helper spring
⇒ “1.3 Removing and installing the over-centre helper spring
(Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .
– Put steering wheel in the lower position.
– Unscrew nut -A- and pull out screw from bracket (to facilitate
pulling out the screw, turn the steering wheel to the corre‐
sponding position).
– Remove clutch pedal.
Install
following points:
• Always replace self-locking nut ⇒ Electronic Catalogue of
Original Parts .

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

the master cylinder.
– To click in the support, press the clutch pedal towards the front
wall in -direction of arrow-. While doing so, make sure it catch‐
es correctly in the support.
gr. 70 .
Tightening torque
Clutch pedal to bracket 1) ⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;
Roomster 2006 ►)”, page 10 -Position 20-
1) Replace self-locking nut.

1.5 Summary of components - foot controls (Fabia II 2011 ►; Roomster 2011

►; Rapid NH)
Note
♦ Summary of components - Hydraulics

⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) ”, page 41 .
1 - Front wall
inder
2 - Bushing
❑ for the top location hole
in the bracket
❑ The bushings for the
bottom location hole in
the bracket are located
in the master cylinder
3 - Bearing bracket
with master cylinder
⇒ “1.7 Removing and in‐
stalling the bracket with
the master cylinder (Fa‐
bia II 2011 ►; Roomster
2011 ►; Rapid NH)”,
page 27
without master cylinder
stalling the bracket with‐
out the master cylinder
(Fabia II 2011 ►; Room‐
ster 2011 ►; Rapid NH)”,
page 32
4 - 25 Nm
❑ self-locking
❑ 3 pieces
tronic Catalogue of
Original Parts
❑ removing and installing ⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”, page 20
6 - Crash strut
❑ is attached to the steering column
❑ different versions ⇒ electronic catalogue of original parts
❑ removing and installing ⇒ “1.5.2 Removing and installing crash strut”, page 21
7 - Screw
❑ for crash strut Pos. 6 at steering column
❑ Tightening torque:
♦ Version with two screws - 9 Nm
♦ Version with one screw - 20 Nm
8 - Stop
❑ for the clutch pedal
9 - Bracket axle
❑ depending on the equipment version, a tension spring or an over-centre helper spring is installed
❑ Assign components via the ⇒ Electronic catalogue of original parts

⇒ “1.11 Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ►;
11 - Clutch pedal
❑ removing and installing with over-centre helper spring
❑ with tension springs (Fabia II 2011 ►; Roomster 2011 ►)
⇒ “1.13 Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster 2011
►)”, page 39
12 - Bushing
13 - Tension spring with vibration damper
❑ is inserted on the bracket Pos. 3 and on the clutch pedal
14 - Cap
15 - Support

⇒ “1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) ”, page 41
⇒ “1.18 Removing and installing the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid 2011 ►;
Rapid NH)”, page 50
17 - Clamp
❑ is pulled out from the side on certain master cylinders
18 - Gasket
❑ stick onto the master cylinder
19 - Supply hose
20 - Clutch position sender - G476-
❑ for vehicles with start-stop system
❑ removing ⇒ page 28
❑ installing ⇒ page 30
❑ can be checked in the “targeted fault finding” ⇒ Vehicle diagnostic tester
Removing and installing tension spring

– Insert the vibration damper with the recess -arrows- as of the
2nd spring coil -arrows-.
1.5.1 Removing and installing clutch pedal

switch - F36-
Note
pedal.
Removing
– Removing the footwell vent ⇒ Heating and Air Conditioning;
Rep. gr. 80 .
Note
The clutch pedal switch is installed from the front wall.

– Turn the clutch pedal switch at the bracket 45° in
-direction of arrow- and remove it from the support.
Vehicles Rapid NH
Note
To improve access to the clutch pedal switch - F36- the securing

nuts for the bearing bracket for the clutch pedal can be removed
and the bearing bracket removed in part
cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”,
page 32 .

Install

• The tappet -A- of the clutch pedal switch must not be pulled
out.
• Grease the tappet head -arrow-.
• Assign the grease via the ⇒ Electronic Catalogue of Original
Parts .
• When installing the clutch pedal switch the clutch pedal must
always remain in the off position. During the complete assem‐
bly, the clutch pedal must only be touched with the tappet head
-arrow- of the clutch pedal switch .

– Insert the clutch pedal switch into the support of the bracket
and turn it 45° in -direction of arrow-.
– Insert connector for the clutch pedal switch .
– Install the footwell vent ⇒ Heating and Air Conditioning; Rep.
gr. 80 .

1.5.2 Removing and installing crash strut

There are two different versions of crash strut for clutch pedal
which can be fitted to the steering column.
Version with two fixing screws
Removing
Rep. gr. 70 .
– Release screws -arrows-.
Install
Tightening torque
Crash strut to steering column (2 screws) 9 Nm
22
Version with one fixing screw

Removing
Rep. gr. 70 .
– Unscrew plug -arrow-.
– Unhook the crash strut from the steering column.
Install
23
Tightening torque
Crash strut to steering column (1 screw) 20 Nm
24
1.6 Summary of components - Foot controls (Rapid)
Note
♦ Summary of components - Hydraulics ⇒ “1.15 Summary of components - Hydraulic (Rapid) ”, page 44 .

♦ After the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical
1 - Front wall
inder
2 - Bushing
in the bracket
3 - Bearing bracket
stalling the bracket with
the master cylinder
(Rapid) ”, page 30
⇒ “1.10 Removing and
installing the bracket
without the master cylin‐
der (Rapid) ”,
page 34
4 - 25 Nm
❑ self-locking
❑ 3 pieces
tronic Catalogue of
Original Parts
⇒ “1.6.1 Removing and
installing clutch pedal switch F36 ”, page 26
6 - Stop
7 - Bracket axle
⇒ “1.12 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) ”,
page 38
25
9 - Clutch pedal
❑ removing and installing with over-centre helper spring
⇒ “1.12 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) ”,
page 38
10 - Bushing
11 - Cap
12 - Support
❑ removing and installing ⇒ “1.15 Summary of components - Hydraulic (Rapid) ”, page 44
⇒ “1.18 Removing and installing the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid 2011 ►;
14 - Clamp
15 - Gasket

16 - Supply hose


switch - F36-
Note
pedal.
Removing
Rep. gr. 80 .
Note
26

Install
out.
Parts .

gr. 80 .
1.7 Removing and installing the bracket with

the master cylinder (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH)
♦ Closing tool - T10249-
1.7.1 Removing
Note
After the battery earth strap is disconnected and connected, carry

out additional operations ⇒ Electrical System; Rep. gr. 27 .
– If necessary, remove engine cover ⇒ Engine; Rep. gr. 10 .

– Remove battery ⇒ Electrical System; Rep. gr. 27 .
– Remove air filter ⇒ Engine; Rep. gr. 23 .
27
– If the master cylinder is not accessible, remove the engine

control unit from the front wall ⇒ Engine; Rep. gr. 23 .
– Lay a cloth under the master cylinder.
– Using an extraction bottle extract as much brake fluid as pos‐
sible from the brake fluid reservoir.
– Detach return hose -1- at master cylinder and close with a
suitable tool e.g. closing tool - T10249/1- .
Note
♦ Do not use the hose clamp - MP7–602- , otherwise the return

hose -1- will be damaged.
♦ 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.
– Pull out the locking clip -2- on the master cylinder up to the
stop.

Note
On certain master cylinders, the locking clip -2- can also be pulled
out from the side.
– Pull the tube-hose line -3- out of the master cylinder and close.
Vehicles with start-stop system

– Unclip clutch position sender - G476- at master cylinder
-arrow A- and -arrow B-.
– Remove the clutch position sender with connected electrical
plug connection from the master cylinder.
Note
When working in the footwell, protect the floor covering with cloths
from escaping brake fluid.

Rep. gr. 87 .
– If present, remove crash strut
⇒ “1.5.2 Removing and installing crash strut”, page 21 .
– Put steering wheel in the highest position.
28
– Remove clutch pedal switch - F36- -1-

⇒ “1.5.1 Removing and installing clutch pedal switch F36 ”,
page 20 .
– Unscrew the top fixing nut -arrow- for the bracket. To do so,
position an long extension on the nut in the opening between
the dash panel -2- and the bottom steering column trim panel
-3-.
– Unscrew the two lower fixing nuts -arrows-.

– Remove the bracket -A- from the front wall -B-.
1.7.2 Install
following points:
Note
Replace self-locking nuts -1- and -2- for bracket -3- on front wall.

page 20
– If present, install the crash strut
gr. 87 .
29

– Insert the clutch position sender - G476- with connected elec‐
trical plug connection up to the stop on the master cylinder.
• The clutch position sender must lock in place -arrow A-.
– For checking, pull at clutch position sender -arrow B-.
– Press in tube-hose line -3- onto the connection of the master
cylinder, until the locking clip -2- is heard to click into position.
– Fit return hose -1- on the master cylinder.
– For checking, pull on the line.
– Bleed clutch mechanism
⇒ “1.20 Bleeding the clutch control ”, page 54 .
– If removed, install the engine control unit at the front wall ⇒
Engine; Rep. gr. 23 .
– Install air filter housing ⇒ Engine; Rep. gr. 23 .
– Install battery ⇒ Electrical System; Rep. gr. 27 .

Tightening torques
Bracket/clutch pedal to front wall 1) ⇒ “1.5 Summary of components - foot controls (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH)”, page 17 -Position 4-
Master cylinder to front wall 1) ⇒ “1.5 Summary of components - foot controls (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH)”, page 17 -Position 4-

the master cylinder (Rapid)
1.8.1 Removing
30
– Detach return hose -A- at master cylinder and close with a

Note

hose -A- will be damaged.
– Remove the locking clip -B- on the master cylinder up to the

stop.
– Release and cut the tube-hose line -C- out of the master cyl‐
inder.
Note
When working in the footwell, protect the floor carpet with cloths

Rep. gr. 87 .
-3-.

1.8.2 Install
following points:
31
Note
Position self-locking nuts -1- and -2- for bracket -3- on front wall
and tighten.
– Connect the connector to the clutch pedal switch - F36- .

gr. 87 .
– Press in tube-hose line -C- onto the connection of the master

cylinder, until the locking clip -B- is heard to click into position.
– Fit return hose -A- on the master cylinder.
– Bleed clutch mechanism
Tightening torques
Bracket/clutch pedal to front wall 1) ⇒ “1.6 Summary of components - Foot controls (Rapid) ”, page 25
-Position 4-
Master cylinder to front wall 1) ⇒ “1.6 Summary of components - Foot controls (Rapid) ”, page 25
-Position 4-
1.9 Removing and installing the bracket

without the master cylinder (Fabia II
2011 ►; Roomster 2011 ►; Rapid NH)
♦ Pliers - T10005-
Removing
Rep. gr. 87 .
32

– Remove clutch pedal switch - F36- -1-
page 20 .
-3-.
– Unlock the actuating rod/master cylinder from the clutch pedal

as follows:
– Press together both sides of the support using the pliers -
T10005- -arrows-.

• The master cylinder is locked into position with the bracket.
• When removing the bracket, the master cylinder in the engine
compartment must be held by a 2nd mechanic.
Install
following points:
33
Note

– To click in the support -A-, press the clutch pedal towards the
front wall in -direction of arrow-. While doing so, make sure it
catches correctly in the support.
page 20
gr. 87 .

without the master cylinder (Rapid)
♦ Pliers - T10005-
Removing
Rep. gr. 87 .
-3-.
34

as follows:
– Press both sides of the support inwards using the pliers -
T10005- -arrows-

Install

following points:
Note
and tighten.

gr. 87 .
35

with the over-centre helper spring (Fa‐
bia II 2011 ►; Roomster 2011 ►; Rapid
NH)
Note
♦ Install the clutch pedal with a new bearing axle.

♦ If only the over-centre helper spring should be removed, the
clutch pedal must not be separated from the master cylinder.

♦ Pliers - T10005-
♦ Allan key, wrench size 8 mm, commercially available
Removing
Rep. gr. 87 .
page 20 .
– Subsequently release the actuating rod of the master cylinder.
T10005- -arrows-
– Remove the bearing axle for the clutch pedal.

– Turn the bearing bolt for the clutch pedal to the left
-in direction of arrow-, so that the pegs are positioned hori‐
zontally.
-1- = Allan key, wrench size 8 mm.
The catches -A- are destroyed.
– Subsequently move the clutch pedal so that the bearing bolt
can be pulled out.
– Remove over-centre helper spring.
– Remove clutch pedal from bracket.
Install
• Install the clutch pedal with a new bearing axle.
36
– Insert the over-centre helper spring laterally from the bottom

into the support -A- in the bracket next to the body of the mas‐
ter cylinder and next to the clutch pedal.
• The area of the support -arrow- for the bearing bolt of the clutch
pedal must be vertical.
– Now position the over-centre helper spring on the centering

The support -2- must be located on the actuating rod -1- of the
master cylinder.
– Press the support -2- into the recess on the clutch pedal -3-
until it clicks audibly into place.
– Press on clutch pedal slightly and insert a new bearing bolt.

– Position the pegs -A- horizontally.
-in direction of arrow-, so that the pegs are positioned hori‐
zontally.
– Turn the bearing bolt to the right -in direction of arrow-, so that
the pegs are positioned vertically.
-1- = 8 mm Allan key.
• The catches -B- must click audibly into place.
page 20
gr. 87 .
37

with the over-centre helper spring (Rap‐
id)
Note
Install the clutch pedal with a new bearing axle.

♦ Pliers - T10005-
Removing
– Remove mounting bracket without master cylinder
⇒ “1.10 Removing and installing the bracket without the mas‐
ter cylinder (Rapid) ”, page 34 .
– Turn the bearing bolt for the clutch pedal to the left in
Then the pegs -B- are positioned horizontally to the fitting posi‐
tion.
can be pulled out.
Install

into the support -A- in the bracket next to the tappet of the
master cylinder and next to the clutch pedal.
38
– Position the over-centre helper spring on the centering pin of

the clutch pedal -arrow-.
– The support -2- must be located on the actuating rod -1- of the
master cylinder.

– Position the pegs -A- horizontally.
– Turn the bearing bolt to the right -in direction of arrow-.
Then the pegs -A- are positioned vertically.
– Install bracket without master cylinder
⇒ “1.10 Removing and installing the bracket without the mas‐
ter cylinder (Rapid) ”, page 34

with the tension spring (Fabia II 2011 ►;
Roomster 2011 ►)
Note

♦ If only the tension spring is removed, pay attention
⇒ page 41 .

♦ Hook - 3438-
♦ Pliers - T10005-
39
Removing
Rep. gr. 87 .
page 20 .
– Unhook the tension spring e.g with hook - 3438- .
Note
Only observe the right part of the fig. -arrows- when installing.

as follows:
T10005- -arrows-.

– Turn the bearing axle for the clutch pedal to the left in
Then the studs -B- are positioned horizontally.
– Subsequently move the clutch pedal so that the bearing axle
can be pulled out.
Install
40
master cylinder.
– Insert a new bearing axle in the bracket and the clutch pedal.
– Position the studs -A- horizontally.

– Turn the bearing axle to the right in -direction of arrow-.
Then the studs -A- are positioned vertically.
– Lock the clutch pedal with the support on the actuating rod of
– Hook in the tension spring.

page 20
gr. 87 .
1.14 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH)
41
1 - Brake fluid reservoir

2 - Supply hose
❑ out of rubber
❑ on certain vehicles out
of plastic ⇒ page 44
❑ if the return hose is
made out of plastic, do
not use hose clamp -
MP7-602-
❑ test tightness
⇒ “1.16 Check hydraulic
clutch control”,
page 47
3 - Master cylinder
ster 2006 ►)
installing the master cyl‐
inder (Fabia II 2007 ►;
Roomster 2006 ►)”,
page 48
ster 2011 ►; Rapid NH
2013 ►)
Roomster 2011 ►; Rap‐
id 2011 ►; Rapid NH)”,
page 50
❑ after installing, bleed the
clutch control
⇒ “1.20 Bleeding the
clutch control ”,
page 54
❑ test tightness ⇒ “1.16 Check hydraulic clutch control”, page 47
4 - Clamp
❑ to remove the tube-hose line -Pos. 9- pull out of the master cylinder -Pos. 3- up to the stop
5 - Support
❑ only replace if the master cylinder Pos. 3 has been removed
6 - Clutch pedal
❑ removing and installing (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)
❑ Removing and installing clutch pedal with tension springs (Fabia II 2011 ►; Roomster 2011 ►)
⇒ “1.13 Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster 2011
►)”, page 39
❑ Removing and installing (Rapid)
⇒ “1.12 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) ”, page 38
7 - 25 Nm
❑ self-locking
42
8 - Gasket ring/O-ring
❑ pull onto line connection
❑ insert with brake fluid
❑ Gasket rings/O-rings are adapted to the version of the line connection ⇒ page 44
❑ Assignment ⇒ Electronic Catalogue of Original Parts
9 - Tube-hose line
10 - Support
❑ fixed at front left frame side rail
❑ for clipping in the tube-hose line -Pos. 9-
11 - Support
❑ not fitted to all vehicles
12 - 20 Nm
13 - Vent valve
❑ Bleed the clutch control ⇒ “1.20 Bleeding the clutch control ”, page 54
14 - Dust cap
15 - Clamp
❑ to remove the tube-hose line Pos. 9 pull out of the slave cylinder up to the stop
❑ to remove the tube-hose line -Pos. 9- pull out of the slave cylinder -Pos. 17- up to the stop
16 - Gearbox
17 - Slave cylinder
❑ removing and installing ⇒ “1.19 Removing and installing the slave cylinder”, page 51
❑ after installing, bleed the clutch control ⇒ “1.20 Bleeding the clutch control ”, page 54
Remove the support -A- from the actuating rod of the master cyl‐
inder in -direction of arrow-
43
Install the support -A- at the actuating rod of the master cylinder
in -direction of arrow-
Gasket rings/O-rings for tube-hose lines

Pos. Version of line connection
-1- Line connection with round slot -arrow 1-
-2- Line connection with shoulder -arrow 2-
-3- Line connection with shoulder -arrow 2- and with
round slot -arrow 3-
• In case of a line connection with round slot -arrow 1- and
-arrow 3-, a gasket ring/O-ring must be inserted.
Vehicles with plastic return hose -1-:

♦ Gaskets -2- must be present on the return hose.
♦ Do not use hose clamp - MP7-602-
1.15 Summary of components - Hydraulic (Rapid)
44

2 - Spring clamp
3 - Supply hose
4 - Master cylinder
Roomster 2011 ►; Rap‐
id 2011 ►; Rapid NH)”,
page 50
clutch control
⇒ “1.20 Bleeding the
clutch control ”,
page 54
5 - Support
❑ only replace if the mas‐
ter cylinder Pos. 3 has
been removed

6 - Clutch pedal
7 - Clamp
❑ to remove the tube-hose
line Pos. 14 pull it out of
the master cylinder up to
the stop
8 - 25 Nm
❑ self-locking
tronic Catalogue of
Original Parts
9 - Brake line
10 - Support
❑ attached to the vehicle body
❑ for tube-hose line pos. 14
11 - Support
12 - Support
14 - Tube-hose line
15 - Support
45
16 - Support
❑ for tube-hose line Pos. 14 on the gearbox
17 - Screw 20 Nm
18 - Dust cap
19 - Vent valve
❑ Bleed the clutch control ⇒ “1.20 Bleeding the clutch control ”, page 54
20 - Screw 20 Nm
21 - Slave cylinder
❑ after installing, bleed the clutch control ⇒ “1.20 Bleeding the clutch control ”, page 54
22 - Clamp

23 - Gearbox
Remove the support -A- from the actuating rod of the master cyl‐
inder in -direction of arrow-
Install the support -A- at the actuating rod of the master cylinder
in -direction of arrow-
46

1.16 Check hydraulic clutch control

• The brake pedal return must not be obstructed by moved or
additional covers (floor coverings).
• If necessary. bleed the clutch control
– 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 little or no brake fluid in this chamber, there is a leak
in the hydraulic system.
Then check the following components of the hydraulic clutch con‐

trol for external leaks:
♦ Return hose between brake fluid reservoir and master cylin‐
der.
♦ Master cylinder.
♦ Tube-hose line or plastic line between master and slave cyl‐
inder
♦ 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 or the plastic
line between the master cylinder and the slave cylinder. The
line must not be kinked or trapped.
– Subsequently depress the clutch pedal carefully, at the same

time hold the clutch pedal in 5 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 47 . At the same time the first person must check if the
clutch pedal falls through on its own while being held.
47
– Remove the slave cylinder from the gearbox last, - do not open
the line system - and check the collar for brake fluid leak.
– To do so, take off the collar from the tappet -arrow-.
1.17 Removing and installing the master cyl‐

inder (Fabia II 2007 ►; Roomster 2006
►)
♦ Pliers - T10005-
Removing
Note
After the battery earth strap is disconnected and re-connected,

carry out additional operations ⇒ Electrical System; Rep. gr. 27 .
– Remove engine cover ⇒ engine; Rep. gr. 10 .

48

Note


stop.
inder.
Rep. gr. 70 .

Note
To remove the master cylinder completely remove the clutch con‐

trol. Before removing first separate the master cylinder from the
clutch pedal.

follows:
master cylinder.
– Removing the over-centre helper spring
⇒ “1.3 Removing and installing the over-centre helper spring
(Fabia II 2007 ►; Roomster 2006 ►)”, page 14 .
– Remove the bearing/over-centre helper spring from the brack‐
et.
49
– Unscrew the nuts -arrows 1- and remove the bracket

-arrow A- together with the master cylinder.
– Unscrew pedal stop
►; Roomster 2006 ►)”, page 10 ,-Pos. 19-.
– Remove the master cylinder.
Install
following points:
– Insert the bearing for over-centre helper spring in the bracket.

gr. 70 .
– After installing the master cylinder bleed the clutch control
Tightening torques
Bracket/clutch pedal to front wall 1) ⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;
Roomster 2006 ►)”, page 10 , -Position 6-
Master cylinder to front wall 1) ⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;
Clutch pedal to bracket 1) ⇒ “1.1 Summary of components - foot controls (Fabia II 2007 ►;

►; Rapid 2011 ►; Rapid NH)
♦ Pliers - T10005-
Removing
Removing bearing bracket with the master cylinder (Fabia II 2011
►; Roomster 2011 ►; Rapid NH 2013 ►)
50
der (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”, page 27 .
Removing bearing bracket with the master cylinder (Rapid 2011
►)
der (Rapid) ”, page 30 .
– Unlock the clutch pedal from the master cylinder with the pliers
- T10005- .
– Remove master cylinder from mounting bracket.
Install
– Insert the master cylinder in the bracket.
– The bracket -2- must be located on the actuating rod -1-.

Installing bearing bracket with the master cylinder (Fabia II 2011
►; Roomster 2011 ►; Rapid NH 2013 ►)
der (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH)”, page 27 ,
(Rapid)
der (Rapid) ”, page 30 .
1.19 Removing and installing the slave cylin‐

der
♦ Hose clamp - MP7-602 (3094)-
♦ Grease - G 000 100-
Note
♦ If the slave cylinder must be replaced due to a predetermined

fault, first of all check the hydraulic clutch control
⇒ “1.16 Check hydraulic clutch control”, page 47 .
♦ If the slave cylinder with the connected tube-hose line is re‐
moved from the gearbox, do no longer depress the clutch
pedal. Otherwise, the piston can be pressed out of the slave
cylinder and thus be destroyed.
♦ When performing the following work, make sure no brake fluid
comes into contact with the gearbox. If this is the case, these
points must be cleaned thoroughly.
51
Removing
Note
If the battery earth strap is disconnected and connected, carry out

certain additional operations ⇒ Electrical System; Rep. gr. 27 .

trical System; Rep. gr. 27 .
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Remove lock washer -arrow 1- for shift cable from gearbox
shift lever -A-.
Vehicles Fabia II and Roomster up to 05.07 and Rapid (metal
relay lever)
– Remove circlip -arrow 2- for selector cable from relay lever

-B-.
– Remove selector cable and shift cable from the studs.
– Detach circlip -arrow 3- from the relay lever -B- and remove
relay lever.
Vehicles Fabia II and Roomster as of 06.07 and Rapid NH (plastic
relay lever)
– Pull off shift cable from the stud.
– Remove relay lever together with cable lock
⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rap‐
id NH)”, page 77 .
– Remove the gearshift lever -A-, for this step unscrew nut
-arrow 4-.
52
– Disconnect the Bowden cable support from gearbox

-arrows-.
– Tie up shift cable and selector cable.
– Place a non-fluffing cloth under the slave cylinder.
– Pull retaining clip -2- for tube-hose line out of the slave cylinder
up to the stop.
– Then pull the tube-hose line -3- out of the slave cylinder and
close openings.
– Pull the tube-hose line -3- out of the bracket -4-, if present, on
the gearbox.
– Unscrew the screws -5- for the slave cylinder and remove the
slave cylinder.
Install
following points:
– Grease tappet head with grease for plug serration of clutch
disc - G 000 100 - .

Note
♦ Replace damaged gasket rings.

♦ Assign all the components via the ⇒ Electronic Catalogue of
Original Parts .
– Screw the slave cylinder onto the gearbox with the screws
-5-.
– Insert the tube-hose line -3- into the slave cylinder up to the
stop.
– Press in retaining clip -2- up to the stop.
– Press the tube-hose line into the bracket -4-, if present, at the
gearbox.
– After installing the slave cylinder bleed the clutch control
– Installing Bowden cable support, relay lever and gearshift lev‐
er.
For vehicles Fabia II and Roomster and Rapid NH
⇒ “1.10 Remove and install shift mechanism (Fabia II, Roomster,
For vehicles Rapid
⇒ “1.11 Removing and installing shift mechanism (Rapid) ”, page
84
– Setting the shift mechanism
⇒ “1.12 Setting the shift mechanism”, page 86
– Install air filter ⇒ Engine; Rep. gr. 23 .
– Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
– Connect earth strap of battery ⇒ Electrical System; Rep. gr.
27 .
53
Tightening torque
Component Tightening torque
Slave cylinder to gearbox Fabia II, Roomster, Rapid NH
⇒ “1.14 Summary of components - Hydraulic (Fabia
II ►; Roomster ►; Rapid NH) ”, page 41
-Position 12-
Rapid
⇒ “1.15 Summary of components - Hydraulic (Rapid)
”, page 44 -Position 20-
bracket for tube-hose line Fabia II, Roomster, Rapid NH
⇒ “1.14 Summary of components - Hydraulic (Fabia
-Position 12-
Rapid
⇒ “1.15 Summary of components - Hydraulic (Rapid)
”, page 44 -Position 20-
Cable support to gearbox ⇒ “1.8 Summary of components - Control cables”,
page 74
Gearbox shift lever to gearbox ⇒ “1.8 Summary of components - Control cables”,
page 74

1.20 Bleeding the clutch control

♦ Brake filling and bleeding device , e. g. -VAS 5234-
Note

♦ During the following work, ensure that no brake fluid lands on
longitudinal member or gearbox.
♦ A pre-filling of the system is not necessary!
Brake fluid specification ⇒ Chassis; Rep. gr. 00 .

gr. 27 .
– Connect brake filling and bleeding device , e. g. -VAS 5234- .
To bleed use bleeder hose .
– Connect the ventilation hose with the drip bottle of the brake
bleeding device.
54
– Insert the bleeder hose on the slave cylinder -arrow- and open
the vent valve.
– Activate system with a pressure of 0.2 MPa (2 bar).
– Allow approx. 100 cm3 of brake fluid to flow out until no more
air bubbles are visible.
– Close vent valve.
– Press clutch pedal forcefully from stop to stop between 10 and
15 times.
– Open vent valve.
– Allow another approx. 100 cm3 of brake fluid to flow out.
– After completing the bleeding procedure activate the clutch
pedal repeatedly.
– If necessary, bleed the clutch control once again

– Separate brake filling and bleeding device , e.g. -VAS 5234- .
gr. 27 .
55
2 Repairing the clutch release mecha‐

nism
♦ Grease for plug serration of clutch disc - G 000 100-
♦ Sealing grease - G 052 128 A1-
1 - Gearbox
2 - Ball stud, 25 Nm
❑ remove previous grease
from the contact surface
of the release lever
❑ grease with grease for
plug serration of clutch
disc - G 000 100-
3 - Gasket ring for drive shaft
❑ fitted in guide bushing
Pos. 4
❑ Renew.
⇒ “5 Repairing gearbox
housing and clutch
housing”, page 151 .
❑ Fill half the space be‐
tween the sealing lips
and dust lips with seal‐
ing grease - G 052 128
A1-
4 - Guide bushing
❑ with vulcanized O-ring
❑ if O-ring is damaged, re‐
place guide bushing to‐
gether with O-ring
housing and clutch
housing”, page 151
❑ for removal, remove
clutch release lever
Pos. 7
❑ grease in the area of the
clutch release lever with
grease for plug serration
of clutch disc -
G 000 100 -
5 - Retaining spring
❑ attach to clutch release lever
6 - 20 Nm
7 - Clutch release lever
❑ remove and install ⇒ page 57 together with clutch release bearing Pos. 8
❑ remove previous grease from the contact surface of the clutch release lever
❑ Grease contact point on the ball stud with grease for plug serration of clutch disc - G 000 100-
8 - Release bearing
❑ Do not wash the bearing, just wipe clean
❑ replace noisy bearings
56
❑ Grease contact point on the clutch release lever with grease for plug serration of clutch disc - G 000 100
-
9 - Slave cylinder
❑ Grease tappet head with grease for plug serration of clutch disc - G 000 100-
10 - 20 Nm
11 - Mounting bolt
❑ secures the clutch release lever when installing the gearbox ⇒ “2.5 Installing the gearbox”, page 120
❑ unscrew after the gearbox has been installed ⇒ “2.5 Installing the gearbox”, page 120
Note
If a mounting bolt is not provided,

use bolt M8 x 35.
Remove and install clutch release lever with release bearing

Removing
– Unhook spring -arrow 1- upwards.
– Remove clutch release lever -arrow 2- from ball stud.

Install
– First mount spring -arrow 1- on the clutch release lever.
– Press clutch release lever -arrow 2- onto the ball stud.
Removing and installing the release bearing

– Press the catch pegs -arrows- together on the rear side of the
clutch release lever and remove the release bearing -A- from
the clutch release lever.
– To install, press the release bearing -A- into the clutch release
lever until the catch pegs -arrows- lock into position.
2. Repairing the clutch release mechanism 57

3 Repairing clutch
Fault finding of power transmission - problems with the clutch and
clutch control
⇒ “3.1 Fault finding power transmission - problems with the clutch
and clutch control”, page 60
♦ Counterholder - MP1-223 (3067)-
♦ Centering mandrel - MP3-475A (3190A)-
(Gearbox removed)
Note
♦ Observe the fault finding of the power transmission before replacing the clutch disc and the pressure plate
- problems with the clutch and clutch control
⇒ “3.1 Fault finding power transmission - problems with the clutch and clutch control”, page 60 .
♦ Replace the clutch discs and pressure plates if the riveting is damaged or loose.
♦ Assign the clutch disc and pressure plate in accordance with engine identification characters ⇒ Electronic
Catalogue of Original Parts .
♦ 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.
♦ Clean the drive shaft serration and hub serration on used clutch discs, remove corrosion. Apply a very thin
layer of grease for plug serration of clutch disc - G 000 100 - onto the serration. Subsequently move the
clutch disc up and down on the drive shaft until the hub fits smoothly on the shaft. Remove all excess grease.
♦ The pressure plates are protected against corrosion and are greased. Only clean the thrust surface as
otherwise the life of the clutch may be considerably reduced.
♦ The thrust surface of the pressure plate and the clutch disc lining must fully rest against the flywheel before
the screws are installed. Only then may the fixing screws be inserted.
58
1 - Flywheel
❑ make sure the centering
pins are tight
❑ The locating face for the
clutch lining must be
free from grooves, oil
and grease
❑ Removing and Installing
⇒ Engine; Rep. gr. 13
2 - Clutch disc
❑ Diameter ⇒ Electronic
Parts
❑ Installation position for
basic flywheel: The
spring cage points to‐
wards the pressure
plate
❑ Fitting position for two-
mass flywheel
⇒ page 60
❑ center ⇒ page 59
❑ slightly grease the ser‐
ration
3 - Pressure plate
⇒ page 59
❑ Check the extremities of
the membrane springs
⇒ page 60
❑ Check feather joints and
riveted joints
⇒ page 60
4 - Screw M6-13 Nm; screw
M7-20 Nm
❑ loosen or tighten gradually and crosswise
Center the clutch disc and remove and install the pressure plate
– Release and tighten screws gradually and crosswise.
– When removing and installing, use counterholder - MP1-223
(3067)- .
Note
♦ The thrust surface of the pressure plate and the clutch disc
lining must fully rest against the flywheel before the screws are
installed.
♦ Tighten the screws crosswise so as not to damage the cen‐
tering holes and the centering pins of the flywheel.
3. Repairing clutch 59
Fitting position of clutch disc in connection with two-mass flywheel

• Legend “side of gearbox” -arrow- points to the gearbox.
Check the extremities of the membrane spring

• Wear is allowed up to half the membrane spring thickness.
Check feather joints and riveted joints

– Check the feather joints between pressure plate and cover for
cracks as well as the riveted joints for firm seating.
• Pressure plate with damaged feather joints or with loose rive‐
ted joints -arrows- must be replaced.
3.1 Fault finding power transmission - prob‐

lems with the clutch and clutch control
Note
Check hydraulic clutch control

⇒ “1.16 Check hydraulic clutch control”, page 47 .
Always check the fault mentioned by the customer first before

repairing the clutch. During this procedure, it must be determined
if indeed there is a fault of the clutch or if the cause is only an
incorrect setting of the shift mechanism.
Complaint 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 or slave – Replace defective part, vent air
cylinder leaking. from the line system; top up with
brake fluid.
60

♦ Release bearing on the guide – Replace guide bushing and re‐
bushing is tilted, seizured. lease bearing.
♦ 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.
♦ Release bearing on the guide – Replace defective components.
bushing is tilted, seizured.
♦ Pressure plate with wrong – Assign pressure plate via the ⇒

spring identification. Electronic catalogue of original
parts .
♦ Mechanical fault of the pressure – Replace defective components.
plate/clutch disc.
♦ Clutch disc on the serration – Check serration of the hub for

sluggish/jams. damage (burrs), if necessary re‐
place clutch disc.
– Clean the hub and the drive

shaft from corrosion and grease
with grease for plug serration of
clutch disc - G 000 100- . Move
clutch disc back and forth, re‐
move excess grease.

Noises when operating the clutch ♦ Release bearing defective, – Always replace noisy release
pedal. guide bushing is not O.K, con‐ bearings.
tact surface worked-in.
– Replace damaged guide bush‐
ing.
♦ The contact surface of the pres‐ – Replace pressure plate.
sure plate is defective (the tips
of the membrane spring are – Check release bearing, guide
kinked, bent). Release bearing bushing, replace if necessary.
is off-center.
– Check adjustment of clutch re‐
lease lever.
– Check dowel sleeves.

♦ Centre displacement of engine/ – Check dowel sleeves.
gearbox.
♦ Clutch disc incorrectly installed. – Correct installation.

♦ Wrong clutch disc installed. – Assign clutch disc via the ⇒
Electronic catalogue of original
parts .

Rattling, scratching occurs when ♦ Air in the system, clutch does – Bleed system; check system,
the forward or reverse gear is en‐ not separate fully. top up with brake fluid.
gaged, gearschift jams, is sluggish,
shifting is not possible, clutch with‐
out operation.
♦ Master cylinder or slave cylinder – Replace defective component,
is leaking, line is leaking. top up with brake fluid, vent air
from the line system.
♦ The travel of the clutch pedal is – Inform customer.
not sufficent (carpet, foot mat
under the foot controls), clutch is
not fully depressed.
♦ Pressure plate uneven due to in‐ – Check components, if necessa‐

correct installation, clutch 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.
♦ Tips of membrane spring broken – Replace pressure plate.
or bent (assembly fault, release
bearing moves off-center). – Check release bearing, guide
bushing, replace if necessary.

♦ Clutch disc too thick. – Assign clutch disc via the ⇒
parts .
♦ Lining glued to the flywheel – Slightly rub down friction surfa‐
(long immobilization time, high ces of the clutch linings or re‐
humidity). place completely the severely
corroded parts.
sluggish/jams. Corroded hub, damage, if necessary replace
damaged during assembly. Hub clutch disc.
profile knocked out on one side.
– Remove corrosion and traces of
grease from hub and shaft.
Grease shaft with grease for
plug serration of clutch disc -
G 000 100 - .
– Move clutch disc back and forth,

remove excess grease.
– Check position of dowel sleeves

on knocked out hub profile.
– Check release bearing, guide

bushing and pressure plate, re‐
place if necessary.
♦ Lifting of pressure plate too low – Assign pressure plate via the ⇒
(wrong pressure plate installed). Electronic catalogue of original
parts .
62

♦ Displacement of engine/gear‐ – Insert dowel sleeves before
box too large (dowel sleeves gearbox has been fitted.
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.

Load change jolts when throttle is ♦ Assembly bearing is too soft. – Inform customer. Assign hanger
depressed and sudden reduction of via the ⇒ Electronic Catalogue
the engine speed. of Original Parts
♦ Irregular engine running. – Check engine setting, correct.
♦ Clutch disc with predamper is – Inform customer.

built in against gear rattling.
♦ Centre displacement of engine/ – Test dowel sleeves, replace if

gearbox. necessary.

Clutch slips through, no or bad pre‐ ♦ Wrong clutch disc, wrong pres‐ – Assign the clutch disc and pres‐
drive. sure plate installed. sure plate via the ⇒ Electronic
catalogue of original parts .
♦ Cutch disc is 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 en‐
gine or the drive shaft 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 disc incorrectly installed. – Correct installation, check
clutch disc, replace if necessary.
♦ Flywheel depth too large or ex‐ – Assign the sealing flange via the
cessive abrasion on the contact ⇒ electronic catalogue of origi‐
surface of the lining. nal parts .
– Inspect clutch disc, pressure

plate, replace if necessary.
♦ Slave cylinder leaking. – Replace slave cylinder.

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

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

when starting.

parts .
♦ Assembly bearing too soft, – Assign the assembly bracket via
knocked out. the ⇒ Electronic catalogue of
original parts .
♦ Clutch lining, contact surface of – Check shaft seal of drive shaft or
pressure plate and flywheel oily crankshaft, if necessary re‐
(oil leakage from the clutch place.
housing).
– Replace clutch disc, clean pres‐
sure plate and flywheel.
♦ Release bearing is tilted on the – Replace release bearing and
guide bushing, seizured guide bushing.
(presses on one side onto the
membrane spring of the pres‐ – Check control elements and
sure plate). bearing for control elements.
♦ The contact surface of the pres‐ – Check the contact surface of the
sure plate lifts off only unilater‐ clutch lining on the flywheel,
ally due to the tilted release check pressure plate and mem‐
bearing. brane springs, replace pressure
plate if necessary.
♦ The housing of the pressure
plate was warped when instal‐ – Replace release bearing and
led. Contact surface of the pres‐ guide bushing.
sure plate lifts off only unilater‐
ally.
♦ Drive schaft too heavily greased – Remove grease from pressure

(traces of grease on the clutch plate and flywheel, replace if
disc, pressure plate and fly‐ damaged (traces of wear, traces
wheel). of overheating, grooves).
– Remove traces of grease from

hub and shaft, grease shaft with
grease for plug serration of
clutch disc - G 000 100 - .


Acoustic knock »klack« when cou‐ ♦ Carrier earth/drive shaft is ac‐ – Inform customer.
pling. celerated with sudden coupling.
The drive shaft serration of the
pinions in mesh knocks; for
clutch discs with predamper the
noise increases as the predam‐
per reaches the stop.
64

Noises in idle. ♦ Torsional damper spring bro‐ – Replace clutch disc.
ken.
♦ Clutch disc without predamper – Assign clutch disc via the ⇒

installed (idle rattling). Electronic catalogue of original
parts .
♦ Pressure plate warped, broken, – Replace pressure plate.
imbalance.
♦ Irregular engine running. – Check engine setting, correct if

necessary.
missing).
♦ Intermediate plate grinds at fly‐ – Insert intermediate plate on

wheel. sealing flange and push onto the
dowel sleeves.
34 – Controls, housing
1 Shift mechanism
⇒ “1.1 Fitting location of shift mechanism”, page 66
⇒ “1.2 Summary of components of the shift mechanism ”,
page 68
⇒ “1.3 Summary of components - gearshift knob and cover”, page
69
⇒ “1.4 Separating collar from gearshift lever (Fabia II, Roomster)
”, page 69
⇒ “1.5 Separating collar from gearshift lever (Rapid)”, page 70
⇒ “1.6 Remove and install gearshift knob and shift lever collar
(Rapid NH)”, page 72 .
⇒ “1.7 Summary of components - Shift lever and shift housing”,
page 72
⇒ “1.8 Summary of components - Control cables”, page 74
⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid
NH)”, page 77
⇒ “1.10 Remove and install shift mechanism (Fabia II, Roomster,
⇒ “1.11 Removing and installing shift mechanism (Rapid) ”, page
84
1.1 Fitting location of shift mechanism

-Arrow A- Shift movement
-Arrow B- Selector movement
66 Rep. gr.34 - Controls, housing

A - Shift cable
B - Selector cable
C - Heat shield
❑ take off before removing
the shift mechanism
1 - Gearshift lever
2 - Reversing lever
1.2 Summary of components of the shift mechanism
Note
♦ To replace the control cables, remove the shift mechanism (Fabia II, Roomster, Rapid NH)
⇒ “1.10 Remove and install shift mechanism (Fabia II, Roomster, Rapid NH)”, page 79 , (Rapid)
⇒ “1.11 Removing and installing shift mechanism (Rapid) ”, page 84 .
♦ Do not kink the control cables.
I - Summary of components -
Gearshift knob and cover
⇒ “1.3 Summary of compo‐
nents - gearshift knob and cov‐
er”, page 69
II - Summary of components -
Shift lever and shift housing
nents - Shift lever and shift
housing”, page 72
III - Summary of components -
Control cables
nents - Control cables”,
page 74
Removing and installing shift
mechanism (Fabia II, Room‐
ster, Rapid NH)
⇒ “1.10 Remove and install
shift mechanism (Fabia II,
Roomster, Rapid NH)”,
page 79 , (Rapid)
⇒ “1.11 Removing and instal‐
ling shift mechanism (Rapid) ”,
page 84
Setting the shift mechanism
⇒ “1.12 Setting the shift mech‐
anism”, page 86

1.3 Summary of components - gearshift knob and cover
1 - Gearshift knob
❑ with collar
❑ it can be different in
shape on individual
models
❑ The gearshift knob and
collar cannot be separa‐
ted
❑ always replace together
⇒ Electronic Catalogue
of Original Parts
(Fabia II, Roomster)
⇒ “1.4 Separating collar
from gearshift lever (Fa‐
bia II, Roomster) ”, page
69 , (Rapid)
⇒ “1.5 Separating collar
from gearshift lever
(Rapid)”, page 70 ,
(Rapid NH)
⇒ “1.6 Remove and in‐
stall gearshift knob and
shift lever collar (Rapid
NH)”, page 72
❑ Plaque of gearshift lever
can only be separated
from the gearshift knob
e.g. with a screwdriver.
2 - Centre console
1.4 Separating collar from gearshift lever

(Fabia II, Roomster)
♦ Disassembly wedge - 3409-
– Lever off the collar with disassembly wedge - 3409- out of the
surround of centre console in -direction of arrow-.
– Pull the collar upwards over the gearshift knob.
– Turn securing mechanism -arrow A- in -direction of arrow B-

and pull off gearshift knob together with the collar.
Install
– Turn collar inside out.
– Position the gearshift knob together with the collar and secure
with securing mechanism -arrow A- against the
-direction arrow B-.
When inserting the gearshift knob on the shift lever the gearshift
knob must lock into the round slot of the gearshift lever.

(Rapid)
♦ Release tool - T30098-
– Lever off the collar frame with the disassembly wedge -
T30098- out of the surround for the centre console in

– For this step, press on the frame in -direction of arrow- and at

the same time raise the frame.
– Lift off the frame.

Install
– Fit the frame with its catches into the rear part of the centre
console.
– Lock the frame into the cover of the centre console in the front
part.
1.6 Remove and install gearshift knob and

shift lever collar (Rapid NH)
♦ Hose strap pliers , e.g. -V.A.G 1275 A-
– Lever the collar frame out of the centre console. To do so, fit
the release tool - T30098- between the collar frame and the
cover of the centre console in the middle of the front side
-arrow 1- and press it forwards in -direction of arrow 2-.
– Open clamp -arrow- and pull off gearshift knob together with
the collar.
Install
Note
When inserting the gearshift knob on the selector lever the gear‐
shift knob must lock up to the stop.
it with the new open warm-type clamp -arrow- by pressing it
together.
– Fit the frame of the collar onto the catch pegs in the rear part
of the centre console.
– Press the frame into the cover of the centre console until it
locks in the front area.
1.7 Summary of components - Shift lever and shift housing
Note
Grease bearing and friction surfaces with grease - G 000 450 02- .

1 - Lock washer
⇒ page 74
2 - Spring
3 - Gasket
❑ between shift housing
and underbody
❑ self-adhesive
❑ stuck onto the shift
housing
4 - Shift lever
5 - Damping
⇒ page 74
6 - Shift housing
7 - Insulating washer
❑ must be present in the
round slot -arrow- of the
shift lever Pos. 4
8 - Gasket
Parts
9 - Floor plate
❑ bend up tabs for remov‐
ing
Parts
10 - Bushing
❑ for selector cable
11 - Selector cable
❑ slacken from selector angle plate within the shift mechanism
❑ press onto selector angle plate within the shift mechanism
❑ Fitting position ⇒ “1.1 Fitting location of shift mechanism”, page 66
❑ after installing set shift mechanism ⇒ “1.12 Setting the shift mechanism”, page 86
12 - Shift cable
❑ slacken from the shift lever guide within the shift mechanism
❑ press onto the selector angle guide within the shift mechanism
❑ Fitting position ⇒ “1.1 Fitting location of shift mechanism”, page 66
13 - 23 Nm
❑ 4 pieces
Removing and installing lock washer

– When removing and installing the circlip -A- pull the gearshift
lever in the -direction of the arrow A- while simultaneously
pressing the spring down with a screwdriver up to the stop in
the -direction of the arrow B-. While doing so remove circlip
-A-.
Note
♦ The mounting slot in shift lever for circlip must be visible.

♦ Release spring carefully.
Removing and installing damping -arrow-

– Press the pressure spring leg -A- to the left until it is located
next to the damping -arrow-.
– Press the shift lever to the lift and pull off the damping.
• After installing the damping, the pressure spring legs -A- and
-B- must rest on the damping -arrow-.

1.8 Summary of components - Control cables
Note

1 - Shift cable
❑ slacken from the shift
lever guide within the
shift mechanism
❑ press onto the selector
angle guide within the
shift mechanism
❑ connect with cable lock
Pos. 11
❑ Fitting position
⇒ “1.1 Fitting location of
shift mechanism”,
page 66
❑ after installing set shift
mechanism
⇒ “1.12 Setting the shift
mechanism”, page 86
2 - Selector cable
❑ slacken from selector
angle plate within the
shift mechanism
❑ press onto selector an‐
gle plate within the shift
mechanism
Pos. 10
⇒ “1.1 Fitting location of
shift mechanism”,
page 66
mechanism
3 - Grommet
4 - Lock washer
❑ do not damage cables when removing
5 - Shift housing
6 - Cable support
❑ out of plastic or metal
7 - Grommet
❑ 3 pieces
❑ for mounting of cable support to gearbox
8 - Spacer
❑ 3 pieces
9 - 20 Nm
❑ 3 pieces
10 - Cable lock
❑ for selector cable at relay lever
❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are
different ⇒ page 77
❑ can be installed in tandem with the plastic relay lever (Fabia II, Roomster, Rapid NH)
⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH)”, page 77
❑ remove from plastic relay lever (Fabia II, Roomster, Rapid NH)
⇒ “1.9.2 Remove and install cable lock for selector cable from plastic relay lever”, page 79
❑ press onto plastic relay lever (Fabia II, Roomster, Rapid NH)
⇒ “1.9.2 Remove and install cable lock for selector cable from plastic relay lever”, page 79
❑ Assignment ⇒ page 77
11 - Cable lock
❑ for shift cable at gearbox shift lever
12 - Lock washer
❑ is not required, if the relay lever is made of plastic
13 - Bushings

14 - Reversing lever
❑ Fitting position ⇒ page 77
❑ The metal relay lever is located in the bushings pos. 13 and secured with a lock washer pos. 12
❑ as of 06.07 the relay lever is made of plastic (Fabia II, Roomster, Rapid NH)
❑ Remove and install plastic relay lever together with cable lock (Fabia II, Roomster, Rapid NH)
⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH)”, page 77
❑ if the relay lever is made of plastic, neither the bushings pos. 13 nor the lock washer pos. 12 are required
(Fabia II, Roomster, Rapid NH)
15 - Sliding shoe
16 - Gearshift lever
❑ with balancing weight
❑ insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft ⇒ page 77
17 - 20 Nm
18 - Lock washer
❑ is not required on cable locks for selector cable at relay lever, if relay lever is made of plastic

Assign cable locks

The holes in the cable locks have different diameters.
Cable lock for Dimension “a”
Shift cable at gearbox shift lever 10 mm
Selector cable at metal relay lever 8 mm
Selector cable at plastic relay lever 10 mm
⇒ “1.9 Plastic relay lever as of 06.07 (Fabia II,
Roomster, Rapid NH)”, page 77
Install gearshift lever

– When inserting the gearbox shift lever, make sure that the
tooth opening -arrow A- is located above the interrupted spac‐
ing of the teeth -arrow B- for the gearshift shaft.
Fitting location of gearbox shift lever/relay lever

1 - Gearbox shift lever with balancing weight
2 - Relay lever is inserted over the sliding shoe -arrow- into the
sliding rail of the gearbox shift lever
1.9 Plastic relay lever as of 06.07 (Fabia II,

Roomster, Rapid NH)
♦ Grease - G 000 450 02-
1.9.1 Removing and installing plastic relay

lever
– Pull forward the locking mechanism as far as the stop in
-direction of arrow 1-, then lock by turning to the left in
-direction of arrow 2-.
• Before removing the plastic relay lever, the cable lock must be
separated from the selector cable in order to avoid damage to
the selector cable.
• The gearbox shift lever is located in the neutral position.
The relay lever is secured with a catch -arrow 1- on the gearshift

cover
– Carefully press down the catch -arrow 1- up to the stop.
– Then move relay lever back and forward in its bearing (direc‐
tion of operation). To do so, carefully pull out the cable lock.
• Only remove cable lock on removed relay lever ⇒ page 79 .
Note
To install, grease bearing points and friction surfaces with grease

- G 000 450 02- .
– Press cable lock onto the relay lever ⇒ page 79 .

– Insert relay lever together with cable lock.
• The catch -arrow 1- secures the relay lever.
• The cable lock must be located behind the catch -arrow 2-.
The relay lever is secured with a clip -arrow 1- on the gearshift

cover
– Remove the clip -arrow 1- from the opening in the relay lever.
– Afterwards, pull the relay lever together with the cable lock out
of its bearing point in the gearshift cover.
Note

- G 000 450 02- .

– Secure the relay lever with a clip -arrow 1-.

1.9.2 Remove and install cable lock for selec‐

tor cable from plastic relay lever
Remove cable lock for selector cable from plastic relay lever
• Relay lever removed.
– Insert cross-head screwdriver -A- between bushing -B- and
relay lever.
Press on cable lock

• The cable lock must only be pressed onto the bushing
-arrow-.
• Cable lock must move freely on relay lever.
• It must be located behind the catch ⇒ page 78 .
1.10 Remove and install shift mechanism

♦ Disassembly wedge - 3409- (2 pieces) (Fabia II, Roomster)
♦ Release tool - T30098- (Rapid NH)
♦ Grease - G 000 450 02-
1.10.1 Removing
Note

additional operations ⇒ Electrical System; Rep. gr. 27 .

gr. 27 .
– Remove circlip -3- for shift cable from gearbox shift lever -1-.
– Pull off shift cable from the stud -arrow-.
Metal relay lever (Fabia II and Roomster up to 05.07)
– Remove circlip -4- for selector cable from relay lever -2-.
Plastic relay lever
Separate cable lock from selector cable

• Before removal, the cable lock must be separated from the
selector cable in order to avoid damage to the selector cable.


-arrows-.
– Remove gearshift knob and shift lever collar.
♦ Fabia II and Roomster
⇒ “1.4 Separating collar from gearshift lever (Fabia II, Room‐
ster) ”, page 69 .
♦ Rapid NH
(Rapid NH)”, page 72 .
– Remove the centre console cover ⇒ Body Work; Rep. gr. 68 .
– If present, remove noise insulation from shift housing.
– Unscrew fixing nuts -arrows- attaching the shift housing.

– Remove underbody cover on right and left (if present)

-arrows-.

Vehicles Fabia and Roomster
– Remove pre-exhaust pipe ⇒ Engine; Rep. gr. 26 .
Vehicles Rapid NH
– Fit the stiff cover onto the decoupling element of the exhaust
system ⇒ Engine; Rep. gr. 26 .
– Separate the exhaust system at the clamping sleeve ⇒ En‐
gine; Rep. gr. 26 and secure the exhaust pipe so that it cannot
unhook freely.
– Push the pre-exhaust pipe out of the retaining straps and se‐
cure the exhaust pipe in such a way that it cannot unhook
freely.
– Remove bracket for retaining straps of rear silencer from the
body.

– Swivel shift housing down and remove with control cables.
1.10.2 Install
Installation is carried out in the reverse order. However, pay at‐
tention to the following:
The holes in the cable locks have different diameters
– Apply a small quantity of grease - G 000 450 02- onto the studs
-arrows- of the gearbox shift lever -1- and of the relay lever
-2-.
– Always replace lock washers -3- and -4- after each removal ⇒
– Secure the shift cable with the lock washer -3- and the selector
cable with the lock washer -4- (for metal relay lever).
Cable lock with plastic relay lever
– The relay lever and the cable lock must be installed together
– Insert the selector cable into the cable lock.
Continued for all gearshift mechanisms
– Align shift housing parallel to vehicle body.

• The distance to the vehicle body must be the same on both
sides.
– Assemble exhaust system free of stress and attach tunnel
bridges ⇒ Engine; Rep. gr. 26 .
– If present, position the noise insulation on the shift housing.
– Install centre console ⇒ Body Work; Rep. gr. 68 .
⇒ “1.12 Setting the shift mechanism”, page 86 .
gr. 27 .
Note


Tightening torques
Components Tightening torque
Underbody cover 2 Nm
Shift housing to body ⇒ “1.7 Summary of components - Shift lever and shift housing”, page 72
Cable support to gearbox ⇒ “1.8 Summary of components - Control cables”, page 74
Tunnel bridge ⇒ Engine; Rep. gr. 26
Unbolt bracket for exhaust pipe ⇒ Engine; Rep. gr. 26
83

nism (Rapid)
♦ Grease - G 000 450 02-
1.11.1 Removing
Note


gr. 27 .
– Remove lock washer -3- for shift cable from gearbox shift lever
-1-.

– Remove circlip -4- for the selector cable from relay lever -2-.
– Pull off selector cable from the stud -arrow-.
– Remove Bowden cable support -arrows-.

– Remove gearshift knob and shift lever collar
⇒ “1.5 Separating collar from gearshift lever (Rapid)”,
page 70 .
– Remove the centre console ⇒ Body Work; Rep. gr. 68 .
– Unscrew nuts -arrows- attaching the shift housing.
84

-arrows-.

unhook freely.
freely.
– Remove bracket for retaining straps of rear silencer from the
body.

1.11.2 Install
following points:
85
The holes in the cable locks have different diameters

-2-.
cable (for metal relay lever) with the lock washer -4-.
sides.
gr. 27 .
Note

Tightening torque
Shift housing to body ⇒ “1.7 Summary of components - Shift lever and shift housing”,
page 72
Cable support to gearbox ⇒ “1.8 Summary of components - Control cables”, page 74
Bracket for pre-exhaust pipe ⇒ Engine; Rep. gr. 26
1.12 Setting the shift mechanism

♦ Rig pin - T10027A-
♦ Disassembly wedge - 3409- (2 pieces - Fabia II, Roomster)
♦ Release tool - T30098- (2 pieces - Rapid, 1 piece - Rapid NH)
Note
The following are required for correct setting of the shift mecha‐
nism:
• Gearbox, clutch and clutch control in perfect condition.
86
• Shift mechanism operates freely.

• Operating and transmission elements of the shift mechanism
are in perfect condition.
• Gearbox in Neutral.
Note


gr. 27 .
– Pull forward the locking mechanism at shift cable and at se‐
lector cable as far as the stop in -direction of arrow 1-, then
lock by turning to the left in -direction of arrow 2-.
Fix the gearshift shaft as follows:

– Press down the gearshift shaft in -direction of arrow 1-.
– When pressing down the gearshift shaft turn angle lever -A- in
-direction of arrow 2- upwards and at the same time press it in
carefully until it locks into the gearshift shaft.
– Remove shift lever collar:
♦ Fabia II, Roomster
⇒ “1.4 Separating collar from gearshift lever (Fabia II, Room‐
ster) ”, page 69
♦ Rapid
⇒ “1.5 Separating collar from gearshift lever (Rapid)”,
page 70
♦ Rapid NH
(Rapid NH)”, page 72
– Guide shift lever in Neutral position to the left into the 1st/2nd
gear gate via the leg.
87
– Insert rig pin - T10027A- into the hole -A- and into the hole
-B-.
– Turn locking mechanism at shift cable and at selector cable to

the right up to the stop -direction of arrow-.
The spring pushes the locking mechanism into the initial position.
– Turn angle lever -A- back to the initial position

-in direction of arrow-.
Note
The angle lever -A- must be pressed out of the gearbox housing
and must point vertically upwards.
– Pull rig pin - T10027A- out of hole -A- and -B-.

– Perform a functional test of the shift mechanism
⇒ “1.12.1 Operation”, page 88 .
– Fit collar into the surround for centre console.
gr. 27 .
1.12.1 Operation
• Shift lever must be positioned in Neutral position in the selector
lever gate of the 3rd/4th gear.
– Actuate clutch pedal.
– Shift through all gears several times. Pay particular attention
to proper operation of the reverse gear lock.
88
If a gear catches when engaged again. set the shift mechanism

once again ⇒ “1.12 Setting the shift mechanism”, page 86 .
89

⇒ “2.1 Removing gearbox (Fabia II 2007 ►; Roomster 2006 ►)”,
page 90
⇒ “2.2 Removing gearbox (Fabia II 2011 ►; Roomster 2011 ►)”,
page 97
⇒ “2.3 Removing gearbox (Rapid) ”, page 106
⇒ “2.4 Removing gearbox (Rapid NH)”, page 113
⇒ “2.5 Installing the gearbox”, page 120
⇒ “2.5.1 Tightening torques (Fabia II, Roomster) ”, page 122
⇒ “2.5.2 Tightening torques (Rapid) ”, page 124
⇒ “2.6 Tightening torques (Rapid NH)”, page 125
⇒ “2.7 Transporting the gearbox”, page 126
2.1 Removing gearbox (Fabia II 2007 ►;

Roomster 2006 ►)

♦ Supporting device - MP9-200 (10-222A)-
♦ Adapter - MP9-200/3 (10-222A/3)-
♦ Gearbox mount - 3282-
♦ Adjusting plate - T30020-
Note
♦ After the battery earth strap is disconnected and re-connected,
carry out additional operations ⇒ Electrical System; Rep. gr.
27 .
– Disconnect the earth strap from the battery with the ignition
off.
gine; Rep. gr. 23 .
gr. 27 .
90

shift lever -A-.
Metal relay lever (up to 05.07)
-B-.
– Pull selector cable off the stud.
relay lever.
Note
Always replace circlips ⇒ Electronic Catalogue of Original Parts
Plastic relay lever


Continued for all vehicles:
-arrow 4-.

– Remove cable support from the gearbox -arrows- and tie up

laterally together with selector cable and shift cable
– Remove bracket -B- from the gearbox and pull off from the
tube-hose line -A-.
– Remove the slave cylinder -arrows- and lay aside, secure with
wire, do not open the line system.
Caution
Do not depress the clutch pedal.
For vehicles with particle filter

– Remove charge-air pipe from exhaust turbocharger to charge
air cooler ⇒ Engine; Rep. gr. 21 .
– Disconnect plug -arrow 1- from reversing light switch - F4- .

– Remove connector -arrow 2- and cable -arrow 3- from the
starter.
– Expose cables.
– Remove engine/gearbox connecting screws at the top.
– Remove top securing screws at starter.
– Unplug connector -arrow- from speedometer sender - G22- (if

available).
92
– Remove bracket for engine cover -arrow- (install in this hole

one of the 2 spindles of the supporting device).
lifting eye of the engine for the supporting device - MP9-200
– Install supporting device - MP9-200 (10-222A)- .

– Remove front left wheel ⇒ Chassis; Rep. gr. 44 and raise
vehicle.
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .

– If present, remove heat shield for drive shaft from the engine
-arrows-.
– Unscrew bracket from starter -arrow- and lay aside together

with lines.
– Removing starter ⇒ Electrical System; Rep. gr. 27 .
– Remove the front left wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
– Turn the sterring wheel up to the stop to the left and remove
drive shafts from the flange shafts ⇒ Chassis; Rep. gr. 40 .
tion.
For vehicles without particle filter
– Remove pre-exhaust pipe with catalytic converter ⇒ Engine;
Rep. gr. 26 .

– Mark installation position of bolts -1- from left steering joint.

– Unscrew screws -1- for left steering joint ⇒ Chassis; Rep. gr.
40 .
– Unbolt coupling rod -2- from the anti-roll bar -arrow- ⇒ Chas‐
sis; Rep. gr. 40 .
– Turn coupling rod upwards.
– Swivel the drive shaft into the wheelhouse and secure it to the
suspension strut, e.g. with cord. Avoid damaging the paint‐
wards. While doing so, disconnect the plug connection.
Note
On vehicles with air conditioning system, additionally unscrew the

fixing screws (in the upper area of the fan shroud) of the bracket
for refrigerant line.
– Remove pendulum support -arrows 1- and -arrow 2-.
Note
When installing the pendulum support position the screws

-arrows 1- in the elongated holes in such a way that there is max‐
imum distance between the gearbox and the assembly carrier.
– Unscrew the engine/gearbox connecting screw below the right

flange shaft.
– Remove small cover plate -A- (if present) for flywheel behind
the right flange shaft -arrows-.
94
– Remove the holding bracket for the exhaust pipe -1-.

– Separate the exhaust system behind the pre-exhaust pipe at
the clamping sleeve and secure with wire to the body ⇒ En‐
gine; Rep. gr. 26 .
– Release the assembly carrier (center) ⇒ Chassis; Rep. gr.
40 .

holder.
Note
– Unscrew the fixing screws -arrows- from the gearbox mount.

– Lower engine/gearbox unit sufficiently at the two spindles until

the fixing screws attaching the gearbox mounting bracket -A-
are accessible from the left wheelhouse.
Note
When lowering the engine/gearbox unit, make sure the gearbox

does not touch the assembly carrier.
Unscrew the fixing screws -arrows- of the gearbox console and

remove the gearbox console -A- from the gearbox.
– Insert gearbox mount - 3282 - into engine/gearbox jack , e.g.
-V.A.G 1383 A- .
Complete engine and gearbox jack with gearbox mount - 3282- ,
adjusting plate - T30020- for gearbox “02R” and support elements
as follows:
– Position adjusting plate - T30020 - onto the gearbox mount -
3282- ( adjusting plate fits in only one position).
adjusting plate .
– Screw in the mounting elements -A- and -C- as shown on ad‐

justing plate .
– Screw in the bolt - 3282/29- , as indicated on the adjusting
plate.
– Position the engine and gearbox jack below the vehicle, the
arrow -symbol B- (in the previous figure) on the adjusting plate
points in the direction of travel/vehicle.
– Align adjusting plate parallel to the gearbox and lock securing
mounts at gearbox.
– Remove the bottom engine/gearbox connecting screws.
– Press gearbox off the engine and swivel towards the assembly
carrier.
– Via the spindles swivel the gearbox backwards and down to‐
wards the assembly carrier.
mount - 3282- when lowering.
96
Note
♦ When removing the gearbox -1- ensure the gearbox does not
touch the frame side rail -2-, -arrows-.
♦ When lowering guide the coolant hoses past the gearbox.
– Installing the gearbox

⇒ “2.5 Installing the gearbox”, page 120 .
2.2 Removing gearbox (Fabia II 2011 ►;

Roomster 2011 ►)
♦ Adapter - MP9-200/3 (10-222A/3)-

Note
♦ After the battery earth strap is disconnected and re-connected,
27 .
off.
– Remove the vacuum lines with the bracket -1- from the air filter
and disconnect the plug -3- -direction of arrow-.
– Unscrew the charge pressure control solenoid valve - N75-
with the bracket -2- -arrow- and place it with the vacuum line
on the engine.
gine; Rep. gr. 23 .
gr. 27 .
– Remove the plenum chamber cover and bulkhead ⇒ Body
work; Rep. gr. 66 .

– Remove the vacuum hose -A- from the brake servo unit -B-
-arrow 1-, in order to avoid damage ⇒ Chassis; Rep. gr. 47 .
– Remove the rubber bearing -arrow 2- of the vacuum hose from
the lifting eye -C- at the engine.
– Pull forward the locking mechanism of the selector cable as

far as the stop in -direction of arrow 1- and then lock by turning
to the left in -direction of arrow 2-.
– Afterwards, pull the relay lever together with the cable lock out
of its bearing point in the gearshift cover.
Note
On some vehicles, the relay lever is secured with a catch

⇒ “1.9.1 Removing and installing plastic relay lever”, page 78 .

shift lever -A-.
-arrow 3-.

– If present, remove the bracket -B- from the gearbox and pull
off from the tube-hose line -A-.
98
– Remove the slave cylinder -arrows-, lay aside and secure it;
do not open the line system.
Caution

starter.
– Expose cables.


available).
Shorten the spindle -I- of the supporting device - MP9-200

(10-222A)- by 100 mm:
I - Spindle
♦ Dimension -a- = 442 mm
♦ Dimension -x- = 100 mm
II - shortened spindle MP9-200/10 (10-222A/10)
♦ Dimension -b- = 342 mm
Note
In order for the spindle -I- of the supporting device - MP9-200

(10-222A)- not to touch the front flap, it must be shortened to the
dimension -x- (100 mm).


– Install supporting device - MP9-200 (10-222A)- . For this pur‐

pose, position the supports -C- next to the screw -arrow 1- and
the support for the front flap -arrow 2- as shown.
– Hook the spindle -A- into the front right engine lifting eye.
– Position the shortened spindle -B- on the adapter - 10-222 A/
3- .
– Hook the rear left shackle - 10-222 A/12- into the lifting eye of
the engine.
Caution
The vacuum hose must move freely in the lifting eye

-arrows-.
It must not be damaged.
– Then connect the shackle - 10-222 A/12- with the shortened

spindle ⇒ page 99 .
vehicle.
gr. 50 .
– Remove the charge air hose »hot« side, to do so slacken the

hose clamps -1- ⇒ Engine; Rep. gr. 21 .
– Remove charge air pipe »cold« side from engine ⇒ Engine;
Rep. gr. 21 .
100
– Unplug connector -arrow-.
driver and remove ⇒ Engine; Rep. gr. 19 .
– Gearboxes for vehicles with start/stop system: Unplug the

connector -arrow- from the transmission neutral sender -
G701- .
– Release the nut -arrow- and remove the bracket for the elec‐
trical cables.
gr. 66 .
– Separate the exhaust pipe at the clamping sleeve and unhook
from the assembly carrier ⇒ Engine; Rep. gr. 26 .

– Remove pendulum support -arrows A- and -arrow B-.
Note

– If present, remove the heat shield for the right drive shaft
-arrows- ⇒ Chassis; Rep. gr. 40 .
– Turn the sterring wheel up to the stop to the left and remove
drive shafts from the flange shafts ⇒ Chassis; Rep. gr. 40 .
– Unscrew nuts -arrows- for left steering joint ⇒ Chassis; Rep.

gr. 44 .
sis; Rep. gr. 40 .
wards.
tion.
102
– If present, remove small cover plate -A- for flywheel -arrows-.
– Remove earth strap -1- from engine mount.

– Remove screws -arrows- for engine cradle at engine mount ⇒
Note
The nut -2- must not be released!

– Remove the screws -arrows- of the left assembly carrier from

the gearbox mount.
– Lower the gearbox to the dimension -a- approx. 55 mm.


The vacuum hose -arrows- must not be jammed.
Caution
The lifting eye of the engine must not touch the brake fluid res‐
ervoir and the brake lines.
• The fixing screws -arrows- for the gearbox console -A- must
be accessible.
– Remove gearbox console -A- -arrows-.
– Remove bottom engine/gearbox connecting screw -1-
Note
Slacken the engine/gearbox connecting screws -2- and -3- and

leave them screwed in hand tight. The screws -2- and -3- are re‐
moved during future work procedure.
– Insert gearbox mount - 3282 - into engine/gearbox jack , e.g.

-V.A.G 1383 A- .
as follows:
– Position adjusting plate - T30020 - onto the gearbox mount -
adjusting plate .

justing plate .
plate.
104
mounts at gearbox.
– Press the gearbox out of the dowel sleeves and carefully swing
towards the assembly carrier.
• The differential gear must point upwards.
• When removing and installing the gearbox, ask a 2nd me‐
chanic to push the engine slightly forwards.
– Guide the gearbox with the differential gear via the assembly
carrier -A- and swivel out.
– If necessary, turn the gearbox in the area of the differential
gear via the spindles of the gearbox mount - 3282- further up‐
wards.
– Swivel out the gearbox further and carefully lower it.

– Lower the gearbox in the area of the 5th gear (sheet metal
cover) via the spindles of the gearbox mount - 3282- .

The gearbox must not touch the engine pump aggregate -A- for
the power-assisted steering.
Note
♦ Pay attention to the coolant hose between the engine and the
heat exchanger for heating.
♦ When removing and installing, pay attention to the charge air
pipe of the engine ⇒ Engine; Rep. gr. 21 .
♦ The engine cradle must not touch the toothed belt guard - top
part ⇒ Engine; Rep. gr. 26 .

2.3 Removing gearbox (Rapid)


♦ Adapter - MP9-200/3 (10-222A/3)-
♦ Hook for MP9-200 - MP9-200/10-
♦ Shackle - (10-222A/12)-
♦ Bolt - 3282/29-
Note
♦ After the battery earth strap is disconnected and connected,
27 .
off.
106
on the engine.
– Remove air filter box completely with air guide hose ⇒ Engine;
Rep. gr. 23 .
gr. 27 .
– Remove the vacuum hose -arrow 1- from the brake servo unit
to the engine at the front wall.
the lifting eye at the engine.

shift lever -A-.
-B-.
relay lever.
-arrow 4-.
– Disconnect the cable support from the gearbox (screws -1-).


Caution

starter.
– Expose cables.


available).

the support for the front flap -arrow 2- as shown.
– Hook the spindle -A- into the front right engine lifting eye.
– Position the spindle -B- on the adapter - 10-222 A/3- .
108
– Hook the rear left shackle - 10-222 A/12- into the engine lifting
eye.
Caution

-arrows-.
– Then connect the shackle - 10-222 A/12- with the spindle.

vehicle.
gr. 66 .
gr. 50 .

– Remove the charge air hose »hot« side, to do so slacken the
hose clamps -1- ⇒ Engine; Rep. gr. 21 .
– Remove charge air pipe »hot« side at engine side ⇒ Engine;
Rep. gr. 21 .
driver and remove ⇒ Engine; Rep. gr. 19 .

trical cables.
unhook freely.
freely.
Note


– Turn steering to full left lock.
– Unscrew nuts -arrows- for left and right steering joint ⇒ Chas‐
sis; Rep. gr. 44 .
– Remove drive shafts from flange shafts ⇒ Chassis; Rep. gr.
40 .
– Swivel out the wheel-bearing housing.
– Swivel the drive shafts into the wheelhouses and secure them
to the suspension struts, e.g. with a cord. Avoid damaging the
paintwork of the drive shafts during this operation.
– Remove right flange shaft from gearbox.
110

the gearbox mount.
Caution

be accessible.
Note


– Insert gearbox mount - 3282- into engine/gearbox jack , e.g. -
V.A.G 1383 A- .
as follows:
– Position adjusting plate - T30020- onto the gearbox mount -
adjusting plate .

justing plate .
plate.
mounts at gearbox.
112
wards.

Note
part ⇒ Engine; Rep. gr. 26 .

2.4 Removing gearbox (Rapid NH)

♦ Bolt - 3282/29-
♦ Supporting device - T30099-
♦ Adapter - MP9-200/3 (10-222A/3)-
♦ Hook for MP9-200 - MP9-200/10 (10-222A/10)-
♦ Surface - T30099/1-

♦ Shackle - (10-222A/12)-
Note
out certain additional operations ⇒ Electrical System; Rep. gr.
27 .
off.
on the engine.
gr. 27 .
gine; Rep. gr. 23 .
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .
the lifting eye at the engine.

114
– Pull the relay lever out of its bearing point in the gearshift cover
together with the cable lock.
Note
♦ On some vehicles, the relay lever can be secured with a catch

⇒ “1.9.1 Removing and installing plastic relay lever”,
page 78 .
♦ Remove circlip -arrow 2- for shift cable from gearbox shift lever
-A-.
♦ Pull off the shift cable from the stud.
♦ Remove the gearshift lever -A-, for this step unscrew nut
-arrow 3-.


– Remove the slave cylinder -arrows-, lay aside and secure it,
Caution
Do not operate clutch pedal any more.

starter.
– Expose cables.
vehicle.
gr. 66 .
gr. 50 .

trical cables.

available).
Note
In order for the spindle -I- of the supporting device - MP9-200

Shorten the spindle -I- of the supporting device - MP9-200

(10-222A)- by 100 mm:
I - Spindle MP9-200/10 (10-222A/10)
– Install supporting device - T30099- with base - T30099/1- .

– Position original spindle -A- on adapter - MP9-200/3 (10-222A/
3)- and hook it into the front engine lifting eye.
– Position the shortened spindle -B- on the rear adapter -
MP9-200/3 (10-222A/3)- .
116
– Hook the shackle - 10-222 A/12- into the rear engine lifting
eye.
– Then hook the shackle - 10-222 A/12- into the shortened spin‐
dle ⇒ page 116 .
Caution

-arrows-.
Note
Support supporting device - T30099- with base - T30099/1- and

lock carrier.

unhook freely.
freely.
Note

– If present, remove heat shield for right drive shaft -arrows-.


– Unscrew nuts -arrows- for left and right steering joint ⇒ Chas‐
sis; Rep. gr. 40 .
– Remove drive shafts from the flange shafts.
– Swivel out the wheel-bearing housing.
– Swivel the drive shafts into the wheelhouses and secure them
to the suspension struts, e.g. with a cord. Avoid damaging the
– Lower the assembly carrier in the service position ⇒ Chassis;
Rep. gr. 40 .

the gearbox mount.
118
Caution
The engine lifting eye must not touch the brake fluid reservoir
nor the brake lines.
be accessible.
Note

– Insert engine mount - 3282- into engine and gearbox jack . e.g.
-V.A.G 1383 A- .
as follows:
– Position adjusting plate - T30020- onto the gearbox mount -
adjusting plate .

justing plate .
plate.

mounts at gearbox.
wards.

Note


The installation of the gearbox occurs in reverse order. Observe
the stress-free assembly bracket in the vehicle.
120
– Before installing the gearbox press the clutch release lever

towards the gearbox housing and secure with mounting bolt
or screw M 8 x 35.
– After installing the gearbox release screw again. The hole is
then closed with the 3rd fixing screw for the cable support/
control cables.
Note
♦ Clean spline of drive shaft and apply a thin film of grease for
the plug serration of the clutch disc - G 000 100 - . The clutch
plate must slide freely up and down the drive shaft.
♦ When inserting the gearbox, slightly turn the engine for easy
insertion.
♦ Install gearbox mount ⇒ Engine; Rep. gr. 10 .

♦ Align the exhaust system, without tightening ⇒ Engine; Rep.
gr. 26 .
♦ Screw on the assembly carrier on vehicles with particle filter
(Fabia II, Roomster) ⇒ Chassis; Rep. gr. 40 .
♦ Installing starter and cable ⇒ Electrical System; Rep. gr. 27 .
♦ Install the left wheelhouse liner ⇒ Body Work; Rep. gr. 50 .
♦ Install left front wheel ⇒ Chassis; Rep. gr. 66 .
♦ Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
♦ Setting the shift mechanism
⇒ “1.12 Setting the shift mechanism”, page 86 .
♦ Check gear oil level ⇒ “3 Check gear oil level”, page 127 .
♦ Install air filter housing complete with air guide hose ⇒ Engine;
Rep. gr. 23 .
♦ Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
out certain additional operations ⇒ Electrical System; Rep. gr.
27 .

2.5.1 Tightening torques (Fabia II, Roomster)

Attach the gearbox to the 3 cylinder engine without particle filter
(flange fig. gearbox)
Pos. Screw Piece Nm
1 M12 x 50 2 80
21) M12 x 150 1 80
31) M12 x 150 1 80
41) M10 x 58 1 40
5 M10 x 50 1 40
6 M12 x 55 1 80
72) M6 x 8 1 10
2) Attachment of cover plate for flywheel.

Attach the gearbox to the 3 cylinder engine with particle filter
Pos. Screw Piece Nm
1 M12 x 50 1 80
21) M12 x 55 1 80
31) M12 x 150 2 80
41) M10 x 50 1 40
5 M10 x 50 1 40
6 M12 x 60 1 80
72) M6 x 8 1 10

Pos. Screw Piece Nm
1 M12 x 50 2 80
21) M12 x 150 2 80
3 M10 x 50 3 40
4 M12 x 55 1 80
52) M6 x 8 1 10
122

Pos. Screw Piece Nm
1 M12 x 50 1 80
21) M12 x 55 1 80
31) M12 x 150 2 80
41) M10 x 50 1 40
5 M10 x 50 2 40
6 M12 x 60 1 80
72) M6 x 8 1 10
Attach the gearbox to the 3 cylinder engine (1.2 ltr./55 kW TDI

CR) with particle filter (flange fig. gearbox)

Pos. Screw Piece Nm
1 M12 x 50 2 80
21) M12 x 150 2 80
3 M10 x 50 3 40
4 M12 x 60 1 80
52) M6 x 8 1 10
Pendulum support
Note
Position the screws -1- in the elongated holes of the pendulum

support in such a way that there is maximum distance between
the gearbox and the assembly carrier.

Gearbox console to gearbox1) 40 Nm + 90°
Fixing screws to gearbox mount1) 40 Nm + 90°
page 74
page 74
Slave cylinder to gearbox ⇒ “1.14 Summary of components - Hydraulic (Fabia
bracket for tube-hose line ⇒ “1.14 Summary of components - Hydraulic (Fabia


Fixing screws of engine mount ⇒ Engine; Rep. gr. 10
Pendulum support ⇒ Engine; Rep. gr. 10
Pre-exhaust pipe with catalytic converter and clamping ⇒ Engine; Rep. gr. 26
sleeve
Drive shaft to flange shaft ⇒ Chassis; Rep. gr. 40
Coupling rod to anti-roll bar ⇒ Chassis; Rep. gr. 40
Heat shield for drive shaft to engine ⇒ Chassis; Rep. gr. 40
Steering joint to track control arm ⇒ Chassis; Rep. gr. 40
Wheel bolts ⇒ Chassis; Rep. gr. 44
1) Always replace these bolts.
2.5.2 Tightening torques (Rapid)

Attach gearbox to engine (flange fig. gearbox)
Pos. Screw Piece Nm
1 M12 x 50 2 80
21) M12 x 150 2 80
3 M10 x 50 3 40
4 M12 x 60 1 80
52) M6 x 8 1 10
Pendulum support
Note


page 74
page 74
Slave cylinder to gearbox ⇒ “1.15 Summary of components - Hydraulic (Rapid)
”, page 44
bracket for tube-hose line ⇒ “1.15 Summary of components - Hydraulic (Rapid)
”, page 44
124

Flange shaft on gearbox (conical screw) ⇒ “2.1 Disassembling and assembling differential
gear”, page 196
2.6 Tightening torques (Rapid NH)

Attach gearbox to engine (flange fig. gearbox)
Pos. Screw Piece Nm
1 M12 x 50 2 80
21) M12 x 150 2 80
3 M10 x 55 3 40
4 M12 x 60 1 80
52) M6 x 8 1 10
Pendulum support
Note


page 74
page 74
Slave cylinder to gearbox ⇒ “1.14 Summary of components - Hydraulic (Fabia
bracket for tube-hose line ⇒ “1.14 Summary of components - Hydraulic (Fabia
Flange shaft on gearbox (conical screw) ⇒ “2.1 Disassembling and assembling differential
gear”, page 196


2.7 Transporting the gearbox

♦ Gearbox attachment device - MP3-478 (3336)-
– Screw down gearbox suspension device - MP3-478 (3336)-
onto clutch housing.

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

Number of visible holes = 5.
– Raise gearbox with workshop crane and gearbox suspension
device - MP3-478 (3336)- .
– Place down gearbox, e.g. in a transport container.
126
3 Check gear oil level

Gearbox oil specification ⇒ Electronic Catalogue of Original
Parts .
gr. 50 .
– Unscrew plug for inspecting gear oil -arrow-.
The oil is at the correct level if the gear is filled up to the lower
edge of the oil filler hole.
– Screw in gearbox inspection plug -arrow- and tighten to tight‐
ening torque
⇒ “5 Repairing gearbox housing and clutch housing”,
page 151 .
If re-filling, do the following:
– Unscrew gearbox oil filler threaded plug -arrow-.
– Pour in gear oil up to lower edge of filler hole.
– Screw in plug -arrow-.

– 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 the filler hole.
– Screw in gearbox inspection plug -arrow- and tighten to tight‐
ening torque
page 151 .
– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
3. Check gear oil level 127

4 Disassembling and assembling the

gearbox
⇒ “4.1 Gearbox overview”, page 128
⇒ “4.2 Summary of components”, page 129
⇒ “4.3 Removing and installing gearbox housing cover and 5th
gear”, page 130
⇒ “4.4 Removing and installing gearbox housing and shift mech‐
anism”, page 131
⇒ “4.5 Removing and installing the drive shaft, output shaft, dif‐
ferential gear and shift forks”, page 133
⇒ “4.6 Mounting sequence - Removing and installing gearbox
housing cover and 5th gear ”, page 134
⇒ “4.7 Mounting sequence - completely disassembling and as‐
sembling the gearbox”, page 139
4.1 Gearbox overview

1 - 1. gear
2 - 2. gear
3 - 3. gear
4 - 4. gear
5 - 5. gear
6 - Gearbox housing
❑ repairing
housing and clutch
housing”, page 151
7 - Shift mechanism
❑ Gearshift forks
❑ disassembling and as‐
sembling
⇒ “7 Disassembling and
assembling the gear‐
shift forks”, page 160
8 - Drive wheel for 1st gear
sliding gear and reverse gear
9 - Drive shaft
sembling
⇒ “1 Drive shaft”,
page 163
10 - Output shaft
sembling
⇒ “2 Output shaft”, page
174
sembling
⇒ “2 Differential gear ”, page 196
128
12 - Clutch housing
❑ repairing ⇒ “5 Repairing gearbox housing and clutch housing”, page 151
4.2 Summary of components

Mounting sequence - Removing and installing gearbox housing
cover and 5th gear
⇒ “4.6 Mounting sequence - Removing and installing gearbox
housing cover and 5th gear ”, page 134
Mounting sequence - completely disassembling and assembling
the gearbox
⇒ “4.7 Mounting sequence - completely disassembling and as‐
sembling the gearbox”, page 139
I - Removing and installing

gearbox housing cover and 5th
gear
⇒ “4.3 Removing and installing
gear”, page 130

II - Removing and installing
gearbox housing and shift
mechanism
III - Removing and installing
the drive shaft, output shaft,
differential gear and shift forks
differential gear and shift
forks”, page 133
4. Disassembling and assembling the gearbox 129

4.3 Removing and installing gearbox housing cover and 5th gear
1 - 18 Nm
❑ for cover to gearbox
housing
2 - Cover for gearbox housing
❑ as of 08.10, with magnet
on the inside ⇒ Elec‐
tronic Catalogue of
Original Parts
Note
If the gearbox housing cover is fitted

with the gearbox mounted, inspect
the gear oil level, if necessary top up
with gear oil
⇒ “3 Check gear oil level”,
page 127 .
3 - Gasket
4 - 80 Nm and torque a further

90°
❑ holds disc spring in po‐
sition with sleeve socket
on screw head
tronic Catalogue of
Original Parts
❑ Clean the threaded
holes for the fixing
screws of the synchron‐
izer body and the 5th
gear pinion using a
screw-tap in order to re‐
move locking agent res‐
idues; otherwise there is
a risk that the screws will
shear
5 - Disc spring
6 - 25 Nm
❑ for bearing pins on the gearbox housing
7 - Bearing pins
8 - 5th gear shift fork
❑ disassembling and assembling ⇒ “7 Disassembling and assembling the gearshift forks”, page 160
9 - Spring
❑ Fitting position ⇒ “1.1 Disassembling and assembling the drive shaft”, page 163
10 - 5th gear sliding sleeve
11 - Arresters
❑ (3 pieces)
130
12 - Synchronizer body with sliding gear and synchronizer ring for 5th gear
❑ remove separately
⇒ “4.6 Mounting sequence - Removing and installing gearbox housing cover and 5th gear ”, page 134
❑ remove together with gearbox housing
⇒ “4.7 Mounting sequence - completely disassembling and assembling the gearbox”, page 139
❑ disassembling and assembling ⇒ “1 Drive shaft”, page 163
13 - Needle bearing
❑ for 5th gear sliding gear
14 - 5th gear pinion
Cover for gearbox housing with magnet -A-

Magnet can only be inserted in the cover with recess -arrow-.

The magnet is held in the correct position on the installed cover
by a fixing screw for the carrier bolt of the 5th gear shift fork.
4.4 Removing and installing gearbox hous‐

ing and shift mechanism
♦ Sealant - AMV 188 200 03-

1 - 25 Nm
2 - Flange shaft with pressure
spring
⇒ “4.7 Mounting se‐
quence - completely dis‐
assembling and assem‐
bling the gearbox”, page
139
❑ complete
⇒ “2 Differential gear ”,
page 196
3 - 25 Nm
❑ for reverse shaft support
❑ self-locking
tronic Catalogue of
Original Parts
4 - 30 Nm
❑ self-locking
tronic Catalogue of
Original Parts
5 - O-ring
tronic Catalogue of
Original Parts
6 - Bearing pins
7 - 25 Nm
8 - 25 Nm
9 - Screw cap
❑ together with 5th gear!
11 - Screw, 5 Nm
12 - Transmission neutral sender - G701 -
❑ for vehicles with start-stop system (Fabia II, Roomster)
13 - Clutch housing
14 - 25 Nm and torque a further 90°
❑ for attaching the gearbox housing to the clutch housing
15 - Shift mechanism
❑ (Gearshift shaft with gearshift cover)
❑ repairing ⇒ “6 Repairing the gearshift mechanism on the gearbox side”, page 155
16 - 25 Nm
132
4.5 Removing and installing the drive shaft, output shaft, differential gear and
shift forks
sembling
⇒ “2 Differential gear ”,
page 196
2 - O-ring
❑ 4 pieces
tronic Catalogue of
Original Parts
3 - Output shaft
sembling
174
4 - reverse shaft support
sembling
⇒ “3 Reverse shaft”,
page 188
5 - Reverse shaft
sembling
⇒ “3 Reverse shaft”,
page 188
6 - Drive shaft
sembling
page 163
7 - Gearshift fork reverse gear
sembling
⇒ “7 Disassembling and
assembling the gearshift forks”, page 160
8 - 25 Nm
9 - Shift mechanism
❑ (Gearshift forks)
❑ disassembling and assembling ⇒ “7 Disassembling and assembling the gearshift forks”, page 160
10 - Clutch housing
❑ 4 nuts for bearing support
12 - Flange shaft with pressure spring
❑ complete ⇒ “2 Differential gear ”, page 196

13 - 25 Nm
4.6 Mounting sequence - Removing and in‐

stalling gearbox housing cover and 5th
gear
Note
♦ If it is intended to only remove the 5th gear, keep to the fol‐

lowing work sequence.
♦ For this work sequence, the gear oil must not be drained. Once
the gearbox housing cover is removed, the gearbox side must
point upwards without the removed cover.
♦ When wishing to remove the gearbox housing, follow the work
instructions for “completely disassembling and assembling the
gearbox”
⇒ “4.7 Mounting sequence - completely disassembling and
assembling the gearbox”, page 139 .


♦ Drive bushing - MP3-402 (VW 244 B)-
♦ Supporting bridge - MP3-425 (30-211 A)-
♦ Pressure washer - MP3-456 (VW 447 i)-
♦ Insertion tool - MP3-466 (32-111)-
♦ Assembly device - MP6-414 (3253)-
♦ Assembly stand - MP9-101-
♦ Assembly device - T10030-
♦ Extractor - T10309-
♦ Supporting bridge - T10323-
♦ Gearbox mount - T30108-
♦ Gearbox mount - T30109 (VW 353)-
♦ Two-arm extractor - Kukko 20/10- with extraction hook -
T10040/2A-
♦ Hot air blower e.g. -V.A.G 1416-
♦ Screw M 10 x 20 mm
134
4.6.1 Removing gearbox housing cover and

5th gear
– Secure the gearbox to the gearbox mount - T30109 (VW 353)-
with screws -arrows-.
– Remove clutch release lever with release bearing
⇒ “2 Repairing the clutch release mechanism”, page 56 .
• If the 5th gear is installed again, then the input shaft and output
shaft bearings must not be damaged.
• Therefore, while securing the gearbox to the gearbox mount -
T30109 (VW 353)- the following tools must be installed for
support:
Under the drive shaft:
♦ Thrust piece - T10030/4-
• The drive shaft must only be supported with the insertion tool
- MP3-466 (32-111)- at a later stage.
Under bearing support/output shaft:
♦ Pressure plate - MP6-414/7 (3253/7)- from assembly device -
MP6-414 (3253)-

– Unscrew the gearbox housing cover -arrow-.
– Check whether the extraction hooks - T10040/2A- can be cor‐

rectly positioned under the 5th gear pinion.
The extraction hooks - T10040/2A- cannot be correctly positioned.

-A- “Joint” disassembly of: “Synchronizer body
the extraction hooks - T10040/2A- come prematurely in 5. gear”, “notched wheel 5th gear” and “gearbox
contact with: housing”
♦ the gearbox housing wall ⇒ “4.7 Mounting sequence - completely disas‐
sembling and assembling the gearbox”,
♦ the ribbing of the gearbox housing below the 5th gear page 139
pinion
-B-
the extraction hooks - T10040/2A- come in contact with the
ribbing in the gearbox housing below the 5th gear pinion.
The extraction hooks - T10040/2A- can be correctly positioned.

The 5th gear can be removed separately ⇒ page 137 .
136
Remove 5th gear separately

Remove 5th gear shift fork as follows:
– Cover the openings with a cloth.
– Put shift fork -1- in Neutral position.
– Release screws -2- for bearing pins.
– Pull out bearing pins -direction of arrow A-.
– Remove 5th gear shift fork from the sliding sleeve in
-direction of arrow B-.
Note
The 5th gear sliding sleeve must not be removed.
– Unscrew screws -A- for synchronizer body and 5th gear pin‐
ion. To this end engage the 5th gear -arrow 1- and 1st gear
-arrows 2- and -3-.
The input and output shafts are blocked after introducing the two
gears, the synchronizer body and pinion cannot rotate. Now it is
possible to release the two bolts.
Note
If the shafts are not replaced, carefully clean the threaded holes
e.g. using a screw-tap in order to remove locking agent residues.
Pull off 5th gear synchronizer body together with sliding sleeve
and arresters.
Use extractor - T10309- .
– First of all insert a shell - T10309/1- between the 5th gear pin‐
ion -A- and the support of the 5th gear shift fork -B-.
• Half of the sleeve - T10309/1- must be attached underneath

the synchronizer ring 5. gear.
– If necessary, the shell must be pressed into the end position.
– Turn the shell - T10309/1- to the opposite side

– Insert the threaded insert - T10309/3- into the shell .

– Now insert the other half of the bushing - T10309/1- and place
the pipe - T10309/2- on the assembly device.
– Check the synchronizer body for damage after removing.
– Replace 5th gear synchronizer ring.
– Remove the 5th gear sliding gear with needle bearing.
– Remove the 5th gear pinion as follows:

– First of all insert the extraction hook -A-.
B - Screw M10 x 20, SW 17
– If necessary, heat the gear pinion using the hot-air blower -
V.A.G 1416- .
Note
♦ The 5th gear pinion can also be removed using the two-arm
extractor - Kukko 20/10- in combination with the extraction
hooks - T10040/2A- .
♦ When pulling off the gear pinion make sure the hooks do not
bend outwards. Check 5th gear for damage after removing.
4.6.2 Mount 5th gear and cover for gearbox

housing
Install 5th gear ⇒ “4.7.3 Install 5th gear”, page 147 .
– Mount the cover for the gearbox housing -arrow- and tighten
the screws to the specified tightening torque
gear”, page 130 .
– Mount clutch release lever with release bearing
– Pour in gear oil ⇒ “3 Check gear oil level”, page 127 .
138
4.7 Mounting sequence - completely disas‐

sembling and assembling the gearbox
Removing and installing cover for gearbox housing, clutch hous‐
ing, gearshift shaft with gearshift cover, drive shaft, output shaft,
differential gear and gearshift mechanism
♦ Driver - MP1-304 (10-206)-
♦ Drive bushing - MP3-402 (VW 244 B)-
♦ Assembly device - T10030-

♦ Extractor plate - T10408-
♦ Spacer (5 pieces) - T10408/1-
♦ Thrust piece (2 pieces) - T10408/2-
♦ Hanger (2 pieces) - T10408/3-
♦ Extractor (2 pieces) e.g. -Kukko 18/1-
♦ Hot air blower e.g. -V.A.G 1416-
♦ Sealant - AMV 188 200 03-
♦ Bolts M 8 x 100 mm
4.7.1 Disassembling gearbox

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

– Secure the gearbox to the gearbox mount - T30109 (VW 353)-

with screws -arrows-.
– Removing the clutch release lever, clutch release bearing and
guide bushing
• The bearing of the input shaft and of the output shaft must not
be damaged when removing and installing the 5th gear.

T30109 (VW 353)- the following devices must be installed for
support:
• Lock the screw of the supporting bridge - MP3-425 (30-211
A)- with the nut -A-.
♦ Pressure plate - MP6-414/7 (3253/7)- from assembly device -
MP6-414 (3253)-
140

– Remove 5th gear shift fork from the sliding sleeve in
-direction of arrow B-.
Note
– Unscrew
screws -A- for synchronizer body and 5th gear pinion. To this
end engage the 5th gear -arrow 1- and 1st gear -arrows 2- and
-3-
.
– The input and output shafts are blocked after introducing the
two gears, the synchronizer body and pinion cannot rotate.

Now it is possible to release the two bolts.
Note
– Remove both flange shafts. To do so secure the flange shaft

with a drift to prevent it from turning and release screw.
– Remove both flange shafts with pressure springs, stop discs
and conical rings.
– Release both screws -arrows- for support/reverse shaft.


– Gearboxes for vehicles with start/stop system: Remove trans‐

mission neutral sender - G701- -arrow-.
– Remove gearshift shaft with cover Put the gearshift shaft into
Neutral. Subsequently unscrew screws -arrows- and remove
the gearshift shaft from the gearbox housing.
– Remove screws -arrows- from the cap -A- and the bearing pins
-B- at the bottom of the gearbox.
– Carefully remove the screw cap -A- with driver -MP1-304

(10-206) - and hammer -B-.
142
– Release screws -A-, that serve to secure the gearbox housing

from the clutch housing.
Note
Do not remove nuts -B- for the output shaft bearing support.
– Remove bearing pins -A- on the top side of the gearbox and
fixing screws -B- for the gearbox housing on the clutch housing
near the differential gear.
Remove the following components together with the gearbox
housing:
♦ 5th gear synchronizer body

♦ 5th gear pinion
♦ Two hangers - T10408/3- must be attached to the 5th gear
pinion
♦ If is required that the hangers are always fitted above 2 re‐
cesses of the housing, which are opposite each other
-arrows-
Note
♦ The needle bearing is located under the 5th gear pinion.

♦ Detach the gearbox housing in such a way that it does not
come in contact with the 5th gear pinion and attach the hang‐
ers.
Use the extractor plate - T10408- in combination with the following

devices:
♦ Spacers - T10408/1- (5 pieces)
♦ Pressure pieces - T10408/2 - (2 pieces)
♦ Hangers - T10408/3 - (2 pieces)
♦ Extractors Kukko 18/1 (2 pieces)
– Tighten the 5° spacers - T10408/1- in the threaded bores of
the cover for the gearbox housing.
– Screw the extractor plate - T10408- on the spacers -
T10408/1- .
A - Screws M7 x 35 with washers
Tightening torque - 18 Nm

– Position the pressure pieces - T10408/2- onto the shafts.

– 2 Mount the extractor -A-, e.g. -Kukko 18/1- .
– Remove 5th gear synchronizer body, 5th gear pinion and
gearbox housing by alternatively tightening the spindles -A-
(1/2 turn) of the extractors , e.g. -Kukko 18/1- , -Kukko 18/1- .
Note
♦ Press off gear pinion for 5th Heat gear with hot-air blower
where necessary, e.g. - V.A.G 1416- .
♦ Check the securing mechanism for the needle bearing/output
shaft. If the 3 caulks are damaged, the needle bearing was
shifted during the removal and must be replaced
page 151 .
– Remove shift forks -A- together with shift rails.

– Unscrew shift mechanism/reverse gear -B-.
– Release nuts -B- for the bearing support/output shaft.
– Successively remove the reverse gear -A-, drive shaft -B- and
output shaft -C- from the clutch housing.
– Remove differential gear.
144
4.7.2 Assembling gearbox

– Insert differential gear.
– Always replace O-rings -arrows- for bearing support/output
shaft ⇒ Electronic Catalogue of Original Parts .
Note
The figure only shows 3 of the 4 O-rings.
– Insert together the drive shaft -1- and the drive shaft -2-.
– Tighten nuts for the bearing support/output shaft to tightening
torque ⇒ “2 Output shaft”, page 174 .
– Position the reverse pinion -3- on the needle bearing in the
clutch housing.
The shoulder -arrow- points away from the clutch housing.
– Check if the reverse shaft -4- is complete
⇒ “3.1 Disassembling and assembling the reverse shaft”, page
188 ; do not yet position the reverse shaft support onto the
reverse shaft.
– Insert the reverse shaft in the clutch housing.
– Clean all threaded holes in the reverse shaft support to remove
locking agent; clean with a screw-tap.
– Position reverse shaft support on the reverse shaft.
– Install the reverse gear shift fork -1- with the support for re‐
verse gear shift fork -2-, the spring -3- and the sliding shoe
-4-.
Fitting location of reverse gear

– Tighten screw -B- for shift mechanism/reverse gear to the

specified tightening torque
⇒ “4.5 Removing and installing the drive shaft, output shaft,
differential gear and shift forks”, page 133 .
– Install shift forks -A- together with shift rails.
– Screw the pin screw -A- M8 x 100 mm in the reverse shaft

support, to ensure it is aligned once the gearbox housing has
been fitted.
– Align shift rails.
Note

The shift segments must be positioned in the slots of the sliding
sleeves.
– Apply sealant - AMV 188 200 03- uniformly on the sealing sur‐
face of the clutch housing.
– Attach the gearbox housing and tighten fixing screws to the
given tightening torque
⇒ “4.4 Removing and installing gearbox housing and shift
mechanism”, page 131 .
Insert the screws for the reverse shaft support -arrow- as follows:
– Insert screw -a-, unscrew pin screw M 8 x 100 mm (⇒ fig.
S34-0314) from the reverse shaft support, insert screw -b- and
tighten by hand.
Tightening sequence:
1- Screw -a- 30 Nm (M8 x 32)
2- Screw -b- 25 Nm (M8 x 26)
– Fit bearing pins -arrow- for shift forks. Align the shift mecha‐
nism with a screwdriver to ensure the relevant bearing pin can
be fitted.
face of the screw cap.
– Fit gearshift shaft cap and tighten screws to tightening torque
146
Install the gearshift shaft as follows:

– Put the shift rails in neutral position.
face of the gearshift cover.
– Position the peg -arrow 1- in the recess of the gearbox hous‐
ing. Align the gearshift shaft in such a way that the shift finger
-arrow 2- is inserted in the shift rails.
– Fit gearshift shaft cover and tighten screws to tightening tor‐
que
– Gearboxes for vehicles with the Start/stop system: Insert gear‐

box neutral position sender - G701- -arrow- and tighten fixing
screw
mechanism”, page 131 -Pos. 11- to the specified tightening
torque.
– Install both flange shafts with pressure springs, stop discs and
conical rings.
4.7.3 Install 5th gear

• Make sure that the supporting bridge - MP3-425 (30-211 A)-
and the supporting bridge - T10323- are installed.
– Lock the screw of the supporting bridge - MP3-425 (30-211
A)- with the nut -A-.

Fitting position of the 5th gear pinion

The round slot -arrow- points to the gearbox housing.
– Heat the 5th gear pinion to approx. 100°C.
WARNING
Wear protective gloves!
– Drive in 5th gear pinion
Checking 5th gear synchronizer ring for wear

– Press the synchronizer ring on the cone of the sliding gear and
measure the clearance -a- with a feeler gauge before installing
the sliding gear and the 5th gear snychronizer ring.
Installation dimen‐ Wear limit
sion
Clearance -a- 1.1 … 1.7 mm 0.5 mm
– Mount the 5th gear sliding gear with needle bearing.
– Position the 5th gear synchronizer ring on the sliding gear.
– If disassembled, assemble the 5th gear synchronizer body/
sliding sleeve before installation
⇒ “1 Drive shaft”, page 163 .
Fitting position of the 5th gear synchronizer body/sliding sleeve

The sharp teeth of the sliding sleeve -arrow 1- and the high collar
of the synchronizer body -arrow 2- point towards the gearbox
housing.
The supports -arrow 3- of the synchronizer body are on the same
line as the integrated arresters of the synchronizer ring (arrows in
Fig. N35-0018 ⇒ page 149 ).
148
5th gear synchronizer ring with integrated arresters -arrows-

– Cover all openings in the gearbox housing with a cloth so that
no foreign bodies can get into the gearbox.
– Heat 5th gear synchonizer body to approx. 100 °C.
WARNING
– Drive in 5th gear synchronizer body/sliding sleeve.
Note
Pay attention to the free travel of the synchronizer ring during the
driving in operation.
– Remove supporting bridge - MP3-425 (30-211 A)- and sup‐

porting bridge - T10323- .
If it is not yet performed, clean the threaded holes of the fixing
screws for the 5th gear synchronizer body and the 5th gear pinion
Otherwise there is a risk that the screws will shear.
Fitting position of the disc springs for fixing screws on the 5th gear
pinion and synchronizer body
The curved side (concave side) -arrows- points to the screw head.

– Screw in new screws -A- for the synchronizer body and the 5th
gear pinion and tighten to tightening torque
gear”, page 130 . To this end engage the 5th gear -arrow 1-
and 1st gear -arrows 2- and -3-.
gears, the synchronizer body and 5th gear pinion cannot rotate.
Now it is possible to tighten the two bolts.
– Fit 5th gear shift fork.
Set 5th gear as follows:

– Engage 5th gear.
– Release screw -1-. Press the sliding sleeve and the gear shift
gate in the -direction of the arrow-.
– Tighten screw -1- to tightening torque
⇒ “7 Disassembling and assembling the gearshift forks”, page
160 .

• Control measurement when 5th gear is engaged: A 0.2 mm
feeler gauge must not be able to be inserted between the slid‐
ing sleeve and sliding gear. If necessary, repeat the adjust‐
ment procedure.
– Remove 5th gear. The sliding sleeve must now be in Neutral.
The 5th gear synchronizer ring must move freely.
– Shift through all gears consecutively.
– Mount the cover for the gearbox housing -arrow- and tighten
the screws to the specified tightening torque
gear”, page 130 .
– Installing the guide bushing for clutch release lever and clutch
release bearing
– Pour in gear oil ⇒ “3 Check gear oil level”, page 127 .
150
5 Repairing gearbox housing and

clutch housing
♦ Drift - MP3-403 (VW 295)-
♦ Adapter - MP3-403/1 (VW 295 A)-
♦ Thrust piece - MP3-411 (VW 454)-
♦ Multi-purpose tool - MP3-419 (VW 771)-
♦ Pipe section - MP3-450 (VW 415A)-
♦ Pressure washer - MP3-455 (VW 447 H)-
♦ Pressure washer - MP3-460 (VW 512)-
♦ Thrust piece - T10148-
♦ Sealant - AMV 188 200 03-
1 - Gearbox housing
❑ when used: Adjust drive
shaft and differential
gear
⇒ “3 Setting overview”,
page 205
2 - Oil filler plug, 30 Nm
3 - Needle bearing
❑ for output shaft
❑ extracting ⇒ page 153
❑ fitting and securing
⇒ page 153
4 - Adjusting washer
❑ for drive shaft
❑ Setting overview
⇒ “3 Setting overview”,
page 205
5 - Outer ring/tapered-roller
bearing
❑ for drive shaft
page 163
❑ when used: Setting
drive shaft
⇒ “1.2 Setting drive
shaft”, page 169
bearing
174
❑ when used: Setting output shaft ⇒ “2.2 Setting output shaft”, page 184
5. Repairing gearbox housing and clutch housing 151

❑ Setting overview ⇒ “3 Setting overview”, page 205
8 - Outer ring/tapered-roller bearing
❑ for drive shaft
❑ removing and installing ⇒ “1 Drive shaft”, page 163
❑ when used: Setting drive shaft ⇒ “1.2 Setting drive shaft”, page 169
9 - Needle bushing
❑ removing and installing ⇒ “3 Reverse shaft”, page 188
10 - Fitting sleeve
❑ 2 pieces
11 - Clutch housing
❑ when used: Setting overview ⇒ “3 Setting overview”, page 205
❑ grease with grease for plug serration of clutch disc - G 000 100-
13 - Guide bushing

❑ with gasket ring for drive shaft and vulcanized O-ring
❑ Driving out gasket ring ⇒ page 153
❑ Driving in gasket ring ⇒ page 153
❑ to replace gasket ring, remove guide bushing
❑ if O-ring is damaged, replace guide bushing and O-ring together ⇒ Electronic Catalogue of Original Parts
14 - 20 Nm
15 - Gasket ring with bushing
❑ for right flange shaft
❑ replace gasket ring together with bushing in the event of damage
⇒ “1.2 Replace gasket ring for right flange shaft (gasket ring and bushing are one component)”,
page 193
16 - Screw plug, 5 Nm
❑ is installed instead of the drive for speedometer on vehicles with ABS
17 - Drive for speedometer, 10 Nm
❑ only mounted on vehicles without ABS
18 - Oil drain plug, 30 Nm
❑ for differential gear
❑ removing and installing ⇒ “2 Differential gear ”, page 196
❑ when used: Adjusting differential gear ⇒ “2.2 Adjusting the differential gear”, page 202
20 - Magnet
❑ is held in position by the separator surface of the housing
❑ removing and installing ⇒ “2 Differential gear ”, page 196
❑ when used: Adjusting differential gear ⇒ “2.2 Adjusting the differential gear”, page 202
❑ Setting overview ⇒ “3 Setting overview”, page 205
152
23 - Sealing ring
❑ for left flange shaft
❑ Renew. ⇒ “1 Replacing the flange shaft gasket rings (gearbox assembled)”, page 191 .
Driving out needle bearing
Drive in needle bearing up to stop

– Using a drift secure needle bearing in 3 points in the gearbox

housing with 120° offset.
Driving out the guide bushing
Driving the gasket ring into the guide bushing up to the stop

Remove bushing with gasket ring

A leg is located in the inner diameter of the bushing.
– Position the extraction hook - MP3-419/37 (VW 771/37) - of
the multi-purpose tool - MP3-419 (VW 771)- directly behind
the leg in the bushing.
– Press the extraction hook - MP3-419/37 (VW 771/37)- force‐
fully into the bushing during the extraction process.
Insert bushing with gasket ring

– Clean point for gasket ring in gearbox.
-A- Screw spindle of assembly device - MP3-434 (3066)- into
the threaded part of the differential gear.
-B- Nut M12
– By turning the nut -B- insert the bushing with the gasket ring
over the pressure plate - T10148 - up to the stop.
Note
If the gearbox is disassembled press in the bushing with the gas‐

ket ring over the pressure plate - T10148- up to the stop.
154
6 Repairing the gearshift mechanism

on the gearbox side
⇒ “6.1 Disassembling and assembling the gearshift mechanism
on the gearbox side (gearshift shaft can be removed from gear‐
shift cover)”, page 155
⇒ “6.2 Disassembling and assembling the gearshift mechanism
on the gearbox side (gearshift shaft cannot be removed from
gearshift cover)”, page 158
6.1 Disassembling and assembling the

gearshift mechanism on the gearbox
side (gearshift shaft can be removed
from gearshift cover)
♦ Pressure plate - MP3-406 (VW 401)-
♦ Pressure spindle - MP3-448 (VW 408 A)-
♦ Guide piece - MP3-454 (VW 439)-
♦ Pressure washer - MP3-456 (VW 447 I)-

♦ Pipe section - MP3-479 (VW 423)-
♦ Interior extractor 18,5…23,5 mm , e.g. -Kukko 21/3-
Note
♦ Grease bearing points and friction surfaces.

♦ Assign the grease via the ⇒ Electronic Catalogue of Original Parts .
6. Repairing the gearshift mechanism on the gearbox side 155

1 - Gearshift shaft
❑ when shifting from the
5th gear to the 4th gear,
the screw Pos. 5 guides
the gearshift shaft into
the 4th gear gate via the
leg -arrow-
❑ pay attention to correct
assignment ⇒ Electron‐
ic catalogue of original
parts
2 - Stop ring
3 - Ball sleeve
❑ inserting ⇒ page 157
4 - Shift cover
❑ with locking angle for
setting the gearshift
mechanism
❑ Remove locking angle
⇒ page 159
❑ Press in locking angle
⇒ page 159
parts
5 - 15 Nm
6 - Reversing light switch - F4- ,
20 Nm
❑ Grease peg lightly with
of clutch disc -
G 000 100-
7 - Reversing lever
❑ Fitting position ⇒ “1.8 Summary of components - Control cables”, page 74
❑ as of 06.07 the relay lever is made of plastic (Fabia II, Roomster, Rapid NH)
❑ Remove and install plastic relay lever together with cable lock (Fabia II, Roomster, Rapid NH)
⇒ “1.9.1 Removing and installing plastic relay lever”, page 78
❑ If the relay lever is made of plastic, neither the bushings pos. 8 nor the lock washer pos. 13 are required
8 - Bushing
9 - Sealing ring
❑ lever out with screwdriver
❑ Fill half the space between the sealing lips and dust lips with sealing grease - G 052 128 A1-
10 - Cap
❑ for gearbox bleeder
11 - 20 Nm
❑ insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft
156
❑ may be replaced with the gearshift mechanism mounted
13 - Lock washer
❑ replace after each disassembly ⇒ electronic catalogue of original parts
14 - Screw cap
15 - Spring
❑ if present, insert in the screw cap Pos. 14
Remove the ball sleeve from the cover

– Before pulling out the ball sleeve destroy the platic cage and
remove the balls.
A - Interior extractor 18,5…23,5 mm , e.g. -Kukko 21/3-
Press the ball sleeve flush into the gearshift cover
Press in the gasket up to the stop.

6.2 Disassembling and assembling the gearshift mechanism on the gearbox

side (gearshift shaft cannot be removed from gearshift cover)
Note

1 - Gearshift unit
❑ consisting of the gear‐
shift shaft and the gear‐
shift cover
❑ Parts cannot be separa‐
ted
2 - Reversing light switch - F4- ,
20 Nm
of clutch disc -
G 000 100-
3 - Locking angle
❑ for setting the gearshift
mechanism
4 - Reversing lever
⇒ “1.8 Summary of com‐
ponents - Control ca‐
bles”, page 74
(Fabia II, Roomster,
Rapid NH)
installing plastic relay
lever”, page 78 , (Rapid)
installing shift mecha‐
nism (Rapid) ”, page 84
mechanism
5 - Clip
❑ for relay lever with hole in the bearing shaft
6 - Gasket for gearshift shaft
❑ release with a screwdriver
7 - 20 Nm
8 - Gearshift lever
158
9 - Cap
10 - Screw cap
11 - Spring
❑ if present, insert in the screw cap
Remove locking angle -A- from gearshift cover

– Remove the outer part of the locking angle.
– Then lever out the locking angle carefully with a screwdriver.
Press locking angle -A- into gearshift cover

Fitting position:
The marking -arrow- points to the upper part of the gearshift shaft.


gearshift forks
♦ Driver - MP1-304 (10-206)-
♦ Distance sleeve - MP3-458 (VW 472)-
♦ Removal tool for inner lining of the door panel - MP8-602/1-
Note
♦ Removing and installing gearshift fork group Pos. 7

⇒ “4.7 Mounting sequence - completely disassembling and assembling the gearbox”, page 139 .

♦ The gearshift fork group (Pos. 7 need not to be disassembled for the disassembly and assembly of the shift
segments, circlips and angular ball bearings.
1 - Shift segment for 5th gear

❑ Identification
⇒ page 161
❑ It must still be possible
to rotate the shift seg‐
ment freely once the cir‐
clip has been fitted
2 - Circlip
tronic Catalogue of
Original Parts
❑ adjust
⇒ “4.7.3 Install 5th
gear”, page 147
4 - 25 Nm
6 - Angular ball bearing
❑ 4 pieces
7 - Gearshift fork group with
shift rails
8 - 1st/2nd gear shift segment
❑ Identification
⇒ page 161
160

9 - 3rd/4th gear shift segment
❑ Identification ⇒ page 161
❑ It must still be possible to rotate the shift segment freely once the circlip has been fitted
10 - Sliding block
❑ Mushroom shape
11 - Spring
13 - Support for reverse gear shift fork
14 - Circlip
Identification of shift segments

Dimension -a-
1 - Shift segments 1st and 2nd gear = 11.4 mm
2 - Shift segments 3rd and 4th gear = 7.6 mm
3 - Shift segments 5th gear = 6.0 mm
Removing the circlip

– Secure the shift fork in a vice fitted with protective jaws -B-.
– Lift off the circlip -A- in -direction of the arrow-.
Fitting the circlip

– Press the circlip with a handle wrench into the slot of the shift
segment.
Note
It must still be possible to rotate the shift segment freely once the
circlip has been fitted.
-A- - Handle wrench, wrench size 10 mm

-B- - Protective jaws
7. Disassembling and assembling the gearshift forks 161

Removing the angular ball bearing
Note
Do not bend the shift forks when removing and installing the an‐
gular ball bearings.
Insert the angular ball bearing up to the stop into the gearshift fork
The recess in the pressure plate - T30100/1- points towards the
ball bearing.
Shift fork with fitted shift segments

Dimension -a- (mm)
Gearshift fork for 1st and 2nd gear 88.4 … 89.1
Gearshift fork for 3rd and 4th gear 96.0 … 96.7
Shift segment assignment ⇒ page 161
162
35 – Gears, shafts
1 Drive shaft
⇒ “1.1 Disassembling and assembling the drive shaft”,
page 163
⇒ “1.2 Setting drive shaft”, page 169

drive shaft
♦ Pressure spindle - MP3-408 (VW 412)-
♦ Thrust piece - MP3-411 (VW 454) -

♦ Separating device 12…75 mm , e.g. -Kukko17/1-
Note
♦ Removing and installing drive shaft

♦ When installing new pinions or a new drive shaft, pay attention to the technical data Fabia II
⇒ “2.1 Identification characters, aggregate assignment (Fabia II)”, page 2 , Roomster
⇒ “2.2 Identification characters, aggregate assignment (Roomster)”, page 3 , Rapid
⇒ “2.3 Identification characters, aggregate assignment (Rapid)”, page 3 and Rapid NH
⇒ “2.4 Identification characters, aggregate assignment (Rapid NH)”, page 3 .
♦ If the position of the tapered-roller bearing is influenced when parts are replaced the drive shaft must be
reset. Setting overview ⇒ “3 Setting overview”, page 205 .
♦ Replace both tapered-roller bearings together.
1. Drive shaft 163

1 - Clutch housing
bearing
❑ pressing out
⇒ page 165
3 - Inner ring/tapered-roller
bearing
❑ pressing off
⇒ page 166
❑ pressing on
⇒ page 166
4 - Drive shaft
❑ adjust
⇒ “1.2 Setting drive
shaft”, page 169
5 - 3rd gear pinion
❑ pressing off
⇒ page 166
❑ pressing on
⇒ page 167
❑ Fitting position: Collar
points towards the slid‐
ing gear, 4th gear
6 - Circlip
tronic Catalogue of
Original Parts
7 - 4th gear pinion
❑ pressing off with inner
ring/tapered-roller bear‐
ing and bushing
⇒ page 166
❑ pressing on ⇒ page 167
❑ Fitting position: Collar points towards the sliding gear, 3rd gear
8 - Inner ring/tapered-roller bearing
❑ pressing off with 4th gear pinion and bushing ⇒ page 166
9 - Thrust washer
❑ pressing out ⇒ page 168
❑ Determine thickness ⇒ “1.2 Setting drive shaft”, page 169
13 - Bushing
❑ for 5th gear needle bearing
❑ pressing off with 4th gear pinion and inner ring/tapered-roller bearing ⇒ page 166
❑ insert thrust washer Pos. 9 before assembly
164 Rep. gr.35 - Gears, shafts

14 - Needle bearing
❑ for 5th gear
15 - 5th gear sliding gear
16 - 5th gear synchronizer ring
❑ with integrated arresters ⇒ “4.7.3 Install 5th gear”, page 147
❑ check for wear ⇒ “4.7.3 Install 5th gear”, page 147
17 - Spring
❑ Fitting position ⇒ page 169 and ⇒ page 169
18 - Arresters
❑ (3 pieces)
19 - 5th gear synchronizer body
❑ remove separately ⇒ “4.6.1 Removing gearbox housing cover and 5th gear”, page 135
❑ installing ⇒ “4.7.3 Install 5th gear”, page 147
❑ remove with 5th gear synchronizer body Pos. 19

❑ Assembling sliding sleeve/5th gear synchronizer body ⇒ page 169
21 - Disc spring
❑ Fitting position ⇒ “4.7.3 Install 5th gear”, page 147
❑ holds disc spring in position with sleeve socket on screw head
Pressing out outer ring/tapered-roller bearing
Pressing on outer ring/tapered-roller bearing
1. Drive shaft 165

Pressing off inner ring/tapered-roller bearing

-A- - separating device 12…75 mm e.g. -Kukko17/1-
Press on inner ring/tapered-roller bearing
Pressing off 4th gearwheel with tapered-roller bearing and bush‐

ing
Pressing off 3rd gear pinion

– Prior to this remove the circlip.

Pressing on 3rd gear pinion
Pressing on 4th gear pinion

Collar points to the 3rd gear.
Press on bushing for 5th gear needle bearing
1. Drive shaft 167


– After setting the drive shaft insert with adjusting washer.
5th gear synchronization

1- Springs for arresters
2- Sliding sleeve with 3 recesses -arrows A- for the arresters
-4-
3- Synchronizer body
4- Arresters (Fitting location: Leg -arrow B- points to the sharp
teeth of the sliding sleeve -2-)

Assembling sliding sleeve/5th gear synchronizer body

– Slide the sliding sleeve over the synchronizer body.
The sharp teeth -A- of the sliding sleeve and the collar -B- of the
synchronizer body point in the same direction.
The recesses for the arresters in the sliding sleeve and the syn‐
chronizer body must be positioned above one another
⇒ page 168
– Insert arresters (Fitting location: ⇒ page 168 ).
– Mount the springs with 120° offset under the shoulder -C-. The
angled ends of the spring must be located before the arresters
-arrows-.
Note
Observe the correct position of springs on the arresters which are

hollow inside ⇒ page 169 .
Springs bent at right angles -A- for the 5th gear synchronisation

These springs are installed on both sides.
– The springs can only be installed on previous gearboxes to‐
gether with arresters, which are hollow inside.
– Insert arresters (Fitting location ⇒ page 168 ).
Fitting location of the springs:

– Mount the springs with 120° offset.
– The angled end -A- of the spring must grip into the hollow ar‐
rester and at the same time be located below the shoulder
-B- of the arresters.
The end bent at right angles always points away from the syn‐
chronizer body -direction of arrow-.
1.2 Setting drive shaft

(Determine adjusting washer for drive shaft)
♦ Gauge block plate - MP3-405/17-
♦ Universal dial gauge holder - MP3-447 (VW 387)-
1. Drive shaft 169

♦ Dial gauge
The drive shaft must be re-set when the following components
are replaced:
♦ Gearbox housing
♦ Clutch housing
♦ Drive shaft
♦ 4th gear pinion
or the
♦ Tapered-roller bearing
Setting overview ⇒ “3 Setting overview”, page 205 .
Note
Sealing surfaces of clutch and gearbox housing must be removed

of sealant residues.
– Press the outer ring/tapered-roller without adjusting washer up

to the stop into the gearbox housing.
– Press the outer ring/tapered-roller bearing up to the stop into

the clutch housing.
– Insert drive shaft in the clutch housing and install gearbox
housing. Tighten screws to tightening torque
– Fit measuring device and dial gauge in the clutch housing.

– Turn the drive shaft several times before measuring to ensure
the tapered-roller bearings set. Set the dial gauge to “0” with
1 mm bias.
Note
This procedure must be repeated before each subsequent meas‐

urement, because otherwise the dial gauge does not return to its
initial setting to “0”.

– Press drive shaft towards the dial gauge -direction of arrow-.

– Read off play on dial gauge and note (in the example = 1.21
mm).
Note
The dial gauge does not return to its initial position.
1.2.1 Determine thickness of the adjusting

washer
Example:
Measured value of bearing play Thickness of the adjusting
washer according to the table
1.21 mm 1.175 mm
1. Drive shaft 171

– Remove drive shaft and press out outer ring/tapered-roller

bearing from the gearbox housing with thrust washer -
MP3-456 (VW 447 I)- .
– Determine the adjusting washer thickness from the table
⇒ page 172 (example 1.175 mm).
Adjusting washer table
Bearing clearance Adjusting washer
Measured value (mm) Thickness (mm)
0.671 … 0.699 0.650
0.700 … 0.724 0.675
0.725 … 0.749 0.700
0.750 … 0.774 0.725
0.775 … 0.799 0.750
0.800 … 0.824 0.775
0.825 … 0.849 0.800
0.850 … 0.874 0.825
0.875 … 0.899 0.850
0.900 … 0.924 0.875
0.925 … 0.949 0.900
0.950 … 0.974 0.925
0.975 … 0.999 0.950
1.000 … 1.024 0.975
1.025 … 1.049 1.000
1.050 … 1.074 1.025
1.075 … 1.099 1.050
1.100 … 1.124 1.075
1.125 … 1.149 1.100
1.150 … 1.174 1.125
1.175 … 1.199 1.150
1.200 … 1.224 1.175
1.225 … 1.249 1.200
1.250 … 1.274 1.225
1.275 … 1.229 1.250
1.300 … 1.324 1.275
1.325 … 1.349 1.300
1.350 … 1.374 1.325
1.375 … 1.399 1.350
1.400 … 1.424 1.375
1.425 … 1.449 1.400
1.450 … 1.474 1.425
1.475 … 1.499 1.450
1.500 … 1.524 1.475
1.525 … 1.549 1.500
1.550 … 1.574 1.525
1.575 … 1.599 1.550
1.600 … 1.624 1.575
1.625 … 1.649 1.600
1.650 … 1.674 1.625
1.675 … 1.699 1.650
1.700 … 1.724 1.675
Note
Assign the adjusting washers via the ⇒ Electronic Catalogue of

Original Parts .

– Press outer ring/tapered-roller bearing with thrust washer -

MP3-413 (VW 510)- into the gearbox housing together with
the adjusting washer (in the example 1.175 mm).
– Position the gearbox housing and tighten screws to the given
tightening torque
1.2.2 Control measurement

– Insert measuring device and dial gauge.
– Turn the drive shaft several times to ensure the tapered-roller
bearings set.
– Press drive shaft in the -direction of the arrow-.
– The bearing clearance must be min. 0.01…max. 0.09 mm.
Note
If no bearing clearance can be measured, however the drive shaft

has a tangible valve rock and can easily be turned, then the set‐
ting is also OK.
1. Drive shaft 173

2 Output shaft
⇒ “2.1 Disassembling and assembling the output shaft”,
page 174
⇒ “2.2 Setting output shaft”, page 184
2.1 Disassembling and assembling the out‐

put shaft
♦ Press-on sleeve - MP3-412 (VW 455)-
♦ Pressure spindle - MP3-423 (VW407)-
♦ Pressure spindle - MP3-449 (VW 409) -

♦ Pipe section - MP3-450 (VW 415 A)-
♦ Thrust ring - MP3-452 (VW 429)-
♦ Alignment rails - MP3-457 (VW 457) -
♦ Tapered-roller bearing extractor - V.A.G 1582-
♦ Gripper - V.A.G 1582/4-
♦ Interior extractor , e.g. -Kukko 21/6-
♦ Countersupport , e.g. -Kukko 22/2-
♦ Separating tool , e.g. -Kukko 17/2-
♦ Feeler gauge
♦ Bolt M10 x 20
Note
♦ When installing new pinions or a new drive shaft, pay attention to the technical data Fabia II
⇒ “2.1 Identification characters, aggregate assignment (Fabia II)”, page 2 , Roomster
⇒ “2.2 Identification characters, aggregate assignment (Roomster)”, page 3 , Rapid
⇒ “2.3 Identification characters, aggregate assignment (Rapid)”, page 3 and Rapid NH
⇒ “2.4 Identification characters, aggregate assignment (Rapid NH)”, page 3 .
♦ Removing and installing output shaft
The output shaft can be disassembled as follows:

– Insert separating device under 2nd gear sliding gear Pos. 21
and press off as shown ⇒ page 178 .

– Remove circlip Pos. 17.

– Press off sliding sleeve with 1st and 2nd gear synchronizer
body as shown in ⇒ page 179 .

90°
❑ 4 nuts for bearing sup‐
port Pos. 9
tronic Catalogue of
Original Parts
2 - Clutch housing
❑ Determine thickness
⇒ “2.2 Setting output
shaft”, page 184
bearing small
❑ pressing on
⇒ page 178
bearing small
❑ Pulling off ⇒ page 178
❑ pressing on
⇒ page 178
6 - Output shaft
❑ adjust
⇒ “2.2 Setting output
shaft”, page 184
bearing large
❑ pressing on
⇒ page 179
8 - O-ring
❑ Position O-rings (4 pieces) on the bearing support screws
9 - Bearing support
❑ with outer ring/tapered-roller bearing large and with screws
❑ Always replace outer ring together with tapered-roller bearing large and bearing support
10 - Thrust washer
❑ Shoulder of thrust washer points to the tapered-roller bearing Pos. 7
11 - 1st gear sliding gear
12 - Needle bearing
❑ for 1st gear
13 - Synchronizer ring
❑ (Inner ring for 1st gear)
❑ check for wear ⇒ page 180
2. Output shaft 175

❑ Check pegs for traces of wear
14 - Outer ring for 1st gear
❑ place onto the inner ring Pos. 13
❑ replace if there are any traces of scoring or friction
15 - 1st gear synchronizer ring
16 - Sliding sleeve with 1st and 2nd gear synchronizer body
❑ after removing the circlip Pos. 17 press off with bearing support Pos. 9 ⇒ page 179
❑ disassembling ⇒ page 180
❑ Assembling sliding sleeve/synchronizer body ⇒ page 180 , ⇒ page 181 and ⇒ page 181
17 - Circlip
18 - 2nd gear synchronizer ring
❑ insert in such a way that the recesses lock into the arresters of the sliding sleeve Pos. 16
19 - Outer ring for 2nd gear
❑ insert into synchronizer ring Pos. 18
❑ replace if there are any traces of scoring and friction ⇒ Electronic Catalogue of Original Parts
❑ (Inner ring for 2nd gear)
21 - 2nd gear sliding gear
22 - Needle bearing
❑ for 2nd gear
23 - Thrust washer
24 - Bushing
❑ for 3rd gear needle bearing
❑ press off with 2nd gear sliding gear ⇒ page 178
25 - Needle bearing
❑ for 3rd gear
26 - 3rd gear sliding gear
27 - 3rd gear synchronizer ring
28 - Sliding sleeve with 3rd and 4th gear synchronizer body
❑ press off ⇒ page 178 together with 2nd gear Pos. 21 and and 3rd gear Pos. 26 sliding gear
❑ Fitting position sliding sleeve/synchronizer body ⇒ page 184

29 - Bushing
❑ Press of together with the sliding sleeve and synchronizer body, 3rd and 4th gear, Pos. 28
⇒ page 178
30 - Needle bearing
❑ for 4th gear
33 - Thrust washer
34 - Needle bearing
❑ removing and installing ⇒ “5 Repairing gearbox housing and clutch housing”, page 151

36 - Bushing
❑ for needle bearing/output shaft Pos. 34
❑ pressing off ⇒ page 178
❑ installing ⇒ “4.7.3 Install 5th gear”, page 147
38 - Disc spring
❑ Fitting position ⇒ “4.7.3 Install 5th gear”, page 147
Removing outer ring/tapered-roller bearing small

-A- interior extractor 37…46 mm , e.g. -Kukko 21/6-
-B- countersupport , e.g. -Kukko 22/2-
2. Output shaft 177

Pressing on small outer ring/tapered-roller bearing
Extracting small inner ring/tapered-roller bearing

-A- vice with protective jaws
– Insert the gripper and tighten behind the rollers of the bearing,
then turn bearing and tighten the gripper.
Press on small inner ring/tapered-roller bearing
Pressing out 3rd and 4th gear synchronizer body/sliding sleeve,

2nd, 3rd and 4th gear sliding gear with bushing for needle bearing
output shaft
-A- separating device 22…115 mm e.g. -Kukko 17/2-
-B- Screw M10 x 20
– Insert separating device under 2nd gear sliding gear and press
off.
Note
Support the separating device in such a way that the 1st and 2nd
gear sliding sleeve is not drawn off.

Press off sliding sleeve with synchronizer body and bearing sup‐
port
– Undo the circlip
( ⇒ “2.1 Disassembling and assembling the output shaft”, page
174 -Pos. 17-) before.
-A- Screw M10 x 20
– Press off together with 1st gear sliding gear and sliding sleeve
with synchronizer body for 1st and 2nd gear.
Pulling off large inner ring/tapered-roller bearing

-A- protective jaws
– Before fitting the extractor insert screw M10 x 20 in the output
shaft bore.
Pressing on large inner ring/tapered-roller bearing

-A- Thrust washer
– Insert thrust washer before pressing in the inner ring. The
shoulder points to the inner ring.
Fitting position of the inner ring, outer ring and 1st gear synchron‐
izer ring
– Position the inner ring -A- on the 1st gear sliding gear.
The angled lands -arrow 1- point towards the outer ring -B-.
– Position the outer ring -B-.
Lock the lands -arrows 2- in the recesses -arrows 3- of the sliding
gear.
– Position the synchronizer ring -C-.
Lock the recesses -arrows 4- in the lands -arrows 1- of the inner
ring -A-.
Note
If these components should not be replaced, make sure that they

are assigned again to the original gear.
2. Output shaft 179

Check 1st and 2nd gear inner ring for wear

– Press the inner ring -2- on the cone of the sliding gear and
measure clearance -a- with a feeler gauge -1-.
Dimension “a” Installation dimen‐ Wear limit
sion
1. and 2nd gear 0.75 … 1.25 mm 0.3 mm
Check 1st and 2nd gear snychronizer rings for wear

– Press the synchronizer ring, outer ring and inner ring on the
cone of the sliding gear and measure clearance -a- with a
feeler gauge.
sion
1. and 2nd gear 1.2 … 1.8 mm 0.5 mm
Disassembling and assembling the sliding sleeve and 1st and 2nd
gear synchronizer body
1 - Spring
Assign the springs via the ⇒ Electronic Catalogue of Original
Parts .
Installation together with arresters, which are hollow inside
⇒ page 181 .
Installation together with arresters, which are not hollow inside
⇒ page 181 .
2 - Sliding sleeve
3 - Synchronizer body
4 - Arresters
Assign the arresters via the ⇒ Electronic Catalogue of Original
Parts .
The collar on both sides of the synchronizer body is identical in
width.
The collar has a chamfer on one side -arrow B-.
The chamfer on the collar of the synchronizer body and the outer
serration of the sliding sleeve -arrow A- point after assembly in
the same direction.
The recesses for the arresters on the synchronizer body and the
sliding sleeve -arrow C- must be positioned above one another.

Assembly of sliding sleeve/1st and 2nd gear synchronizer body

together with arresters, which are hollow inside
• The sliding sleeve is drawn over the synchronizer body.
– Insert arresters and mount springs with 120° offset. The an‐
gled end of the spring must grip into the hollow arrester.

together with arresters, which are not hollow inside
gled ends of the springs must be located before the arresters
-arrows-.
Fitting position of the sliding sleeve and 1st and 2nd gear syn‐
chronizer body
The teeth of the sliding sleeve -arrow- point towards the serration
for the 3rd/4th gear synchronizer body -A-.
Press on the sliding sleeve and 1st and 2nd gear synchronizer
body
Rotate the synchronizer ring in such a way that the slots are flush
with the arresters.
2. Output shaft 181

Fitting position of the 2nd gear outer ring

The pegs -arrows- point towards the 1st gear sliding gear -A-.
Fitting position for synchronizer ring (inner ring for 2nd gear) -A-
The pegs -arrow 1- lock into the recesses -arrow 2- of the syn‐
chronizer ring -B-.
Fitting position 2nd gear sliding gear

The higher collar -A- points towards the 1st gear -B-. The recess‐
es in the collar -arrows- lock into the pegs of the outer ring
⇒ page 182 .
Place on thrust washer and press on bushing for 3rd gear needle
bearing
– Install needle bearing, sliding gear and 3rd gear synchronizer
ring.

Check 3rd and 4th gear snychronizer ring for wear

measure clearance -a- with a feeler gauge.
sion
3. and 4th gear 1.0 … 1.7 mm 0.5 mm
Disassembling and assembling the sliding sleeve and 3rd and 4th
1 - Spring
Parts .
⇒ page 183 .

⇒ page 183 .
2 - Arresters
Parts .
3 - Sliding sleeve
sliding sleeve must be in line with each other.
Assembly of sliding sleeve/3rd and 4th gear synchronizer body


gled ends of the spring must be located before the arresters
-arrows-.
2. Output shaft 183

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

body
Chamfer -arrow- points towards the 4th gear.
Press on the synchronizer body with the 3rd and 4th gear sliding
sleeve
Pressing on bushing for 4th gear needle bearing

– Install needle bearing, 4th gear sliding gear and synchronizer
ring.
– Place thrust washer
⇒ “2.1 Disassembling and assembling the output shaft”, page
174 -Pos. 33- onto sliding gear 4th gear.
Pressing on bushing for needle bearing/output shaft -A-
2.2 Setting output shaft



♦ Bolts M8 and M10 - 3114/2-
♦ Interior extractor 37…46 mm , e.g. -Kukko 21/6-
♦ Countersupport e.g. -Kukko 22/2-
♦ Dial gauge
The output shaft must be re-set when the following components
are replaced:
♦ Output shaft
♦ Clutch housing
or the
Note

– 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 nuts for bearing support to 25
Nm.
– Turn output shaft 20 to 30 times in one direction.
Note
♦ Therefore, it must be turned in one direction so that the rolling

elements/tapered-roller bearings settle in one direction.
♦ This requires 20 to 30 turns.
♦ Otherwise, the result of the measurement will be incorrect.
– Insert dial gauge (3 mm measuring range) and set to “0” with

a 1 mm bias.
– Move the output shaft up and down, read off and write down
the clearance on the dial gauge. (Example: 0.20 mm).

washer
The prescribed bearing preload is reached by adding the estab‐
lished measured value (in the example 0.20 mm) to the inserted
adjusting washer (0.65 mm) and by adding a constant value
(0.10…0.15 mm).
Example:
2. Output shaft 185

inserted washer 0.65 mm

+ measured value 0.20 mm
+ compression (constant value) 0.15 mm
Thickness of the adjusting washer 1.00 mm
Example:
Bearing clearance = Thickness of the adjusting
(adjusting washer 0.65 mm washer according to the table
and the determined measured
value)
0.850 mm 1.000 mm
– Remove output shaft and pull out small outer ring/tapered-
roller bearing.
-A- interior extractor 37…46 mm , e.g. -Kukko 21/6-
The following adjusting washers are available:

Bearing clearance = Adjusting washer
(adjusting washer 0.65 mm thickness (mm)
and the determined measured
value)
0.650 0.750
0.660 … 0.689 0.800
0.690 … 0.739 0.850
0.740 … 0.789 0.900
0.790 … 0.839 0.950
0.840 … 0.889 1.000
0.890 … 0.939 1.050
0.940 … 0.989 1.100
0.990 … 1.039 1.150
1.040 … 1.089 1.200
1.090 … 1.139 1.250
1.140 … 1.189 1.300
1.190 … 1.239 1.350
1.240 … 1.289 1.400
1.290 … 1.339 1.450
1.340 … 1.389 1.500
1.390 … 1.429 1.550
Note

Original Parts .
– Insert adjusting washers of the determined thickness, the

thickest adjusting washer first.
• If the previous adjusting washer 0.65 mm should be inserted
again, it must be checked for damage.
If the measured washer thickness is greater than the one listed in
the table, 2 washers corresponding to the measured value may
be fitted.
Different tolerances allow to measure the required thickness for
each washer very precisely.

– Press in small outer ring/tapered-roller bearing with the deter‐

mined adjusting washer (in the example 1.00 mm).
– Install output shaft and tighten nuts for the bearing support in
the clutch housing to tightening torque
⇒ “2.1 Disassembling and assembling the output shaft”, page
174 .
2. Output shaft 187

3 Reverse shaft
⇒ “3.1 Disassembling and assembling the reverse shaft”,
page 188
3.1 Disassembling and assembling the re‐

verse shaft
♦ Pressure spindle - MP3-423 (VW407)-
♦ Centering mandrel - MP3-463 (12-551)-
♦ Interior extractor 14.5 up to 18.5 mm , e.g. -Kukko 21/2-

Note
Always replace the needle bushing from the clutch housing or from the reverse shaft support after removing ⇒

1 - Clutch housing
2 - Needle bushing
❑ always replace after re‐
moving ⇒ Electronic
Parts
3 - Reverse pinion
4 - Circlip
Parts
❑ carefully fit on new cir‐
clip
❑ do not over-extend
5 - Reverse gear sliding gear
❑ remove circlip Pos. 4
before replacing
❑ the collar points to the
return flow gear pinion
Pos. 3
6 - Reverse shaft
⇒ “4.7 Mounting se‐
quence - completely dis‐
assembling and assem‐
bling the gearbox”, page
139
7 - Needle bushing
❑ pressing out
⇒ page 190
❑ always replace after removing ⇒ Electronic Catalogue of Original Parts
Removing needle bushing from clutch housing

A - Countersupport , e.g. -Kukko 22/1-
B - Interior extractor 14,5…18,5 mm , e.g. -Kukko 21/2-
Note
The needle bushing is damaged when removed and must be re‐

placed ⇒ Electronic Catalogue of Original Parts .
3. Reverse shaft 189

Pressing in needle bushing -A- in the clutch housing
Pressing out needle bushing from the reverse shaft support
Pressing the needle bushing in the reverse shaft support

39 – Final drive - differential

1 Replacing the flange shaft gasket
rings (gearbox assembled)
⇒ “1.1 Replacing the left flange shaft gasket ring”, page 191
⇒ “1.2 Replace gasket ring for right flange shaft (gasket ring and
bushing are one component)”, page 193

ring
♦ Extraction hook - MP3-419/37 (VW 771/37)-
♦ Catch pan

Removing
vehicle.
gr. 50 .
gr. 66 .
– Unscrew drive shaft from flange shaft ⇒ Chassis; Rep. gr.
40 .
Fabia II 2007 ►; Roomster 2006 ►
– Mark the fitting position of the screws -1-.
– Release screws -1- ⇒ Chassis; Rep. gr. 40
– Unbolt coupling rod -2- from the anti-roll bar -arrow- ⇒ Chas‐
sis; Rep. gr. 40 .
Fabia II 2011 ►; Roomster 2011 ►; Rapid, Rapid NH
1. Replacing the flange shaft gasket rings (gearbox assembled) 191


gr. 40 .
– Unscrew the nut -1- from the coupling rod -3- ⇒ Chassis; Rep.
gr. 40 .
wards.
– Release the fixing screw for the flange shaft, to this end insert
two screws in the flange and using a tyre iron hold the shaft.
– Remove the flange shaft together with the pressure spring.
– Pull out gasket ring for flange shaft with multi-purpose tool -
MP3-419 (VW 771)- and extraction hook - MP3-419/37
(VW 771/37)- .
Install
192 Rep. gr.39 - Final drive - differential

ring.
– Secure the flange shaft with the conical screw and tighten with
tightening torque.
– Bolt drive shaft to flange shaft ⇒ Chassis; Rep. gr. 40 .
– Install coupling rod and steering joint to track control arm ⇒
Chassis; Rep. gr. 40 .
– Check gear oil level, if necessary fill up to lower edge of filler
hole ⇒ “3 Check gear oil level”, page 127 .
– Install the wheelhouse liner into the left wheelhouse ⇒ Body
Work; Rep. gr. 66 .
– Install wheel ⇒ Chassis; Rep. gr. 44 .
Tightening torque
Flange shaft on gearbox (conical screw) ⇒ “2.1 Disassembling and assembling differential gear”, page 196
1.2 Replace gasket ring for right flange shaft

(gasket ring and bushing are one com‐
ponent)
♦ Extraction hook - MP3-419/37 (VW 771/37)-
♦ Catch pan
Removing
gr. 50 .
– Turn steering to full right lock.
-arrows-.

– Unscrew the drive shaft -1- from the flange shaft ⇒ Chassis;
Rep. gr. 40 .
– Position the catch pan under the gearbox and the engine.
– If necessary, unscrew oil return-flow line for exhaust turbo‐
charger from engine -arrow- ⇒ Engine; Rep. gr. 21 .
– Pull out gasket ring with bushing.

– Position the extraction hook - VW 771/37 (MP3-419/37) - di‐
rectly behind the leg in the bushing.
– Press the extraction hook - VW 771/37 (MP3-419/37)- force‐
Install
– Clean point for gasket ring in gearbox.
– Insert gasket ring together with bushing.

A - Screw threaded rod from assembly device - MP3-434 (3066)-
into the threaded part of the differential gear.
B - Nut M12 with washer
– By turning the nut -B- insert the gasket ring with the bushing
over the pressure plate - T10148- up to the stop.
tightening torque.

– If the oil return line for exhaust turbocharger was unscrewed

at the engine, install it again -arrow- ⇒ Engine; Rep. gr. 21 .
– Install drive shaft -1- on gearbox ⇒ Chassis; Rep. gr. 40 .
– If present, screw on heat shield for drive shaft -arrows-.

– Check gear oil level ⇒ “3 Check gear oil level”, page 127 .
Tightening torques
Flange shaft on gearbox (conical screw) ⇒ “2.1 Disassembling and assembling differen‐
tial gear”, page 196

2 Differential gear
⇒ “2.1 Disassembling and assembling differential gear”,
page 196
⇒ “2.2 Adjusting the differential gear”, page 202
2.1 Disassembling and assembling differen‐

tial gear
♦ Drive bushing - MP3-427 (40-21)-

♦ Thrust plate - MP3-464 (30-205)-
♦ Thrust plate - MP3-467 (40-105)-
♦ Thrust piece - MP3-468 (2007)-
♦ Bushing - MP3-474 (3144)-
♦ Interior extractor 46 up to 58 mm , e.g. -Kukko 21/7-
Note
♦ Before installing heat the inner ring of the tapered-roller bearing to 100°C.
♦ Removing and installing differential gear
♦ When replacing the tapered-roller bearings. the differential housing. the gearbox housing or the clutch
housing. set the differential gear ⇒ “2.2 Adjusting the differential gear”, page 202 .

1 - Gearbox housing
❑ for the differential gear
⇒ “2.2 Adjusting the dif‐
ferential gear”,
page 202
bearing
bearing
❑ pressing on
⇒ page 199
5 - Differential gear housing
❑ with gear pinion for final
drive
❑ The hole of the tension‐
ing sleeve is adapted to
the length of the ten‐
sioning sleeve
⇒ page 200
Parts
6 - Drive wheel for speedome‐
ter
❑ if present, place it on the
differential gear housing
up to the stop before
pressing on the inner
ring Pos. 7
9 - Clutch housing
❑ one-piece (a component part)
❑ replace gasket ring together with bushing in the event of damage
page 193
11 - 25 Nm
❑ screw to threaded connector Pos. 19 to attach the flange shaft
12 - Flange shaft
❑ left - removing and installing ⇒ “1.1 Replacing the left flange shaft gasket ring”, page 191
❑ right - removing and installing
page 193
2. Differential gear 197

13 - Pressure spring for flange shaft

❑ fitted behind flange shaft
14 - Thrust washer
❑ Fitting position: Collar for compression spring ⇒ page 202
15 - Conical ring
❑ with slots for thrust washer catch
❑ Fitting position: Cone for differential gear housing
16 - Circlip
❑ holds the conical ring, stop disc and pressure spring in position when the flange shaft is removed
17 - Stop disc compound
❑ insert with gear oil
18 - Large differential bevel gear
19 - Threaded part
20 - Differential bevel gear shaft
❑ remove in combination with short tensioning sleeve ⇒ page 200
❑ remove in combination with long tensioning sleeve ⇒ page 201
21 - Tensioning sleeve
❑ to secure the differential bevel gear shaft
❑ Tensioning sleeves having different lengths are mounted
❑ Difference between the tensioning sleeves ⇒ page 200
❑ short tensioning sleeve: removing and installing ⇒ page 200
❑ long tensioning sleeve: is cut when removing ⇒ page 201
❑ long tensioning sleeve: installing ⇒ page 201
22 - Small differential bevel gear
23 - Sealing ring
❑ replace with installed gearbox ⇒ “1.1 Replacing the left flange shaft gasket ring”, page 191
Press outer ring/tapered-roller bearing out of clutch housing

– First remove gasket ring with bushing for right flange shaft.

Press outer ring/tapered-roller bearing into the clutch housing

No adjusting washer is fitted at the side of the clutch housing.
Removing inner ring/tapered-roller bearing

– Before fitting the extractor, position pressure plate - MP3-467
(40-105) - 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 rings/tapered-roller bearings for the gearbox housing

and clutch housing are pressed on with the same special tools.
Remove outer ring/tapered-roller bearing from gearbox housing

B - Interior extractor 46…58 mm , e.g. -Kukko 21/7-

Press in outer ring/tapered-roller bearing in the gearbox housing

– Position adjusting washer under outside ring.
– Support the gearbox housing with a bushing - MP3-474 (3144)
- directly below the bearing support.
Difference between the tensioning sleeves

Dimension “a” (mm) Distinguishing feature
28.5 (short tensioning sleeve), round slot -arrows-
removing and installing ⇒ page 200
36.0 (long tensioning sleeve), no round slot
remove ⇒ page 201 ,
install ⇒ page 201

Assign differential gear housing

– Check the hole for the tensioning sleeve in the differential gear
housing.
The hole in the differential gear housing was adapted due to the
longer tensioning sleeves.
Bore Length of tensioning sleeve (mm)
-A- 28.5 (short tensioning sleeve)
-A- and -B- 36.0 (long tensioning sleeve)
Tensioning sleeve with groove all the way around (short tension‐
ing sleeve): removing and installing
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.
– Press off the differential bevel gear shaft using an extractor.
Install
– Drive the new tensioning sleeve into the differential gear hous‐
ing up to the stop.

Remove tensioning sleeve without round slot (long tensioning

sleeve); press out differential bevel gear shaft
When pressing out the tensioning sleeve, it is sheared off during
this procedure.
– Drive the remaining part of the tensioning sleeve out of the
differential gear housing and the differential bevel gear shaft.
Install tensioning sleeve without round slot (long tensioning

sleeve)
– Align the hole in the differential bevel gear shaft to the hole in
the differential gear housing.
– Drive in the new tensioning sleeve with a drift -1- to the di‐
mension -a- = 3.0 mm.
• When turning, the tensioning sleeve must not come in contact

with the housing wall of the clutch housing when the differential
gear is installed.
Install differential bevel gears and differential gear shaft

– Install stop disc compound with gearbox oil.
– Insert both large differential bevel gears and secure (e.g. with
flange shaft).
– Insert the small differential bevel gears offset at 180° and slide
in.
– Push in the differential bevel gear shaft -arrow A- up to the first
small differential bevel gear.
– Insert the threaded parts -arrows B- in the large differential
bevel gears.
Fitting position: Heel of the differential bevel gear.
– Drive in the differential gear shaft up to end position and se‐
cure with new tensioning sleeve.

Fitting position of thrust washer for the conical ring -1-

The collar -arrow- points towards the pressure spring -B-.
The lands -A- are available on certain gearboxes.
The lands -A- point towards the conical ring -1-.
2.2 Adjusting the differential gear

♦ Thrust plate - MP3-464 (30-205)-
♦ Bushing - MP3-474 (3144)-
♦ Interior extractor 46 up to 58 mm , e.g. -Kukko 21/7-
♦ Countersupport e.g. -Kukko 22/2 -
♦ Dial gauge
The differential gear must be re-set when the following compo‐
nents are replaced:
♦ Gearbox housing
♦ Clutch housing
♦ Differential gear housing
or the
♦ Tapered-roller bearings of the differential gear

– Press the outer ring/tapered-roller bearing with thrust plate -

MP3-464 (30-205) - into the clutch housing.
Note
The inner and outer ring of the tapered-roller bearing are paired.
Do not interchange!
– Press outer ring/tapered-roller bearing without adjusting

washer with thrust plate - MP3-464 (30-205)- into the gearbox
housing.
– Insert the differential gear in the clutch housing.
– Position the gearbox 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: 0.70 mm).

washer
The prescribed bearing preload is reached by adding to the es‐
tablished measured value a constant compression value (0.25
mm).
Example:
measured value 0.70 mm
Thickness of the adjusting washer = 0.95 mm
Example:
0.70 mm 0.95 mm

– Remove the gearbox housing and pull the outer ring/tapered-

roller bearing out of the gearbox housing.
0.303 … 0.449 0.650
0.450 … 0.499 0.700
0.500 … 0.549 0.750
0.550 … 0.599 0.800
0.600 … 0.649 0.850
0.650 … 0.699 0.900
0.700 … 0.749 0.950
0.750 … 0.799 1.000
0.800 … 0.849 1.050
0.850 … 0.899 1.100
0.900 … 0.949 1.150
0.950 … 0.999 1.200
1.000 … 1.049 1.250
1.050 … 1.099 1.300
1.100 … 1.149 1.350
1.150 … 1.199 1.400
Note

Original Parts .

be fitted.
– Press outer ring/tapered-roller bearing with the determined

adjusting washer (in the example 0.95 mm) again into the
gearbox housing.
– Fit gearbox housing and tighten

3 Setting overview
Note
♦ When working on the gearbox it is only necessary to re-set the

drive shaft, output shaft or differential gear if parts were re‐
placed that directly affect the setting of the gearbox.
♦ To avoid unnecessary settings, refer to the following table:
Set:
Drive shaft Output shaft Differential gear
⇒ “1.2 Set‐ ⇒ “2.2 Set‐ ⇒ “2.2 Adjusting
ting drive ting output the differential
shaft”, shaft”, gear”, page 202
page 169 page 184
Replaced part: Gearbox housing x x
Clutch housing x x x
Drive shaft x
Output shaft x
Differential gear housing x
Tapered-roller bearing for drive shaft x
Tapered-roller bearing for output x
shaft
Tapered-roller bearings for differen‐ x
tial gears.
4th gear pinion x
3. Setting overview 205

Service
Workshop Manual
FABIA II 2007 ➤
Gearbox 02R
Edition 12.06

Service
Repair Group
00 - Technical data
30 - Clutch
35 - Wheels, shafts

FABIA II 2007 ➤
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification characters, aggregate assignment, ratios, filling capacities; Fabia II 2007 ?
........................................................................ 1
1.2 Identification characters, aggregate assignment, ratios, filling capacities; Fabia II 2011 ?
........................................................................ 2
3 General repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Summary of components - foot controls; Fabia II 2007 ? . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Removing and installing the crash strut for the clutch pedal; Fabia II 2007 ? . . . . . . . . . . 12
1.3 Removing and installing the over-centre helper spring; Fabia II 2007 ? . . . . . . . . . . . . . . 12
1.4 Removing and installing the clutch pedal; Fabia II 2007 ? . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.6 Removing and installing the bracket with the master cylinder; Fabia II 2011 ? . . . . . . . . . . 18
1.7 Removing and installing the bracket without the master cylinder; Fabia II 2011 ? . . . . . . . . 21
1.8 Removing and installing the clutch pedal with the over-centre helper spring; Fabia II
2011 ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.9 Removing and installing the clutch pedal with the tension spring; Fabia II 2011 ? . . . . . . 25
1.10 Summary of components - Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.12 Removing and installing the master cylinder; Fabia II 2007 ? . . . . . . . . . . . . . . . . . . . . . . 30
1.15 Bleed the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
34 - Control, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.2 Summary of components of the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3 Summary of components - gearshift knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.4 Separating collar from gearshift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Plastic relay lever as of 06.07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Removing the gearbox; Fabia II 2007 ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.2 Removing the gearbox; Fabia II 2011 ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.4 Transporting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3 Check gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Contents i
FABIA II 2007 ➤
4.4 Removing and installing gearbox housing and shift mechanism . . . . . . . . . . . . . . . . . . . . 89
4.5 Removing and installing the drive shaft, output shaft, differential gear and shift forks . . . . 90
4.6 Mounting sequence - Removing and installing gearbox housing cover and 5th gear . . . . 91
4.7 Mounting sequence - completely disassembling and assembling the gearbox . . . . . . . . . . 96
6 Repairing the gearshift mechanism on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 112
can be removed from gearshift cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
cannot be removed from gearshift cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
35 - Wheels, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

1 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.2 Setting drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.2 Setting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Disassembling and assembling the reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.2 Replace gasket ring for right flange shaft (gasket ring and bushing are one component) . . 149
3 Setting overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
ii Contents
FABIA II 2007 ➤
Assignment Fabia II 2007 ? ⇒ page 1
Assignment Fabia II 2011 ? ⇒ page 2

Example: JDE 18 02 7
I I I I
Identifica‐ Day Month Manufacturing
tion char‐ year (2007)
acters
1.1 Identification characters, aggregate assignment, ratios, filling capacities;

Fabia II 2007 ?
through 03.10 03.10 03.10
Identification characters JCZ JDE JDD
Assignment: Engine 1.4 ltr./59 kW TDI
Ratio: Z 2 : Z 1 Final drive 61 : 18 = 3,389 60 : 19 = 3,158
1st gear 33 : 10 = 3,300 34 : 09 = 3,378 34 : 09 = 3,378
2nd gear 35 : 18 = 1,944 33 : 16 = 2,063 33 : 16 = 2,063

FABIA II 2007 ➤

3rd gear 34 : 26 = 1,308 31 : 23 = 1,348 30 : 24 = 1,250
4th gear 34 : 35 = 0,971 29 : 30 = 0,967 27 : 32 = 0,844
5th gear 34 : 45 = 0,756 30 : 39 = 0,769 27 : 41 = 0,659
Reverse gear 17 : 10 x 36 : 20 = 18 : 09 x 36 : 20 = 18 : 09 x 36 : 20 =
3,060 3.600 3.600
Speedometer1) 13:22 = 0,591 electronic
Filling capacity 2,0 litres
Gear oil specification ⇒ Electronic Catalogue of Original Parts
Clutch control hydraulic
Clutch plate ∅ ⇒ Electronic Catalogue of Original Parts
1) Only on vehicles without ABS.

Note
Vehicles with ABS do not have the sender for speedometer -

G22- .

through 04.07 03.10
Identification characters JDA JXY
Assignment: Engine 1.9 ltr./77 kW TDI 1.9 ltr./77 kW TDI
1st gear 34 : 09 = 3,378 34 : 09 = 3,378
2nd gear 33 : 16 = 2,063 33 : 16 = 2,063
3rd gear 30 : 23 = 1,304 34 : 26 = 1,308
4th gear 28 : 31 = 0,903 33 : 36 = 0,917
5th gear 28 : 40 = 0,700 28 : 40 = 0,700
Reverse gear 18 : 09 x 36 : 20 = 18 : 09 x 36 : 20 =
3.600 3.600
Speedometer electronic
1.2 Identification characters, aggregate assignment, ratios, filling capacities;

Fabia II 2011 ?
through 10.10 10.10

FABIA II 2007 ➤

Identification characters KFK, MZL MAL MNY
1st gear 34 : 09 = 3,378
2nd gear 36 : 17 = 2,118
3rd gear 33 : 26 = 1,269
4th gear 32 : 37 = 0,865
5th gear 31 : 47 = 0,659
Reverse gear 18 : 09 x 36 : 20 = 3.600
Speedometer1) electronic 13:22 = 0,591 electronic
Note

G22- .

through 10.10
Identification characters MUW MZR
Ratio: Z 2 : Z 1 Final drive 63 : 16 = 3,937
1st gear 34 : 09 = 3,378
2nd gear 36 : 17 = 2,118
3rd gear 34 : 25 = 1,360
4th gear 34 : 35 = 0,971
5th gear 33 : 45 = 0,733
Reverse gear 18 : 09 x 36 : 20 = 3.600
Speedometer1) 13:22 = 0,591

FABIA II 2007 ➤
Note

G22- .

through
Identification characters MZK MZN
Ratio: Z 2 : Z 1 Final drive 61 : 18 = 3,389
1st gear 34 : 09 = 3,378
2nd gear 36 : 17 = 2,118
3rd gear 33 : 26 = 1,269
4th gear 32 : 37 = 0,865

5th gear 31 : 47 = 0,659
Reverse gear 18 : 09 x 36 : 20 = 3.600
Speedometer1) 13:22 = 0,591 electronic
Note

G22- .

FABIA II 2007 ➤
Note
The -arrows- show the direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Drive shaft
5 - Output shaft

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
❑ for vehicles without ABS

FABIA II 2007 ➤
3 General repair information

workshop manual.
Gearbox
before releasing.
♦ When installing the manual gearbox, ensure the dowel
sleeves are correctly located between the engine and gear‐
box.
♦ When installing mounts as well as waxed components, the
contact surfaces must be cleaned. Contact surfaces must be
free of wax and grease.
♦ When replacing the gearbox, inspect the gearbox oil level and
top up with oil if necessary ⇒ page 85 .
♦ Filling capacity, Fabia II 2007 ? ⇒ page 1 .
♦ Filling capacity, Fabia II 2011 ? ⇒ page 2 .
♦ Oil specification ⇒ Electronic Catalogue of Original Parts .
Sealant
♦ Thoroughly clean the contact surfaces of the housing before
applying the silicone sealant.
♦ Apply sealant AMV 188 200 03 evenly and not too thick.
♦ After removing gaskets, check the contact surface in the hous‐
ing or shaft for burrs or damage which occured during the
assembly.
♦ Shaft seals - before mounting lightly oil at outside diameter
and fill half the space between the sealing lips -arrow- with
sealing grease -G 052 128 A1- .
♦ The open side of the shaft seals is turned towards the fluid to
be sealed.
♦ Press in new shaft seal in such a way that the sealing lip is not
located on the same point as the sealing lip of the old seal (use
tolerance for insertion depth).
♦ Before inserting lightly oil the O-rings, in order to prevent the
rings being squashed during installation.
♦ Inspect the oil level after replacing the gaskets and gasket
rings, top up oil if necessary ⇒ page 85 .
Locking elements

FABIA II 2007 ➤

♦ Always replace damaged or over-tensioned circlips ⇒ Elec‐
♦ Replace roll pins. Fitting position: Slot -A- longitudinal to power
flow -arrow-.
Screws, nuts

♦ Slacken the bolts and nuts against the tightening sequence.
housings without tightening sequence diagonally across in
stages.
♦ Clean the threaded holes into which self-locking screws or
screws with locking agent were screwed in (using e.g. a screw-
tap). Otherwise there is a risk that the bolts will shear at the
next disassembling.
Bearings
♦ Insert moist all bearings into the gearbox with gear oil.
ing plate or with the induction heater unit -VAS 6414- to
to the stop.
ing instrument.
♦ Do not mix up the outer and inner races of bearings of the
same size.
♦ Always jointly replace tapered-roller bearings on the same
shaft and use products of the same manufacturer.
♦ Always position needle bearing with the lettered side (thicker
end) towards the drift pin.
Shims
3. General repair information 7

FABIA II 2007 ➤
♦ Gauge shims at several points with a micrometer. Different

washer very precisely.
♦ Inspect for burrs and damage.
Synchronizer rings

of Original Parts .
♦ When installing the intermediate ring -B-, check whether it has
no scores, blue coloring (caused by overheating) and other
damages on the outer -arrow 2- and inner -arrow 3- friction
surface.
♦ Insert with some gearbox fluid.
Pinions
♦ Clean and heat on a heating plate or with the induction heater
unit -VAS 6414- to approx. 100°C before pressing on.
ing instrument.
Sliding gears
♦ Check 1st to 5th gear sliding gears after assembly for low axial
play or smooth operation.
Clutch control
tach the tube-hose line.
system must be bled (further measures ⇒ page 29 ).

FABIA II 2007 ➤
30 – Clutch
1 Clutch control
1.1 Summary of components - foot controls;

Fabia II 2007 ?
♦ Polycarbamide grease -G 052 142 A2-
Note
♦ Summary of components - Hydraulics ⇒ page 28 .

♦ After the battery earth strap is disconnected and reconnected, carry out additional operations ⇒ Electrical
System ⇒ Rep. Gr. 27 .
♦ Grease all bearing points 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 .
1 - Front wall
inder
2 - Gasket
tronic Catalogue of
Original Parts
3 - Bearing bracket
❑ for attaching clutch ped‐
al
4 - Screw
6 - 25 Nm
❑ self-locking
tronic Catalogue of
Original Parts
7 - Clutch pedal switch -F36-
clutch pedal switch
⇒ page 11
Parts
⇒ page 11 angular
clutch pedal switch
⇒ page 11 cylindrical
clutch pedal switch
1. Clutch control 9
FABIA II 2007 ➤

9 - Bushing
10 - Bushing
11 - Clutch pedal
12 - Support
13 - 25 Nm
❑ self-locking
❑ for master cylinder to front wall
15 - Clamp
16 - Tubing
17 - Bearing
❑ for over-centre helper spring
❑ Fitting position: the peg -arrow- clips into the master cylinder recess
18 - Screw
❑ for pedal stop on bracket
19 - Pedal stop
❑ screw onto bracket with screw Pos.18 with the master cylinder installed
20 - 25 Nm
❑ self-locking


FABIA II 2007 ➤
Difference between clutch pedal switches -F36-

♦ -A- Clutch pedal switch with angular housing
Removing and installing ⇒ page 11 .
♦ -B- Clutch pedal switch with cylindrical housing
Removing and installing ⇒ page 11 .
1.1.1 removing and installing, setting angular

clutch pedal switch -F36-
Note
The clutch pedal switch -F36- may only be installed once to en‐
pedal.
Removing
– Remove the storage area on the driver's side ⇒ Body Work
⇒ Rep. Gr. 70 .
– Unplug connector from the clutch pedal switch -F36- .
– Turn clutch pedal switch -F36- 90° to the left and remove it
from the support.
– Pull out the tappet of the clutch pedal switch up to the stop.
– Press down the clutch pedal as far as possible.
– Insert clutch pedal switch into the support and turn switch by
90° to the right.
– Insert connector for the clutch pedal switch -F36- .
– Install the storage area on the driver's side ⇒ Body Work ⇒
Rep. Gr. 70 .
1.1.2 removing and installing, setting cylindri‐

cal clutch pedal switch -F36-
Note
pedal.

⇒ Rep. Gr. 70 .
FABIA II 2007 ➤
– Unplug connector -1- from the clutch pedal switch -F36- .

– Turn clutch pedal switch -F36- -2- in the bracket 45° to the left
Note
Clutch pedal always remains in the off position in this case (do
not depress the clutch pedal).
– Before installing the clutch pedal switch -F36- pull out tappet
-3- fully.
– Fit the clutch pedal switch -F36- through the assembly open‐
ing, press against the clutch pedal and attach by turning it 45°
to the right.

Rep. Gr. 70 .

for the clutch pedal; Fabia II 2007 ?
Removing
⇒ Rep. Gr. 70 .
– Release screws -arrows- and remove crash strut.
Install
Tightening torque

helper spring; Fabia II 2007 ?
♦ Pliers -T10005-

FABIA II 2007 ➤
Removing
⇒ Rep. Gr. 70 .
– Remove crash strut (if present) ⇒ page 12 .
– Remove clutch pedal switch -F36- , if present
⇒ Item 7 (page 9) .
follows:
– Insert pliers -T10005- in the clutch pedal recesses.
ers -T10005- -arrows- and separate the clutch pedal from the
master cylinder.
– Press the over-centre helper spring towards the front wall

-in direction of arrow- and remove it downwards.
Install
• Check whether the bearing -arrow 1- for the over-centre helper

spring is inserted in the bracket.
Fitting position:
inder -arrow 2-.
– First of all, insert the over-centre helper spring in the rear
bearing.
– Then press the over-centre helper spring onto the centering

– Connect clutch pedal to master cylinder ⇒ page 14 .
– Install the clutch pedal switch -F36- ⇒ Item 7 (page 9) .
– Install crash strut (if present) ⇒ page 12 .
Rep. Gr. 70 .
FABIA II 2007 ➤
1.4 Removing and installing the clutch ped‐

al; Fabia II 2007 ?
♦ Pliers -T10005-
Removing
⇒ Rep. Gr. 70 .
follows:
master cylinder.
– Removing the over-centre helper spring ⇒ page 12 .
– Unscrew nut -A- and pull out screw from bracket (to facilitate
pulling out the screw, turn the steering wheel to the corre‐
sponding position).
Install
following points:
• Always replace self-locking nut ⇒ Electronic Catalogue of
Original Parts .

– To click in the support, press the clutch pedal towards the front
wall in -direction of arrow-. While doing so, make sure it catch‐
es correctly in the support.
Rep. Gr. 70 .
Tightening torque
Clutch pedal to bracket 1) ⇒ Item 20 (page 10)


FABIA II 2007 ➤
1.5 Summary of components - foot controls; Fabia II 2011 ?
Note

♦ After the battery earth strap is disconnected and reconnected, carry out additional operations ⇒ Electrical
♦ Grease all bearing points and contact surfaces with Polycarbamide Grease -G 052 142 A2- .
1 - Front wall
inder
2 - Bushing
in the bracket
❑ The sleeves for the bot‐
tom location hole in the
bracket are located in
the master cylinder
3 - Bearing bracket
⇒ page 18
⇒ page 21
4 - 25 Nm
❑ self-locking
❑ 3 pieces
tronic Catalogue of
Original Parts
⇒ page 17
6 - Crash strut
❑ is attached to the steer‐
ing column
7 - 9 Nm
❑ for crash strut Pos. 7 at steering column
8 - Stop
9 - Bearing axle
FABIA II 2007 ➤
11 - Clutch pedal
❑ removing and installing with over-centre helper spring ⇒ page 23
❑ removing and installing with tension spring ⇒ page 25
12 - Bushing
❑ is inserted on the bracket Pos. 3 and on the clutch pedal
14 - Cap
15 - Support
17 - Clamp

18 - Gasket
19 - Tubing
20 - Clutch position sender -G476-
❑ can be checked in the “Targeted fault finding” with the Vehicle diagnosis, measurement and information
system -VAS 5051-
removing and installing tension spring


FABIA II 2007 ➤

switch -F36-
Note
pedal.
Removing
– Remove the footwell vent ⇒ Heating, Air Conditioning ⇒ Rep.
Gr. 80 .
Note

Install
out.
Parts .

– Install the footwell vent ⇒ Heating, Air Conditioning ⇒ Rep.
Gr. 80 .
FABIA II 2007 ➤

the master cylinder; Fabia II 2011 ?
♦ Closing tool -T10249-
1.6.1 Removing
Note

27 .
– If necessary, remove engine cover ⇒ Engine ⇒ Rep. Gr. 10 .

control unit from the front wall ⇒ Engine ⇒ Rep. Gr. 23 .
– Lay a cloth below the master cylinder.

suitable tool, e.g. closing tool -T10249/1- .
Note
♦ Do not use the hose clamp -MP7–602- , otherwise the return

stop.
Note
out from the side.

FABIA II 2007 ➤
Vehicles with start-stop system:

– Unclip clutch position sender -G476- at master cylinder
– Remove the clutch position sender with connected electrical
plug connection from the master cylinder.
Note

Gr. 87 .
– If present, release screws -arrows- and remove crash strut

-A-.

– Remove clutch pedal switch -F36- -1- ⇒ page 17 .

-3-.

1.6.2 Install
following points:
FABIA II 2007 ➤
Note
– Install the clutch pedal switch -F36- ⇒ page 17 .
– If present, install crash strut -A-. To do so, tighten fixing screws

-arrows- to tightening torque ⇒ Item 7 (page 15) .

Gr. 87 .
Vehicles with start-stop system:

– Insert the clutch position sender -G476- with connected elec‐
trical plug connection up to the stop on the master cylinder.
– Bleed the clutch control ⇒ page 35 .
Engine ⇒ Rep. Gr. 23 .
– Install battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Install air filter housing ⇒ Engine ⇒ Rep. Gr. 23 .
Tightening torques
Bracket/clutch pedal to front wall 1) ⇒ Item 4 (page 15)

Master cylinder to front wall 1) ⇒ Item 4 (page 15)

FABIA II 2007 ➤

without the master cylinder; Fabia II
2011 ?
♦ Pliers -T10005-
Removing
Gr. 87 .
-A-.

-3-.

as follows:
T10005- -arrows-
FABIA II 2007 ➤

• The assistance of a 2nd mechanic is required to counterhold
it when removing the bracket from the engine compartment.
Install
following points:
Note


Gr. 87 .

FABIA II 2007 ➤

with the over-centre helper spring; Fabia
II 2011 ?
Note


♦ Pliers -T10005-
Removing
Gr. 87 .
-A-.
– Remove clutch pedal switch -F36- ⇒ page 17 .

as follows:
T10005- -arrows-
FABIA II 2007 ➤

can be pulled out.
Install
master cylinder.

• The area of the support -arrow- for the bearing pin of the clutch


FABIA II 2007 ➤
– Press on clutch pedal slightly and slide through new bearing

axle.

Gr. 87 .

with the tension spring; Fabia II 2011 ?
Note

⇒ page 27 .

♦ Hook -3438-
♦ Pliers -T10005-
Removing
Gr. 87 .
-A-.
FABIA II 2007 ➤
– Unhook the tension spring e.g with hook -3438- .
Note

as follows:
T10005- -arrows-.

can be pulled out.
Install
master cylinder.
– Insert a new bearing axle in the bracket and the clutch pedal.

FABIA II 2007 ➤



Gr. 87 .
FABIA II 2007 ➤
1.10 Summary of components - Hydraulics

2 - Tubing
3 - Master cylinder
❑ removing and installing;
Fabia II 2007 ?
⇒ page 30
❑ removing and installing;
Fabia II 2011 ?
⇒ page 32
clutch control
⇒ page 35
4 - Clamp
line Pos. 9 pull it out of
the master cylinder up to
the stop
5 - Support
been removed
6 - Clutch pedal
7 - 25 Nm
❑ self-locking
tronic Catalogue of
Original Parts
9 - Tube-hose line
10 - Support
11 - Support
❑ for tube-hose line Pos. 9 on the gearbox
12 - 20 Nm
13 - Vent valve
❑ Bleed the clutch control ⇒ page 35

FABIA II 2007 ➤
14 - Dust cap
15 - Clamp
16 - Gearbox
17 - Slave cylinder
❑ after installing, bleed the clutch control ⇒ page 35
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-.


• The brake pedal return must not be obstructed by moved or
• If necessary, bleed the clutch control ⇒ page 35 .
FABIA II 2007 ➤
– First of all check brake fluid level in the brake fluid reservoir.
Note

-arrow 1-.
in the system.
– Then check the following components of the hydraulic clutch

control for external leaks:
♦ Return hose between brake fluid reservoir and master cylinder
♦ Master cylinder
♦ Tube-hose line or plastic line between master and slave cyl‐
inder
visible area

♦ Slave cylinder
Note

♦ Check the correct routing of the tube-hose line or the plastic
line between the master cylinder and the slave cylinder. The
line must not be kinked or trapped.
– Subsequently depress the clutch pedal carefully, at the same

time hold the clutch pedal in 5 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 30 . 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 do so, take off the collar from the tappet -arrow-.

inder; Fabia II 2007 ?
♦ Pliers -T10005-

FABIA II 2007 ➤
Removing
Note

27 .
– Remove engine cover ⇒ engine ⇒ Rep. Gr. 10 .

Note


stop.
inder.
⇒ Rep. Gr. 70 .
Note

clutch pedal.

follows:
master cylinder.
– Remove the bearing/over-centre helper spring from the brack‐
et.
FABIA II 2007 ➤
– Unscrew the nuts -arrows 1- and remove the bracket

– Unscrew pedal stop ⇒ Item 19 (page 10) .
Install
following points:
– Insert the bearing for over-centre helper spring in the bracket.

Rep. Gr. 70 .
⇒ page 35 .
Tightening torques

Clutch pedal to bracket 1) ⇒ Item 20 (page 10)

♦ Pliers -T10005-
Removing
Remove bracket with master cylinder ⇒ page 18 .

FABIA II 2007 ➤
-T10005- .
– Remove the master cylinder from the bracket.
Install

Install bracket with master cylinder ⇒ page 18 .

der
♦ Grease for plug serration of clutch disc -G 000 100-
Removing
Note

27 .

Gr. 27 .
FABIA II 2007 ➤

shift lever -A-.
Vehicles up to 05.07 (metal relay lever)
-B-.
relay lever.
Vehicles as of 06.07 (plastic relay lever)
– Remove relay lever together with cable lock ⇒ page 55 .
-arrow 4-.
– Disconnect the cable support from the gearbox (screws -1-).

– Pull retaining clip -2- for tube-hose line out of the slave cylinder
up to the stop.
– Then pull the tube-hose line -3- out of the slave cylinder and
close openings.
– Pull the tube-hose line -3- out of the bracket -4-, if present, on
the gearbox.
– Unscrew the screws -5- for the slave cylinder and remove the
slave cylinder.
Note
Install
following points:
– Grease tappet head with grease for plug serration of clutch
disc -G 000 100 - .
Note
♦ Replace damaged gasket rings.

♦ Assign all the components via the ⇒ Electronic Catalogue of
Original Parts .

FABIA II 2007 ➤
– Screw the slave cylinder at the gearbox with the screws -5-.
– Insert the tube-hose line -3- into the slave cylinder up to the
stop.
– Press in retaining clip -2- up to the stop.
– Press the tube-hose line into the bracket -4-, if present, at the
gearbox.
⇒ page 35 .
er ⇒ page 57 .
– Setting the shift mechanism ⇒ page 61 .
Gr. 27 .
Gr. 27 .
Tightening torque

Slave cylinder to gearbox ⇒ Item 12 (page 28)
bracket for tube-hose line ⇒ Item 12 (page 28)
Cable support to gearbox ⇒ page 53
Gearbox shift lever to gearbox ⇒ page 53
1.15 Bleed the clutch control

♦ Brake filling and bleeding device e.g. -VAS 5234- or -ROM‐
ESS-
Note

comes into contact with the gearbox.
♦ After the battery earth strap is disconnected and reconnected,
Gr. 27 .
Brake fluid specification ⇒ Chassis ⇒ Rep. Gr. 00 .

Gr. 27 .
– Connect the brake filling and bleeding device .
To bleed use bleeder hose .
– Connect the ventilation hose with the drip bottle of the brake
bleeding device.
FABIA II 2007 ➤
– Fit the bleeder hose -A- on the slave cylinder -arrow- and open
the bleeder valve.
– Press clutch pedal forcefully from stop to stop between 10 and
15 times.
pedal repeatedly.
– Disconnect brake filling and bleeding device.
– If necessary, bleed the clutch control once again ⇒ page 35 .

– Install battery and battery tray ⇒ Electrical System ⇒ Rep.
Gr. 27 .

FABIA II 2007 ➤
2 Repairing clutch control

♦ Grease for the plug serration of the clutch disc -G 000 100-
1 - Gearbox
❑ remove previous grease
from the contact surface
of the release lever
❑ grease with grease for
plug serration of clutch
disc -G 000 100-
❑ fitted in guide bushing
Pos. 4
❑ replace ⇒ page 108
❑ Fill half the space be‐
tween the sealing lips
and dust lips with seal‐
ing grease -G 052 128
A1-
4 - Guide bushing
❑ with vulcanized O-ring
❑ if O-ring is damaged, re‐
place guide bushing to‐
gether with O-ring
⇒ page 108
❑ for removal, remove
clutch release lever
Pos. 7
❑ grease in the area of the
clutch release lever with
of clutch disc -
G 000 100-
❑ attach to clutch release
lever
6 - 20 Nm
❑ remove and install ⇒ page 38 together with clutch release bearing Pos. 8
❑ remove previous grease from the contact surface of the clutch release lever
❑ Grease contact surface on the ball stud with grease for plug serration of clutch disc -G 000 100-
8 - Release bearing
❑ Do not wash the bearing, just wipe clean
❑ Grease contact surface on the clutch release lever with grease for plug serration of clutch disc -G 000 100-
9 - Slave cylinder
❑ Grease tappet head with grease for plug serration of clutch disc -G 000 100-
2. Repairing clutch control 37

FABIA II 2007 ➤
10 - 20 Nm
11 - Mounting bolt
❑ secures the clutch release lever when installing the gearbox ⇒ page 80
❑ unscrew after the gearbox has been fitted ⇒ page 80
Note
remove and install clutch release lever with clutch release bearing
Removing
– Unhook spring -arrow 1- upwards.
– Remove clutch release lever -arrow 2- from ball stud.
Install
– First mount spring -arrow 1- on the clutch release lever.
– Press clutch release lever -arrow 2- onto the ball stud.

– Press the catch pegs -arrows- together on the rear side of the
clutch release lever and remove the release bearing -A- from
the clutch release lever.

FABIA II 2007 ➤
3 Repairing clutch
♦ Counterholder -MP1-223 (3067)-
♦ Centering mandrel -MP3-475A (3190A)-
(Gearbox removed)
Note
♦ Before replacing the clutch disc and pressure plate fault finding power transmission - observe complaints
of the clutch and clutch control ⇒ page 41 .
♦ 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.
♦ Clean the drive shaft serration and hub serration on used clutch discs, remove corrosion. Apply a very thin
layer of grease for plug serration of clutch disc -G 000 100- onto the serration. Subsequently move the clutch
disc up and down on the drive shaft until the hub fits smoothly on the shaft. Remove all excess grease.
♦ The thrust surface of the pressure plate and the clutch disc lining must fully rest against the flywheel before
the screws are inserted. Only then may the fixing screws be inserted.
FABIA II 2007 ➤
1 - Flywheel
pins are tight
and grease
⇒ Engine ⇒ Rep. Gr.
13
2 - Clutch disc
Parts
❑ Fitting position for sim‐
ple flywheel: the spring
cage points towards the
pressure plate
❑ Fitting position for two-
mass flywheel
⇒ page 41
❑ center ⇒ page 40
ration
3 - Pressure plate
⇒ page 40
❑ Check the extremities of
the membrane springs
⇒ page 41
❑ Check feather joints and
riveted joints
⇒ page 41
4 - Screw M6 - 13 Nm; screw
M7 - 20 Nm
❑ Release or tighten gradually and crosswise
Center the clutch disc and remove and install the pressure plate
– When removing and installing, use counterholder -MP1-223
(3067)- .
Note
inserted.
♦ Tighten the screws crosswise so as not to damage the cen‐
tering holes and the centering pins of the flywheel.

FABIA II 2007 ➤
Fitting position of clutch disc in connection with two-mass flywheel

• Legend “side of gearbox” -arrow- points to the gearbox.

Check feather joints and riveted joints

– Check the feather joints between pressure plate and cover for
cracks as well as the riveted joints for firm seating.
• Pressure plate with damaged feather joints or with loose rive‐
ted joints -arrows- must be replaced.

Note
Check hydraulic clutch control ⇒ page 29 .
Always check the fault mentioned by the customer first before

repairing the clutch. During this procedure, it must be determined
if indeed there is a fault of the clutch or if the cause is only an
incorrect setting of the shift mechanism.
tial position top up with brake fluid.
brake fluid.
♦ Release bearing on the guide – Replace guide bushing and re‐
bushing is tilted, seizured. lease bearing.
FABIA II 2007 ➤

sure plate broken.



mm.
♦ Release bearing on the guide – Replace defective parts.

parts .
♦ Mechanical fault of the pressure – Replace defective parts.
plate/clutch disc.

place clutch disc.

shaft from corrosion and grease
with grease for plug serration of
clutch disc -G 000 100- . Move
clutch disc back and forth, re‐
move excess grease.

Noises when pressing the clutch ♦ Release bearing defective, – Always replace noisy release
pedal. guide bushing is not O.K, con‐ bearings.
tact surface worked-in.
ing.
♦ The contact surface of the pres‐ – Replace pressure plate.
sure plate is defective (the tips
of the membrane spring are bro‐ – Check release bearing, guide
ken, kinked). Release bearing is bushing, replace if necessary.
off-center.
– Check adjustment of clutch re‐
lease lever.

gearbox.
♦ Clutch disc incorrectly installed. – Correct installation.

parts .

FABIA II 2007 ➤

out operation.
is leaking, line is leaking. top up with brake fluid, vent air
from the line system.
under the pedal) clutch is not
fully depressed.
♦ Pressure plate uneven due to in‐ – Check components, if necessa‐

correct installation, clutch disc ry replace, make sure the cen‐
warped due to improper han‐ tering pins are correctly fitted.
dling.
– If scratching still occurs, check
the serration of the clutch disc
on the drive shaft for ease of
movement, if necessary repair

the gearbox.
bearing moves off-center). – Check release bearing and
guide bushing, replace if neces‐
sary.

parts .
♦ Lining glued to the flywheel – Slightly rub down friction surfa‐
(long immobilization time, high ces of the clutch linings or re‐
humidity). place completely the severely
corroded parts.
G 000 100 - .



place if necessary.
parts .
replace.
FABIA II 2007 ➤

speeds).
long a time.

Load change jolts when throttle is ♦ Suspension assembly too soft. – Inform customer. Assign hanger
depressed and sudden reduction of via the ⇒ Electronic catalogue
the engine speed. of original parts .


gearbox. necessary.

♦ Cutch disc is worn out, burnt, – Replace clutch disc.
ural wear.

wheel oily. Shaft seal of the en‐
gine or the drive shaft 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‐
♦ Clutch disc incorrectly installed. – Correct installation, check
clutch disc, replace if necessary.


FABIA II 2007 ➤

unit shaking level, check system for tight‐
ness.

♦ Driving error, speed too low – Inform customer.

when starting.

parts .
original parts .
♦ Clutch lining, contact surface of – Check shaft seal of drive shaft or
pressure plate and flywheel oily crankshaft, if necessary re‐
(oil leakage from the clutch place.
housing).
guide bushing, seizured guide bushing.
membrane spring of the pres‐ – Check actuating elements and
sure plate). bearing for actuating elements.
plate if necessary.
♦ The housing of the pressure
plate was warped when instal‐ – Replace release bearing and
led. Contact surface of the pres‐ guide bushing.
sure plate lifts off only unilater‐
ally.
♦ 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 (rattle
wheel). markings, traces of overheating,
scoring).

clutch disc -G 000 100- .


Acoustic knock “klack” when cou‐ ♦ Carrier earth/drive shaft is ac‐ – Inform customer.
FABIA II 2007 ➤

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

parts .
♦ Pressure plate warped, broken, – Replace pressure plate.
imbalance.

necessary.
missing).

dowel sleeves.


FABIA II 2007 ➤
1 Shift mechanism

-Arrow A- Shift movement
-Arrow B- Selector movement
A - Shift cable
B - Selector cable
C - Heat shield
the shift mechanism
1 - Gearshift lever

2 - Reversing lever
FABIA II 2007 ➤
1.2 Summary of components of the shift mechanism
Note
♦ Remove shift mechanism for replacing control cables ⇒ page 57 .
gearshift knob and cover
⇒ page 49
II - Summary of components -
Shift lever and shift housing
⇒ page 51
Control cables ⇒ page 53

Removing and installing shift
mechanism ⇒ page 57 .
Setting the shift mechanism
⇒ page 61 .

FABIA II 2007 ➤
1.3 Summary of components - gearshift knob and cover
1 - Gearshift knob
❑ with collar
❑ the gearshift knob and
collar cannot be separa‐
ted
of Original Parts
⇒ page 49
e.g. with a screwdriver.
2 - Centre console

♦ Disassembly wedge -3409-
FABIA II 2007 ➤
Vehicles up to 09.08
– Lever off the collar with disassembly wedge -3409- out of the
Vehicles as of 09.08
– Raise the silver frame for the collar using a disassembly
wedge -3409- and remove it from the shift lever.
– Release the catch pegs of the circlip for the bottom collar with
a suitable cross-head screwdriver out of the surround for cen‐
tre console.

Install

FABIA II 2007 ➤
Note
1 - Circlip
⇒ page 52
2 - Spring
3 - Gasket
and underbody
❑ self-adhesive
housing
4 - Shift lever
5 - Damping
⇒ page 52
6 - Shift housing
shift lever Pos. 4
8 - Gasket
Parts
9 - Floor plate
ing
Parts
10 - Bushing
11 - Selector cable
❑ after installing set shift mechanism ⇒ page 61
12 - Shift cable
13 - 23 Nm
❑ 4 pieces
FABIA II 2007 ➤

the -direction of the arrow B-. While doing so remove circlip
-A-.
Note


– Press the pressure spring leg -A- to the left until it is located
next to the damping -arrow-.
• After installing the damping, the pressure spring legs -A- and
-B- must rest on the damping -arrow-.


FABIA II 2007 ➤
Note
1 - Shift cable
shift mechanism
shift mechanism
Pos. 11
⇒ page 47
mechanism
⇒ page 61
2 - Selector cable
shift mechanism
mechanism
Pos. 10
⇒ page 47
mechanism
⇒ page 61
3 - Grommet
4 - Circlip
❑ do not damage cables
when removing
tronic Catalogue of Original Parts
5 - Shift housing
6 - Cable support
❑ out of plastic or metal
7 - Grommet
❑ 3 pieces
8 - Spacer
❑ 3 pieces
9 - 20 Nm
❑ 3 pieces
FABIA II 2007 ➤
10 - Cable lock
❑ for selector cable at relay lever
❑ can be fitted together with the plastic relay lever ⇒ page 55
❑ remove from plastic relay lever ⇒ page 57
❑ press onto plastic relay lever ⇒ page 57
11 - Cable lock
❑ for shift cable at gearbox shift lever
12 - Circlip
13 - Bushings
14 - Reversing lever
❑ The metal relay lever is located in the bushings pos. 13 and secured with a lock washer pos. 12
❑ as of 06.07 the reversing level is plastic
❑ Removing and installing plastic relay lever together with cable lock ⇒ page 55
15 - Sliding shoe
❑ insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft ⇒ page 55
17 - 20 Nm
18 - Circlip
❑ is not required for cable lock for selector cable at relay lever, if relay lever is made of plastic

FABIA II 2007 ➤
Assign cable locks

Cable lock Dimension “a”
⇒ page 55
Install gearshift lever

– When positioning the gearshift lever, make sure that the tooth
opening -arrow A- is located above the interrupted spacing of
the teeth for the gearshift shaft -arrow B-.
Fitting location of gearbox shift lever/relay lever

1 - Gearbox shift lever with balancing weight
2 - Relay lever is inserted over the sliding shoe -arrow- into the
sliding rail of the gearbox shift lever
1.7 Plastic relay lever as of 06.07

♦ Grease -G 000 450 02-
FABIA II 2007 ➤
1.7.1 Removing and installing plastic relay

lever
• Gearbox shift lever is located in the neutral position.
The relay lever is secured with a catch -arrow 1- on the gearshift

cover
– Carefully press down the catch -arrow°1- up to the stop.
– Afterwards move relay lever in its bearing point back and for‐
ward (direction of operation). To do so, carefully pull out cable
lock.
Note

-G 000 450 02- .

• The catch -arrow 1- secures the relay lever.
The relay lever is secured with a clip -arrow°1- on the gearshift

cover
– Remove the clip -arrow 1- from the opening at the relay lever.
Note

-G 000 450 02- .

– Secure the relay lever with a clip -arrow 1-.

FABIA II 2007 ➤
1.7.2 Remove and install cable lock for selec‐

tor cable from plastic relay lever
Remove cable lock for selector cable from plastic relay lever
relay lever.
Press on cable lock

• The cable lock must only be pressed onto the bush -arrow-.
• It must be located behind the catch ⇒ page 56 .

nism
♦ Disassembly wedge -3409 -
♦ Grease -G 000 450 02-
1.8.1 Removing
Note


Gr. 27 .
FABIA II 2007 ➤
– Remove lock washer -3- for shift cable from gearbox shift lever
-1-.
– Pull off the shift cable from the stud -arrow-.
Metal relay lever
– Pull off the selector cable from the stud -arrow-.
Plastic relay lever
Separate cable lock from selector cable

– Remove plastic relay lever together with cable lock

⇒ page 56 .

tre console.

FABIA II 2007 ➤


– Remove the bracket for the exhaust pipe -1- from the assem‐
bly carrier, if necessary unhook the pre-exhaust pipe from the
retaining straps.
– Disconnect the exhaust system at the clamping sleeve ⇒ En‐
-arrows-.
FABIA II 2007 ➤


1.8.2 Install
following points:
The holes in the cable locks have different diameters ⇒ page 53

FABIA II 2007 ➤
– Apply a small quantity of grease -G 000 450 02- onto the studs
-2-.
– Relay lever and cable lock must be installed together
⇒ page 56 .
sides.
bridges ⇒ Engine ⇒ Rep. Gr. 26 .

Gr. 27 .
Note

Tightening torque
Shift housing to body ⇒ page 51
Tunnel bridge ⇒ Engine ⇒ Rep. Gr. 26
Bracket for pre-exhaust pipe ⇒ Engine ⇒ Rep. Gr. 26

♦ Rig pin -T10027A-
FABIA II 2007 ➤
Note
♦ The following are required for correct setting of the shift mech‐
anism:
♦ Control elements and transmission elements of the shift mech‐
anism are in perfect condition.
♦ Shift mechanism operates freely.
♦ Gearbox, clutch and clutch control in perfect condition.
Note


Gr. 27 .


-direction of arrow 2- upwards and at the same time press it in
carefully until it locks into the gearshift shaft.

FABIA II 2007 ➤
tre console.
– Guide shift lever in Neutral to the left into the selector lever
gate of the 1st/2nd gear.
– Insert rig pin -T10027A- into the hole -A- and into the hole
-B-.


FABIA II 2007 ➤
– Pull rig pin -T10027A- out of hole -A- and -B-.

⇒ page 64 .
Gr. 27 .
1.9.1 Operation
• Shift lever must be positioned in Neutral in the selector lever
gate of the 3rd/4th gear.
– Press clutch pedal.

If a gear catches when engaged again, set the shift mechanism
once again ⇒ page 61 .

FABIA II 2007 ➤
2.1 Removing the gearbox; Fabia II 2007 ?

♦ Adapter -MP9-200/3 (10-222A/3)-
♦ Retaining plate -3282-
♦ Adjusting plate -T30020-
Note
Gr. 27 .
off.
Gr. 27 .
shift lever -A-.
Metal relay lever
-B-.
relay lever.
Note
Always replace circlips ⇒ Electronic Catalogue of Original Parts .

FABIA II 2007 ➤
Plastic relay lever

Continued for all vehicles:
-arrow 4-.

– Remove bracket -B- from the gearbox and pull off from the
tube-hose line -A-.
– Remove the slave cylinder -arrows- and lay aside, secure with
wire, do not open the line system.
Caution

– Remove charge-air pipe from exhaust turbocharger to charge
air cooler ⇒ Engine ⇒ Rep. Gr. 21 .

FABIA II 2007 ➤
– Disconnect plug -arrow 1- from reversing light switch -F4- .

starter.
– Expose cables.
– Unplug connector -arrow- from speedometer sender -G22- (if

available).
– Remove bracket for engine cover -arrow- (install in this hole

one of the 2 spindles of the supporting device).
– Install supporting device -MP9-200 (10-222A)- .

– Remove front left wheel ⇒ Chassis ⇒ Rep. Gr. 44 and raise
vehicle.

FABIA II 2007 ➤
-arrows-.
– Unscrew bracket from starter -arrow- and lay aside together

with lines.
Gr. 66 .
drive shafts from flange shafts ⇒ Chassis ⇒ Rep. Gr. 40 .

tion.
For vehicles without particle filter
– Remove pre-exhaust pipe with catalytic converter ⇒ Engine
⇒ Rep. Gr. 26 .
– Mark installation position of bolts -1- from left steering joint.

– Unscrew screws -1- for left steering joint ⇒ Chassis ⇒ Rep.
Gr. 40 .
– Unscrew coupling rod -2- from anti-roll bar -arrow- ⇒ Chassis
⇒ Rep. Gr. 40 .
wards. While doing so, disconnect the plug connection.
Note
On vehicles with air conditioning system additionally unscrew the

fixing screw (in the upper area of the fan shroud) of the bracket
for AC line.

FABIA II 2007 ➤
– Remove pendulum support -arrows 1- and -arrow 2-.
Note

– Unscrew the engine/gearbox connecting screw below the right

flange shaft.
– Remove the holding bracket for the exhaust pipe -1-.

– Separate the exhaust system behind the pre-exhaust pipe at
the clamping sleeve and secure with wire to the body ⇒ Engine
⇒ Rep. Gr. 26 .
– Release the assembly carrier (centre) ⇒ Chassis ⇒ Rep. Gr.
40 .

holder.
Note

FABIA II 2007 ➤

Note

Unscrew the fixing screws -arrows- of the gearbox console and

remove the gearbox console -A- from the gearbox.
– Insert gearbox mount -3282 - into engine/gearbox jack , e.g. -
V.A.G 1383 A- .
Complete engine and gearbox jack with gearbox mount -3282- ,
adjusting plate -T30020- for “02R” gearbox and support elements
as follows:
– Position adjusting plate -T30020 - onto the gearbox mount
-3282- ( adjusting plate fits in only one position).
adjusting plate .

justing plate .
– Screw in the bolt -3282/29- , as indicated on the adjusting
plate.

FABIA II 2007 ➤
mounts at gearbox.
carrier.
– Via the spindles swivel the gearbox backwards and down to‐
wards the assembly carrier.
– After this lower gearbox carefully.
Note
♦ When removing the gearbox -1- ensure the gearbox does not
touch the frame side rail -2-, -arrows-.
♦ When lowering guide the coolant hoses past the gearbox.
– Installing the gearbox ⇒ page 80 .
2.2 Removing the gearbox; Fabia II 2011 ?

♦ Adapter -MP9-200/3 (10-222A/3)-
♦ Retaining plate -3282-
♦ Adjusting plate -T30020-
Note
Gr. 27 .
off.

FABIA II 2007 ➤
– Unscrew the charge pressure control solenoid valve -N75-
with the bracket -2- -arrow- and lay with the vacuum line on
the engine.
Gr. 27 .
– Remove the cooling water tank cover and partition panel ⇒
Body work ⇒ Rep. Gr. 66 .
– In order not to damage the vacuum hose -A- from the brake
servo unit -B- to the engine, it must be removed from the brake
servo unit -arrow 1- ⇒ Chassis ⇒ Rep. Gr. 47 .
the lifting eye -C- at the engine.

– Remove the clip -arrow 1- from the opening at the relay lever.
Note
On certain vehicles the relay lever is secured with a catch

⇒ page 56 .

shift lever -A-.
-arrow 3-.

FABIA II 2007 ➤

Caution

– Disconnect plug -arrow 1- from reversing light switch -F4- .

starter.
– Expose cables.

available).

FABIA II 2007 ➤
Shorten the
original spindle -I- of the supporting device -MP9-200 (10-222A)-
by 100 mm:
I - Original spindle
Note
In order for the original spindle -I- of the supporting device -

MP9-200 (10-222A)- not to touch the front flap, it must be short‐
ened to the dimension -x- (100 mm).


– Hook the original spindle -A- into the front right engine lifting
eye.
– Position the shortened spindle -B- on the adapter -10-222 A/
3- .
– Hook the rear left shackle -10-222 A/12- into the lifting eye of
the engine.
Caution

-arrows-.
– Then connect the shackle -10-222 A/12- with the shortened

vehicle.

FABIA II 2007 ➤
– Remove the charge air hose “hot” side, to do so slacken the

hose clamps -1- ⇒ Engine ⇒ Rep. Gr. 21 .
– Remove charge air pipe “cold” side from engine ⇒ Engine ⇒
Rep. Gr. 21 .
– Gearbox for vehicles with start-stop system: disconnect plug

-arrow- from transmission neutral sender -G701- .

FABIA II 2007 ➤
trical cables.
Gr. 66 .
– Separate the exhaust system at the double clamp and unhook
from the assembly carrier ⇒ Engine ⇒ Rep. Gr. 26 .
Note


-arrows- ⇒ Chassis ⇒ Rep. Gr. 40 .
drive shafts from flange shafts ⇒ Chassis ⇒ Rep. Gr. 40 .

Gr. 40 .

FABIA II 2007 ➤
sis ⇒ Rep. Gr. 40 .
wards.
tion.
– Remove earth strap -1- from engine mount.

– Remove screws -arrows- for engine cradle at engine mount ⇒
Note
The nut -2- must not be released!

the gearbox mount.

FABIA II 2007 ➤

Caution
be accessible.
Note
Slacken the engine/gearbox connecting screw -3- and leave it

screwed in hand tight. The screws -2- and -3- are removed during
future work procedure.
– Insert gearbox mount -3282 - into engine/gearbox jack , e.g. -

V.A.G 1383 A- .
Complete engine and gearbox jack with gearbox mount -3282- ,
adjusting plate -T30020- for “02R” gearbox and support elements
as follows:
– Position adjusting plate -T30020 - onto the gearbox mount
-3282- ( adjusting plate fits in only one position).
adjusting plate .

FABIA II 2007 ➤

justing plate .
– Screw in the bolt -3282/29- , as indicated on the adjusting
plate.
mounts at gearbox.
gear via the spindles of the gearbox mount -3282- further up‐
wards.

FABIA II 2007 ➤

– Screw down the gearbox in the area of the 5th gear (sheet
metal cover) via the spindles of the gearbox mount -3282- .
The gearbox must not touch the engine pump aggregate -A- for
the power-assisted steering.
Note

pipe on the gearbox side of the engine ⇒ Engine ⇒ Rep. Gr.
21 .
part ⇒ Engine ⇒ Rep. Gr. 26 .
– Installing the gearbox ⇒ page 80 .


FABIA II 2007 ➤
– Before installing the gearbox press the clutch release lever

towards the gearbox housing and secure with mounting bolt
or screw M 8 x 35.
– After installing the gearbox release screw again. The hole is
then closed with the 3rd fixing screw for the cable support/
control cables.
Note
♦ Clean splines of drive shaft and apply a thin film of grease for
plug serration of clutch disc -G 000 100 - . The clutch plate
must slide freely up and down the drive shaft.
♦ Install engine mounting ⇒ Engine ⇒ Rep. Gr. 10 .
♦ Align the exhaust system, without tightening ⇒ Engine ⇒ Rep.
Gr. 26 .

♦ Screw on the assembly carrier on vehicles with particle filter
⇒ Chassis ⇒ Rep. Gr. 40 .
♦ Installing starter and cable ⇒ Electrical System ⇒ Rep. Gr.
27 .
♦ Install the left wheelhouse liner ⇒ Body Work ⇒ Rep. Gr. 50 .
♦ Install left front wheel ⇒ Chassis ⇒ Rep. Gr. 66 .
♦ Install the noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
♦ Setting the shift mechanism ⇒ page 61 .
♦ Check gear oil level ⇒ page 85 .
♦ Install air filter housing complete with air guide hose ⇒ Engine
⇒ Rep. Gr. 23 .
♦ Install battery and battery tray ⇒ Electrical System ⇒ Rep.
Gr. 27 .
Gr. 27 .

FABIA II 2007 ➤

Pos. Screw Pieces Nm
1 M12 x 50 2 80
21) M12 x 150 1 80
31) M12 x 150 1 80
41) M10 x 58 1 40
5 M10 x 50 1 40
6 M12 x 55 1 80
72) M6 x 8 1 10

1 M12 x 50 1 80
21) M12 x 55 1 80
31) M12 x 150 2 80
41) M10 x 50 1 40
5 M10 x 50 1 40
6 M12 x 60 1 80
72) M6 x 8 1 10

1 M12 x 50 2 80
21) M12 x 150 2 80
3 M10 x 50 3 40
4 M12 x 55 1 80
52) M6 x 8 1 10

FABIA II 2007 ➤

1 M12 x 50 1 80
21) M12 x 55 1 80
31) M12 x 150 2 80
41) M10 x 50 1 40
5 M10 x 50 2 40
6 M12 x 60 1 80
72) M6 x 8 1 10
Attach the gearbox to the 3 cylinder engine (1.2 ltr./55 kW TDI

CR) with particle filter (flange fig. gearbox)

1 M12 x 50 2 80
21) M12 x 150 2 80
3 M10 x 50 3 40
4 M12 x 60 1 80
52) M6 x 8 1 10
Pendulum support
Note


Slave cylinder to gearbox ⇒ page 28
bracket for tube-hose line ⇒ page 28
Fixing screws of engine mount ⇒ Engine ⇒ Rep. Gr. 10
Pendulum support ⇒ Engine ⇒ Rep. Gr. 10

FABIA II 2007 ➤

Pre-exhaust pipe with catalytic converter and clamping ⇒ Engine ⇒ Rep. Gr. 26
sleeve
Drive shaft to flange shaft ⇒ Chassis ⇒ Rep. Gr. 40
Coupling rod to anti-roll bar ⇒ Chassis ⇒ Rep. Gr. 40
Heat shield for drive shaft to engine ⇒ Chassis ⇒ Rep. Gr. 40
Steering joint to track control arm ⇒ Chassis ⇒ Rep. Gr. 40
Wheel bolts ⇒ Chassis ⇒ Rep. Gr. 44
2.4 Transporting the gearbox

♦ Gearbox attachment device -MP3-478 (3336)-
– Screw down gearbox suspension device -MP3-478 (3336)-

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

Number of visible holes = 5.
device -MP3-478 (3336)- .

FABIA II 2007 ➤
3 Check gear oil level

Gearbox oil specification ⇒ Electronic Catalogue of Original
Parts .
– Screw in the screw of the filler hole -arrow- and tighten to
about 2 minutes.

– Switch off engine, unscrew plug -arrow- and once again top
up gear oil to lower edge of the filler hole.
– Screw in the screw of the filler hole -arrow- and tighten to
3. Check gear oil level 85

FABIA II 2007 ➤

gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Gearbox housing
❑ repairing ⇒ page 108
7 - Shift mechanism
❑ Gearshift forks

sembling ⇒ page 117
8 - Drive wheel for 1st gear
sliding gear and reverse gear
9 - Drive shaft
10 - Output shaft
12 - Clutch housing

FABIA II 2007 ➤

Mounting sequence - Removing and installing gearbox housing
cover and 5th gear ⇒ page 91
Mounting sequence - completely disassembling and assembling
the gearbox ⇒ page 96

gear ⇒ page 88
II - Removing and installing
mechanism ⇒ page 89
differential gear and shift forks
⇒ page 90

FABIA II 2007 ➤
1 - 18 Nm
❑ for cover to gearbox
housing
Note
3 - Gasket
90°
❑ holds disc spring in po‐
sition with sleeve socket
on screw head
tronic Catalogue of
Original Parts
❑ Clean the threaded
holes for the fixing
screws of the synchron‐
izer body and the 5th
gear pinion using a
screw-tap in order to re‐
move locking agent res‐
idues; otherwise there is
a risk that the screws will
shear
5 - Disc spring
6 - 25 Nm
❑ for bearing pins on the
gearbox housing
7 - Bearing pins
❑ disassembling and assembling ⇒ page 117
9 - Spring
11 - Arresters
❑ (3 pieces)
12 - Synchronizer body with sliding gear and synchronizer ring for 5th gear
❑ remove separately ⇒ page 91
❑ remove together with gearbox housing ⇒ page 96
13 - Needle bearing
❑ for 5th gear sliding gear

FABIA II 2007 ➤
4.4 Removing and installing gearbox hous‐

ing and shift mechanism
♦ Sealant -AMV 188 200 03-
1 - 25 Nm
spring
⇒ page 96
❑ complete ⇒ page 152
3 - 25 Nm

❑ self-locking
tronic Catalogue of
Original Parts
4 - 30 Nm
❑ self-locking
tronic Catalogue of
Original Parts
5 - O-ring
tronic Catalogue of
Original Parts
6 - Bearing pins
7 - 25 Nm
8 - 25 Nm
9 - Screw cap
❑ remove together with
5th gear ⇒ page 96
11 - Screw, 5 Nm
12 - Transmission neutral sender -G701 -
13 - Clutch housing
❑ for attaching the gearbox housing to the clutch housing
❑ (Gearshift shaft with gearshift cover)

FABIA II 2007 ➤
❑ Repairing ⇒ page 112
16 - 25 Nm
4.5 Removing and installing the drive shaft, output shaft, differential gear and
shift forks
2 - O-ring
❑ 4 pieces
tronic Catalogue of
Original Parts
3 - Output shaft

5 - Reverse shaft
6 - Drive shaft
⇒ page 96
8 - 25 Nm
9 - Shift mechanism
❑ (Gearshift forks)
10 - Clutch housing
❑ 4 nuts for bearing support
12 - Flange shaft with pressure spring
13 - 25 Nm

FABIA II 2007 ➤
4.6 Mounting sequence - Removing and in‐

stalling gearbox housing cover and 5th
gear
Note
♦ If it is intended to only remove the 5th gear, keep to the fol‐

lowing work sequence.
♦ For this work sequence, the gear oil must not be drained. Once
the gearbox housing cover is removed, then the cover side of
the gearbox must point upwards.
♦ If it is intended to remove the gearbox housing, the work se‐
quence “completely disassembling and assembling the gear‐
box” must be observed ⇒ page 96 .

♦ Drive bushing -MP3-402 (VW 244 B)-
♦ Supporting bridge -MP3-425 (30-211 A)-
♦ Pressure washer -MP3-456 (VW 447 i)-
♦ Insertion tool -MP3-466 (32-111)-
♦ Assembly device -MP6-414 (3253)-
♦ Assembly device -T10030-
♦ Supporting device -T10323-
♦ Two-arm extractor -Kukko 20/10- with pull-off hook -
T10040/2A-
♦ Hot air blower , e.g. -V.A.G 1416-
♦ Screw M 10 x 20 mm

FABIA II 2007 ➤
4.6.1 Removing gearbox housing cover and

5th gear
– Secure gearbox to gearbox mount -T30109 (VW 353)- with
screws -arrows-.
– Remove clutch release lever with release bearing
⇒ page 37 .
support:
♦ Thrust piece -T10030/4-
• The drive shaft must only be supported with the insertion tool
-MP3-466 (32-111)- at a later stage.
♦ Pressure plate -MP6-414/7 (3253/7)- from assembly device -
MP6-414 (3253)-

FABIA II 2007 ➤
– Check whether the pull-off hooks -T10040/2A- can be correct‐

ly positioned under the 5th gear pinion.
The pull-off hooks -T10040/2A- cannot be correctly positioned.

-A- Remove “together”: “5th gear synchronizer
Pull-off hooks -T10040/2A- prematurely touch: body”, “5th gear pinion” and “gearbox housing”
♦ the walls of the gearbox housing ⇒ page 96
♦ the ribbing in the gearbox housing under the 5th gear
pinion
-B-
Pull-off hooks -T10040/2A- touch the ribbing in the gearbox
housing under the 5th gear pinion.
The pull-off hooks -T10040/2A- can be correctly positioned.

The 5th gear can be removed separately ⇒ page 94 .

FABIA II 2007 ➤
Remove 5th gear separately

– Cover the openings with a cloth.
– Remove the 5th gear shift fork in -direction of arrow B- from
the sliding sleeve.
Note
– Unscrew screws -A- for synchronizer body and 5th gear pin‐
ion. To this end engage the 5th gear -arrow 1- and 1st gear
-arrows 2- and -3-.
gears, the synchronizer body and pinion cannot rotate. Now it is
possible to release the two bolts.
Note
Pull off 5th gear synchronizer body together with sliding sleeve
and arresters.
Use extractor -T10309- .
– First of all insert the shell -T10309/1- between the 5th gear
pinion -A- and the support for the 5th gear shift fork -B-.
• The shell -T10309/1- must be positioned below the 5th gear

synchronizer ring.
– If necessary, the shell must be pressed into the end position.
– Turn the shell -T10309/1- to the opposite side

FABIA II 2007 ➤
– Insert the threaded insert -T10309/3- into the shell .

– Now insert the second shell -T10309/1- and position the pipe
-T10309/2- onto the device.
– Check the synchronizer body for damage after removing.
– Replace 5th gear synchronizer ring.
– Remove the 5th gear sliding gear with needle bearing.
– Remove the 5th gear pinion as follows:

– First of all insert the pull-off hook -A-.
B - Screw M10 x 20, wrench size 17
– If necessary, slightly heat the pinion using the hot-air blower -
V.A.G 1416- .
Note
♦ The 5th gear pinion can also be removed using the two-arm
extractor -Kukko 20/10- in combination with the pull-off hooks
-T10040/2A- .
♦ When pulling off the gear pinion make sure the hooks do not
bend outwards. Check 5th gear for damage after removing.
4.6.2 Mount 5th gear and cover for gearbox

housing
Install 5th gear ⇒ page 104 .
– Install the cover for the gearbox housing -arrow- and tighten
the screws to tightening torque ⇒ page 88 .
– Mount clutch release lever with release bearing ⇒ page 37 .

FABIA II 2007 ➤
4.7 Mounting sequence - completely disas‐

sembling and assembling the gearbox
Removing and installing cover for gearbox housing, gearbox
housing, gearshift shaft with gearshift cover, drive shaft, output
shaft, differential gear and gearshift mechanism.
♦ Driver -MP1-304 (10-206)-
♦ Drive bushing -MP3-402 (VW 244 B)-
♦ Assembly device -T10030-

♦ Removal plate -T10408- with pressure pieces -T10408/2-
♦ Extractor (2 pieces) e.g. -Kukko 18/1-
♦ Sealant -AMV 188 200 03-
♦ Bolts M 8 x 100 mm
4.7.1 Disassembling gearbox

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

FABIA II 2007 ➤
– Secure gearbox to gearbox mount -T30109 (VW 353)- with

screws -arrows-.
– Removing the clutch release lever, clutch release bearing and
guide bushing ⇒ page 37 .
• The bearing of the input shaft and of the output shaft must not
be damaged when removing and installing the 5th gear.

support:
• Lock the screw of the supporting bridge -MP3-425 (30-211 A)-
with the nut -A-.
♦ Pressure plate -MP6-414/7 (3253/7)- from assembly device -
MP6-414 (3253)-

FABIA II 2007 ➤

– Remove the 5th gear shift fork in -direction of arrow B- from
the sliding sleeve.
Note
– Unscrew
screws -A- for synchronizer body and 5th gear pinion. To this
-3-
.
– The input and output shafts are blocked after introducing the
two gears, the synchronizer body and pinion cannot rotate.

Now it is possible to release the two bolts.
Note
– Remove both flange shafts. To do so secure the flange shaft

with a drift to prevent it from turning and release screw.
– Remove both flange shafts with pressure springs, stop discs
and conical rings.
– Release both screws -arrows- for support/reverse shaft.

FABIA II 2007 ➤
– Gearbox for vehicles with start-stop system: remove the trans‐

mission neutral sender -G701- -arrow-.
– Remove gearshift shaft with cover Put the gearshift shaft into
Neutral. Subsequently unscrew screws -arrows- and remove
the gearshift shaft from the gearbox housing.
– Remove screws -arrows- from the cap -A- and the bearing pins
-B- at the bottom of the gearbox.
– Carefully remove the screw cap -A- with driver -MP1-304

(10-206) - and hammer -B-.

FABIA II 2007 ➤
– Release screws -A-, that serve to secure the gearbox housing

from the clutch housing.
Note
Do not release nuts -B- for the output shaft bearing support.
– Remove bearing pins -A- on the top side of the gearbox and
fixing screws -B- for the gearbox housing on the clutch housing
near the differential gear.
Remove the following components together with the gearbox
housing:
♦ 5th gear synchronizer body
♦ 5th gear pinion

Mount the removal plate -T10408- in combination with the follow‐

ing special tools:
♦ Spacers -T10408/1- (5 pieces)
♦ Pressure pieces -T10408/2 - (2 pieces)
♦ Extractors Kukko 18/1 (2 pieces)
– Tighten the 5° spacers -T10408/1- in the threaded bores of the
cover for the gearbox housing.
– Tighten the removal plate -T10408- on the pressure pieces -
T10408/1- .
A - Screws M7 x 35 with washers
Tightening torque - 18 Nm
– Position the pressure pieces -T10408/2- onto the shafts.

– 2 Mount the extractor -A-, e.g. -Kukko 18/1- .
– Remove 5th gear synchronizer body, 5th gear pinion and
gearbox housing by alternatively tightening the spindles -A-
(1/2 turn) with the extractors e.g. -Kukko 18/1- .
Note
♦ If necessary, heat the 5th gear pinion using the hot-air blower
e.g. - V.A.G 1416- .
♦ Check the catch of the needle bearing for the drive shaft in the
gearbox housing. If the 3 caulks are damaged, the needle
bearing was shifted during the removal and must be replaced
⇒ page 108 .

FABIA II 2007 ➤
– Remove shift forks -A- together with shift rails.

– Unscrew shift mechanism/reverse gear -B-.
– Release nuts -B- for the bearing support/output shaft.
– Successively remove the reverse gear -A-, drive shaft -B- and
output shaft -C- from the clutch housing.
– Remove differential gear.
4.7.2 Assembling gearbox

– Always replace O-rings -arrows- for bearing support/output
shaft ⇒ Electronic Catalogue of Original Parts .
Note
The fig. only shows 3 of the 4 O-rings.

FABIA II 2007 ➤
– Insert together the drive shaft -1- and the drive shaft -2-.
– Tighten nuts for the bearing support/output shaft to tightening
torque ⇒ page 131 .
– Position the reverse pinion -3- on the needle bearing in the
clutch housing.
The shoulder -arrow- points away from the clutch housing.
– Check if the reverse shaft -4- is complete ⇒ page 144 ; do not
yet position the reverse shaft support onto the reverse shaft.
– Insert the reverse shaft in the clutch housing.
– Clean all threaded holes in the reverse shaft support to remove
locking agent; clean with a screw-tap.
– Position reverse shaft support on the reverse shaft.
– Install the reverse gear shift fork -1- with the support for re‐
verse gear shift fork -2-, the spring -3- and the sliding shoe
-4-.
Fitting location of reverse gear
– Tighten the screw -B- for the shift mechanism/reverse gear to

the tightening torque ⇒ page 90 .
– Install shift forks -A- together with shift rails.

FABIA II 2007 ➤
– Screw the pin screw -A- M8 x 100 mm in the reverse shaft

support, to ensure it is aligned once the gearbox housing has
been fitted.
– Align shift rails.
Note
The shift segments must be positioned in the slots of the sliding

sleeves.
– Apply sealant -AMV 188 200 03- uniformly on the sealing sur‐
face of the clutch housing.
– Position the gearbox housing and tighten fixing screws to the
given tightening torque ⇒ page 89 .
Insert the screws for the reverse shaft support -arrow- as follows:
– Insert screw -a-, release pin screw M 8 x 100 mm (⇒ fig.°
S34-0314) from the reverse shaft support, insert screw -b- and
tighten by hand.

Tightening sequence:
1- Screw -a- 30 Nm (M8 x 32)
2- Screw -b- 25 Nm (M8 x 26)
– Fit bearing pins -arrow- for shift forks. Align the shift mecha‐
nism with a screwdriver to ensure the relevant bearing pin can
be fitted.
face of the screw cap.
– Fit gearshift shaft cap and tighten screws to tightening torque
⇒ page 89 .
Install the gearshift shaft as follows:

– Put the shift rails in neutral position.
face of the cover.
– Position the peg -arrow 1- in the recess of the gearbox hous‐
ing. Align the gearshift shaft in such a way that the shift finger
-arrow 2- is inserted in the shift rails.
– Fit gearshift shaft cover and tighten screws to tightening tor‐
que ⇒ page 89 .

FABIA II 2007 ➤
– Gearbox for vehicles with start-stop system: insert the trans‐

mission neutral sender -G701- -arrow- and tighten the fixing
screw to the tightening torque ⇒ Item 11 (page 89) .
conical rings.
4.7.3 Install 5th gear

• Make sure that the supporting bridge -MP3-425 (30-211 A)-
and the supporting device -T10323- are mounted.
– Lock the screw of the supporting bridge -MP3-425 (30-211 A)-
with the nut -A-.
Fitting position of the 5th gear pinion

The round slot -arrow- points to the gearbox housing.
– Heat the 5th gear pinion to approx. 100°C.
WARNING

FABIA II 2007 ➤
– Drive in 5th gear pinion
Checking 5th gear synchronizer ring for wear

measure the clearance -a- with a feeler gauge before installing
the sliding gear and the 5th gear snychronizer ring.
Fitting dimension Wear limit
Clearance -a- 1,1…1,7 mm 0.5 mm

– If disassembled, assemble the 5th gear synchronizer body/
sliding sleeve before installation ⇒ page 120 .
Fitting position of the 5th gear synchronizer body/sliding sleeve

The sharp teeth of the sliding sleeve -arrow 1- and the high collar
of the synchronizer body -arrow 2- point towards the gearbox
housing.
The supports -arrow 3- of the synchronizer body are on the same
line as the integrated arresters of the synchronizer ring (arrows in
Fig. N35-0018 ⇒ page 105 ).
5th gear synchronizer ring with integrated arresters -arrows-

– Cover all openings in the gearbox housing with a cloth so that
no foreign bodies can get into the gearbox.
– Heat 5th gear synchonizer body to approx. 100 °C.
WARNING

FABIA II 2007 ➤
– Drive in 5th gear synchronizer body/sliding sleeve.
Note
Pay attention to the free travel of the synchronizer ring during the
driving in operation.
– Remove supporting bridge -MP3-425 (30-211 A)- and sup‐

porting device -T10323- .
If it is not yet performed, clean the threaded holes of the fixing
screws for the 5th gear synchronizer body and the 5th gear pinion
Otherwise there is a risk that the screws will shear.
Fitting position of the disc springs for fixing screws on the 5th gear
pinion and synchronizer body
The curved side (concave side) -arrows- points to the screw head.
– Screw in new screws -A- for the synchronizer body and the 5th
gear pinion and tighten to tightening torque ⇒ page 88 . To this
-3-.
gears, the synchronizer body and 5th gear pinion cannot rotate.
Now it is possible to tighten the two bolts.
– Fit 5th gear shift fork.

FABIA II 2007 ➤
Set 5th gear as follows:

– Engage 5th gear.
– Release screw -1-. Press the sliding sleeve and the gear shift
gate in the -direction of the arrow-.
– Tighten screw -1- to tightening torque ⇒ page 117 .
• Control measurement when the 5th gear is engaged: A feeler
gauge of 0.2 mm must not be pushed in between the sliding
sleeve and the sliding gear. If necessary repeat the adjustment
procedure.
– Remove 5th gear. The sliding sleeve must now be in Neutral.
The 5th gear synchronizer ring must move freely.
– Shift through all gears consecutively.
– Install the cover for the gearbox housing -arrow- and tighten
the screws to tightening torque ⇒ page 88 .
– Installing the guide bushing for clutch release lever and clutch
release bearing ⇒ page 37 .


FABIA II 2007 ➤

clutch housing
♦ Drift -MP3-403 (VW 295)-
♦ Adapter -MP3-403/1 (VW 295 A)-
♦ Thrust piece -MP3-411 (VW 454)-
♦ Pipe section -MP3-450 (VW 415A)-
♦ Pressure washer -MP3-455 (VW 447 H)-
♦ Pressure washer -MP3-460 (VW 512)-
♦ Sealant -AMV 188 200 03-
1 - Gearbox housing
❑ when replacing: set the
drive shaft and the dif‐
ferential gear
⇒ page 161
2 - Oil filler plug, 30 Nm
3 - Needle bearing
❑ fitting and securing
⇒ page 110
❑ for drive shaft
❑ Setting overview
⇒ page 161
bearing
❑ for drive shaft
⇒ page 120
drive shaft ⇒ page 126
bearing
⇒ page 131
output shaft
⇒ page 141
❑ Setting overview ⇒ page 161

FABIA II 2007 ➤

❑ for drive shaft
❑ when replacing: set the drive shaft ⇒ page 126
9 - Needle bushing
10 - Fitting sleeve
❑ 2 pieces
11 - Clutch housing
❑ when replacing: setting overview ⇒ page 161
❑ grease with grease for plug serration of clutch disc -G 000 100-
13 - Guide bushing
❑ with gasket ring for drive shaft and vulcanized O-ring
❑ Driving out gasket ring ⇒ page 110
❑ Driving in gasket ring ⇒ page 110
❑ to replace gasket ring, remove guide bushing
❑ if O-ring is damaged, replace guide bushing and O-ring together ⇒ Electronic Catalogue of Original Parts
14 - 20 Nm
❑ replace gasket ring together with bushing in the event of damage to the gasket ring ⇒ page 149
16 - Screw plug, 5 Nm
❑ is installed instead of the drive for speedometer on vehicles with ABS
17 - Drive for speedometer, 10 Nm
❑ only mounted on vehicles without ABS
18 - Oil drain plug, 30 Nm
❑ when replacing: Set the differential gear ⇒ page 158
20 - Magnet
❑ when replacing: Set the differential gear ⇒ page 158
❑ Setting overview ⇒ page 161
23 - Sealing ring

FABIA II 2007 ➤
Driving out needle bearing
Drive in needle bearing up to stop

– Using a drift secure needle bearing in 3 points in the gearbox
housing with 120° offset.
Driving out the guide bushing
Driving the gasket ring into the guide bushing up to the stop

FABIA II 2007 ➤
Pull out bushing with gasket ring

– Position the extraction hook -MP3-419/37 (VW 771/37) - of the
multi-purpose tool -MP3-419 (VW 771)- directly behind the leg
in the bushing.
– Press the extraction hook -MP3-419/37 (VW 771/37)- force‐
Insert bushing with gasket ring

– Clean the gasket ring seat in the gearbox.
-A- Screw spindle of assembly device -MP3-434 (3066)- into
the threaded part of the differential gear.
-B- Nut M12
– By turning the nut -B- insert the bushing with the gasket ring
over the pressure plate -T10148 - up to the stop.
Note
If the gearbox is disassembled press in the bushing with the gas‐

ket ring over the pressure plate -T10148- up to the stop.

FABIA II 2007 ➤

on the gearbox side

gearshift mechanism on the gearbox
side (gearshift shaft can be removed
from gearshift cover)
♦ Pressure plate -MP3-406 (VW 401)-
♦ Pressure spindle -MP3-448 (VW 408 A)-
♦ Guide piece -MP3-454 (VW 439)-
♦ Pressure washer -MP3-456 (VW 447 I)-
♦ Pipe section -MP3-479 (VW 423)-
♦ Interior extractor 18.5 … 23.5 mm , e.g. -Kukko 21/3-
Note


FABIA II 2007 ➤
1 - Gearshift shaft
❑ when shifting from the
5th gear to the 4th gear,
the screw Pos. 5 guides
the gearshift shaft into
the 4th gear shift gate
via the leg -arrow-
parts
2 - Stop ring
3 - Ball sleeve
4 - Shift cover
❑ with locking angle for
setting the gearshift
mechanism
❑ Remove locking angle
⇒ page 116
❑ Press in locking angle
⇒ page 116
parts
5 - 15 Nm
6 - Reversing light switch -F4- ,
20 Nm
of clutch disc -
G 000 100-
7 - Reversing lever
❑ as of 06.07 the reversing level is plastic
8 - Bushing
9 - Sealing ring
❑ lever out with screwdriver
❑ Fill half the space between the sealing lips and dust lips with sealing grease -G 052 128 A1-
10 - Cap
11 - 20 Nm

FABIA II 2007 ➤
13 - Lock washer
❑ replace after each disassembly ⇒ electronic catalogue of original parts
14 - Screw cap
15 - Spring
❑ if present, insert in the screw cap Pos. 14
Remove the ball sleeve from the cover

– Before pulling out the ball sleeve destroy the platic cage and
remove the balls.
A - Interior extractor 18.5 … 23.5 mm , e.g. -Kukko 21/3-
Press the ball sleeve flush into the gearshift cover
Press in the gasket up to the stop.

FABIA II 2007 ➤
6.2 Disassembling and assembling the gearshift mechanism on the gearbox

side (gearshift shaft cannot be removed from gearshift cover)
Note

1 - Gearshift unit
❑ consisting of the gear‐
shift shaft and the gear‐
shift cover
❑ the components cannot
be separated
2 - Reversing light switch -F4- ,
20 Nm
of clutch disc -
G 000 100-
3 - Locking angle
mechanism
4 - Reversing lever
⇒ page 53
⇒ page 56
5 - Clip
❑ for relay lever with hole
in the bearing shaft
6 - Gasket for gearshift shaft
❑ release with a screw‐
driver
7 - 20 Nm
8 - Gearshift lever
9 - Cap

FABIA II 2007 ➤
10 - Screw cap
11 - Spring
❑ if present, insert in the screw cap
Remove locking angle -A- from gearshift cover

– Remove the outer part of the locking angle.
– Then lever out the locking angle carefully with a screwdriver.
Press locking angle -A- into gearshift cover

Fitting position:
The marking -arrow- points to the upper part of the gearshift shaft.

FABIA II 2007 ➤

gearshift forks
♦ Driver -MP1-304 (10-206)-
♦ Distance sleeve -MP3-458 (VW 472)-
Note
♦ Removing and installing gearshift fork group Pos. 7 ⇒ page 96 .

♦ The gearshift fork group (Pos. 7 need not to be disassembled for the disassembly and assembly of the shift
segments, circlips and angular ball bearings.
1 - Shift segment for 5th gear

❑ Identification
⇒ page 118
2 - Circlip
tronic Catalogue of
Original Parts
4 - 25 Nm
❑ 4 pieces
shift rails
❑ Identification
⇒ page 118

FABIA II 2007 ➤

❑ It must still be possible to rotate the shift segment freely once the circlip has been fitted
10 - Sliding block
❑ Mushroom shape
11 - Spring
13 - Support for reverse gear shift fork
14 - Circlip
Identification of shift segments

Dimension -a-
1 - Shift segments 1st and 2nd gear = 11.4 mm
2 - Shift segments 3rd and 4th gear = 7,6 mm
3 - Shift segments 5th gear = 6,0 mm

Fitting the circlip

segment.
Note
-A- - Handle wrench, wrench size 10 mm

-B- - Protective jaws

FABIA II 2007 ➤
Removing the angular ball bearing
Note
The recess in the pressure plate -T30100/1- points towards the
ball bearing.
Shift fork with fitted shift segments

Dimension -a- (mm)
1st/2nd gear shift fork 88,4 … 89,1
3rd/4th gear shift fork 96,0 … 96,7
Shift segment assignment ⇒ page 118

FABIA II 2007 ➤
1 Drive shaft

drive shaft
♦ Pressure spindle -MP3-408 (VW 412)-
♦ Thrust piece -MP3-411 (VW 454) -

♦ Separating device 12...75 mm , e.g. -Kukko17/1-
Note
♦ Removing and installing drive shaft ⇒ page 96 .

♦ When installing new pinions or a new input shaft observe the technical data ⇒ page 1 and ⇒ page 2 .
♦ If the position of the tapered-roller bearing is influenced when parts are replaced the drive shaft must be
reset. Setting overview ⇒ page 161 .

FABIA II 2007 ➤
1 - Clutch housing
bearing
❑ pressing out
⇒ page 122
bearing
❑ pressing off
⇒ page 123
❑ pressing on
⇒ page 123
4 - Drive shaft
5 - 3rd gear pinion
❑ pressing off
⇒ page 123
❑ pressing on
⇒ page 124
points to the 4th gear
sliding gear
6 - Circlip
tronic Catalogue of
Original Parts
7 - 4th gear pinion
❑ pressing off with inner
ring/tapered-roller bear‐
ing and bushing
⇒ page 123
❑ pressing on
⇒ page 124
❑ Fitting position: Collar points to the 3rd gear sliding gear
❑ pressing off with 4th gear pinion and bushing ⇒ page 123
9 - Thrust washer
❑ Determine thickness ⇒ page 126
13 - Bushing
❑ pressing off with 4th gear pinion and inner ring/tapered-roller bearing ⇒ page 123
❑ insert thrust washer Pos. 9 before assembly
14 - Needle bearing
❑ for 5th gear
1. Drive shaft 121

FABIA II 2007 ➤

❑ with integrated arresters ⇒ page 104
17 - Spring
18 - Arresters
❑ (3 pieces)
❑ remove with 5th gear synchronizer body Pos. 19
❑ Assembling sliding sleeve/5th gear synchronizer body ⇒ page 126

21 - Disc spring

FABIA II 2007 ➤
Pressing off inner ring/tapered-roller bearing

-A- - separating device 12...75 mm e.g. -Kukko17/1-
Pressing off 4th gearwheel with tapered-roller bearing and bush‐

ing
Pressing off 3rd gear pinion

– Prior to this remove the circlip.
1. Drive shaft 123

FABIA II 2007 ➤
Pressing on 3rd gear pinion
Pressing on 4th gear pinion

Collar points to the 3rd gear.
Press on bushing for 5th gear needle bearing

FABIA II 2007 ➤

– After setting the drive shaft insert with adjusting washer.
5th gear synchronization

1- Springs for arresters
2- Sliding sleeve with 3 recesses -arrows A- for the arresters
-4-
3- Synchronizer body
4- Arresters (Fitting location: Leg -arrow B- points to the sharp
teeth of the sliding sleeve -2-)
1. Drive shaft 125

FABIA II 2007 ➤
Assembling sliding sleeve/5th gear synchronizer body

The sharp teeth -A- of the sliding sleeve and the collar -B- of the
synchronizer body point in the same direction.
The recesses for the arresters in the sliding sleeve and the syn‐
chronizer body must be positioned above one another
⇒ page 125
– Insert arresters (Fitting location: ⇒ page 125 ).
– Mount the springs with 120° offset under the shoulder -C-. The
angled ends of the spring must be located before the arresters
-arrows-.
Note
Observe the correct position of springs on the arresters which are

hollow inside ⇒ page 126 .
Springs bent at right angles -A- for the 5th gear synchronisation

These springs are installed on both sides.
– The springs can only be installed on previous gearboxes to‐
gether with arresters, which are hollow inside.
– Insert arresters (Fitting location ⇒ page 125 ).
Fitting location of the springs:

– Mount the springs with 120° offset.
– The angled end -A- of the spring must grip into the hollow ar‐
rester and at the same time be located below the shoulder
-B- of the arresters.
The end bent at right angles always points away from the syn‐
chronizer body -direction of arrow-.
1.2 Setting drive shaft

♦ Universal dial gauge holder -MP3-447 (VW 387)-

FABIA II 2007 ➤
♦ Dial gauge
The drive shaft must be re-set when the following components
are replaced:
♦ Gearbox housing
♦ Clutch housing
♦ Drive shaft
♦ Gear pinion for 4th gear
Or the
Setting overview ⇒ page 161 .
Note

– Press the outer ring/tapered-roller without adjusting ring up to

the stop into the gearbox housing.
– Press the outer ring/tapered-roller bearing up to the stop into

the clutch housing.
– Insert drive shaft in the clutch housing and install gearbox
housing. Tighten screws to tightening torque ⇒ page 89 .
– Fit measuring device and dial gauge in the clutch housing.

– Turn the drive shaft several times before measuring to ensure
the tapered-roller bearings set. Set the dial gauge to “0” with
1 mm bias.
Note
This procedure must be repeated before each subsequent meas‐

urement, because otherwise the dial gauge does not return to its
initial setting to “0”.
1. Drive shaft 127

FABIA II 2007 ➤
– Press drive shaft towards the dial gauge -direction of arrow-.

– Read off play on dial gauge and note (in the example = 1.21
mm).
Note
Dial gauge does not return to initial position.

washer
Example:
1.21 mm 1.175 mm

FABIA II 2007 ➤
– Remove drive shaft and press out outer ring/tapered-roller

bearing from the gearbox housing with thrust washer -
MP3-456 (VW 447 I)- .
– Determine the adjusting washer thickness from the table
⇒ page 129 (example 1.175 mm).
0,671 … 0,699 0,650
0,700 … 0,724 0,675
0,725 … 0,749 0,700
0,750 … 0,774 0,725
0,775 … 0,799 0,750
0,800 … 0,824 0,775
0,825 … 0,849 0,800
0,850 … 0,874 0,825
0,875 … 0,899 0,850
0,900 … 0,924 0,875
0,925 … 0,949 0,900
0,950 … 0,974 0,925
0,975 … 0,999 0,950
1,000 … 1,024 0,975
1,025 … 1,049 1,000
1,050 … 1,074 1,025
1,075 … 1,099 1,050
1,100 … 1,124 1,075
1,125 … 1,149 1,100
1,150 … 1,174 1,125
1,175 … 1,199 1,150
1,200 … 1,224 1,175
1,225 … 1,249 1,200
1,250 … 1,274 1,225
1,275 … 1,229 1,250
1,300 … 1,324 1,275
1,325 … 1,349 1,300
1,350 … 1,374 1,325
1,375 … 1,399 1,350
1,400 … 1,424 1,375
1,425 … 1,449 1,400
1,450 … 1,474 1,425
1,475 … 1,499 1,450
1,500 … 1,524 1,475
1,525 … 1,549 1,500
1,550 … 1,574 1,525
1,575 … 1,599 1,550
1,600 … 1,624 1,575
1,625 … 1,649 1,600
1,650 … 1,674 1,625
1,675 … 1,699 1,650
1,700 … 1,724 1,675
Note

Original Parts .
1. Drive shaft 129

FABIA II 2007 ➤
– Press outer ring/tapered-roller bearing with thrust washer -

MP3-413 (VW 510)- into the gearbox housing together with
the adjusting washer (in the example 1.175 mm).
– Position the gearbox housing and tighten screws to the given
1.2.2 Control measurement

– Insert measuring device and dial gauge.
– Turn the drive shaft several times to ensure the tapered-roller
bearings set.
– Press drive shaft in the -direction of the arrow-.
– The bearing clearance must be min. 0.01...max. 0.09 mm.
Note
If no bearing clearance can be measured, however the drive shaft

has a tangible valve rock and can easily be turned, then the set‐
ting is also OK.

FABIA II 2007 ➤
2 Output shaft

put shaft
♦ Drive bushing -MP3-408 (VW 412)-
♦ Press-on sleeve -MP3-412 (VW 455)-
♦ Drive bushing -MP3-423 (VW407)-
♦ Pressure spindle -MP3-449 (VW 409) -
♦ Pipe section -MP3-450 (VW 415 A)-
♦ Thrust ring -MP3-452 (VW 429)-
♦ Thrust plate -MP3-455 (VW 447 H)-

♦ Alignment rails -MP3-457 (VW 457) -
♦ Thrust plate -MP3-460 (VW 512)-
♦ Tapered-roller bearing extractor -V.A.G 1582-
♦ Gripper -V.A.G 1582/4-
♦ Separating device , e.g. -Kukko 17/2-
♦ Feeler gauge
♦ Bolt M10 x 20
Note
♦ When installing new pinions or a new output shaft observe the technical data ⇒ page 1 and ⇒ page 2 .
♦ Removing and installing output shaft ⇒ page 96 .
The output shaft can be disassembled as follows:

– Insert separating device under 2nd gear sliding gear Pos. 21
and press off as shown ⇒ page 135 .
– Remove circlip Pos. 17.
– Press off sliding sleeve with 1st and 2nd gear synchronizer
body as shown ⇒ page 135 .
2. Output shaft 131

FABIA II 2007 ➤

90°
❑ 4 nuts for bearing sup‐
port Pos. 9
tronic Catalogue of
Original Parts
2 - Clutch housing
⇒ page 141
bearing small
❑ pressing on
⇒ page 134
bearing small
❑ remove ⇒ page 135
❑ pressing on
⇒ page 135
6 - Output shaft
bearing large
❑ pressing on
⇒ page 136
8 - O-ring
❑ Position O-rings (4
pieces) on the bearing
support screws
9 - Bearing support
❑ with outer ring/tapered-roller bearing large and with screws
❑ Always replace outer ring together with tapered-roller bearing large and bearing support
10 - Thrust washer
❑ Shoulder of thrust washer points to the tapered-roller bearing Pos. 7
12 - Needle bearing
❑ for 1st gear
❑ (Inner ring for 1st gear)

FABIA II 2007 ➤
❑ after removing the circlip Pos. 17 press off with bearing support Pos. 9 ⇒ page 135
17 - Circlip
❑ insert in such a way that the recesses lock into the arresters of the sliding sleeve Pos. 16
❑ insert into synchronizer ring Pos. 18
❑ replace if there are any traces of scoring and friction ⇒ Electronic Catalogue of Original Parts
❑ (Inner ring for 2nd gear)
22 - Needle bearing
❑ for 2nd gear
23 - Thrust washer
24 - Bushing
❑ for 3rd gear needle bearing
❑ press off with 2nd gear sliding gear ⇒ page 135
25 - Needle bearing
❑ for 3rd gear
❑ press off ⇒ page 135 together with 2nd gear Pos. 21 and and 3rd gear Pos. 26 sliding gear
29 - Bushing
❑ press off together with sliding sleeve and 3rd and 4th gear synchronizer body Pos. 28 ⇒ page 135
2. Output shaft 133

FABIA II 2007 ➤
30 - Needle bearing
❑ for 4th gear
33 - Thrust washer
34 - Needle bearing
36 - Bushing
❑ for needle bearing/output shaft Pos. 34
37 - Gear pinion for 5th gear
38 - Disc spring
Removing outer ring/tapered-roller bearing small

-A- interior extractor 37...46 mm , e.g. -Kukko 21/6-
Pressing in small outer ring/tapered-roller bearing

FABIA II 2007 ➤
Extracting small inner ring/tapered-roller bearing

-A- vice with protective jaws
– Insert the gripper and tighten behind the rollers of the bearing,
then turn bearing and tighten the gripper.
Press on small inner ring/tapered-roller bearing
Pressing out 3rd and 4th gear synchronizer body/sliding sleeve,

2nd, 3rd and 4th gear sliding gear with bushing for needle bearing
output shaft
-A- separating device 22...115 mm e.g. -Kukko 17/2-
-B- Screw M10 x 20
– Insert separating device under 2nd gear sliding gear and press
off.
Note
Support the separating device in such a way that the 1st and 2nd
gear sliding sleeve is not drawn off.
Press off sliding sleeve with synchronizer body and bearing sup‐
port
– First remove the circlip ( ⇒ Item 17 (page 133) ).
-A- Screw M10 x 20
– Press off together with 1st gear sliding gear and sliding sleeve
with synchronizer body for 1st and 2nd gear.
2. Output shaft 135

FABIA II 2007 ➤
Pulling off large inner ring/tapered-roller bearing

-A- protective jaws
– Before fitting the extractor insert screw M10 x 20 in the output
shaft bore.
Pressing on large inner ring/tapered-roller bearing

-A- Thrust washer
– Insert thrust washer before pressing in the inner ring. The
shoulder points to the inner ring.
Fitting position of the inner ring, outer ring and 1st gear synchron‐
izer ring
– Position the inner ring -A- on the 1st gear sliding gear.
Lock the lands -arrows 2- in the recesses -arrows 3- of the sliding
gear.
Lock the recesses -arrows 4- in the lands -arrows 1- of the inner
ring -A-.
Note
If these components should not be replaced, make sure that they

are assigned again to the original gear.

Dimension “a” Fitting dimension Wear limit
1st and 2nd gear 0.75…1.25 mm 0.3 mm

FABIA II 2007 ➤
Check 1st and 2nd gear snychronizer rings for wear

feeler gauge.
1st and 2nd gear 1.2…1.8 mm 0.5 mm
Disassembling and assembling the sliding sleeve/1st and 2nd

1 - Spring
Parts .
⇒ page 137 .

⇒ page 138 .
2 - Sliding sleeve
4 - Arresters
Parts .
The collar on both sides of the synchronizer body is identical in
width.
The collar has a chamfer on one side -arrow B-.
The chamfer on the collar of the synchronizer body and the outer
serration of the sliding sleeve -arrow A- point after assembly in
the same direction.
sliding sleeve -arrow C- must be positioned above one another.

2. Output shaft 137

FABIA II 2007 ➤

gled ends of the springs must be located before the arresters
-arrows-.
Fitting position of the sliding sleeve and 1st and 2nd gear syn‐
chronizer body
The teeth of the sliding sleeve -arrow- point towards the serration
for the 3rd/4th gear synchronizer body -A-.
Press on the sliding sleeve/1st and 2nd gear synchronizer body

Rotate the synchronizer ring in such a way that the slots are flush
with the arresters.
Fitting position of the 2nd gear outer ring

The pegs -arrows- point towards the 1st gear sliding gear -A-.

FABIA II 2007 ➤
Fitting position for synchronizer ring (inner ring for 2nd gear) -A-
chronizer ring -B-.
Fitting position 2nd gear sliding gear

The higher collar -A- points towards the 1st gear -B-. The recess‐
es in the collar -arrows- lock into the pegs of the outer ring
⇒ page 138 .
Place on thrust washer and press on bushing for 3rd gear needle
bearing
– Install needle bearing, sliding gear and 3rd gear synchronizer
ring.
Check 3rd and 4th gear synchronizer ring for wear

3rd and 4th gear 1.0…1.7 mm 0.5 mm
2. Output shaft 139

FABIA II 2007 ➤
Disassembling and assembling the sliding sleeve/3rd and 4th

1 - Spring
Parts .
⇒ page 140 .
⇒ page 140 .
2 - Arresters
Parts .
3 - Sliding sleeve
sliding sleeve must be positioned above one another.



gled ends of the spring must be located before the arresters
-arrows-.

body
Chamfer -arrow- points towards the 4th gear.

FABIA II 2007 ➤
sleeve
Pressing on bushing for 4th gear needle bearing

– Install needle bearing, 4th gear sliding gear and synchronizer
ring.
– Place thrust washer ⇒ Item 33 (page 134) on 4th gear sliding
gear.
Pressing on bushing for needle bearing/output shaft -A-
2.2 Setting output shaft

♦ Gauge block plate -MP3-405/17-
♦ Drive bushing -MP3-423 (VW 407)-
♦ Thrust plate -MP3-460 (VW 512)-
♦ Bolts M8 and M10 -3114/2-
♦ Interior extractor 37…46 mm , e.g. -Kukko 21/6-
♦ Dial gauge
The output shaft must be re-set when the following components
are replaced:
♦ Output shaft
♦ Clutch housing
2. Output shaft 141

FABIA II 2007 ➤
Or the
Note

– 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 nuts for bearing support to 25
Nm.
– Turn output shaft 20 to 30 times in one direction.
Note
♦ Therefore, it must be turned in one direction so that the rolling

elements of the tapered-roller bearing settle in one direction.
♦ To this end it is also necessary to turn it 20 to 30 times.
♦ Otherwise the alignment result will be distorted.
– Insert dial gauge (3 mm measuring range) and set to “0” with

a 1 mm bias.
– Move the output shaft up and down, read off and write down
the clearance on the dial gauge. (Example: 0,20 mm).

washer
The prescribed bearing preload is reached by adding the estab‐
lished measured value (in the example 0.20 mm) to the inserted
adjusting washer (0.65 mm) and by adding a constant compres‐
sion value (0.10...0.15 mm).
Example:
inserted washer 0.65 mm
+ measured value 0.20 mm
Thickness of the adjusting washer 1.00 mm
Example:
Bearing clearance = Thickness of the adjusting
(adjusting washer 0.65 mm washer according to the table
and determined measured val‐
ue)
0.850 mm 1.000 mm

FABIA II 2007 ➤
– Remove output shaft and pull out small outer ring/tapered-

roller bearing.
-A- interior extractor 37...46 mm , e.g. -Kukko 21/6-
Bearing clearance = Adjusting washer
(adjusting washer 0.65 mm thickness (mm)
and determined measured val‐
ue)
0,650 0,750
0,660 … 0,689 0,800
0,690 … 0,739 0,850
0,740 … 0,789 0,900
0,790 … 0,839 0,950
0,840 … 0,889 1,000
0,890 … 0,939 1,050
0,940 … 0,989 1,100
0,990 … 1,039 1,150
1,040 … 1,089 1,200
1,090 … 1,139 1,250
1,140 … 1,189 1,300
1,190 … 1,239 1,350
1,240 … 1,289 1,400
1,290 … 1,339 1,450
1,340 … 1,389 1,500
1,390 … 1,429 1,550
Note

Original Parts .

• If it is intended to insert again the existing adjusting washer
0.65 mm, then check whether it is not damaged.
be fitted.
– Press in small outer ring/tapered-roller bearing with the deter‐

mined adjusting washer (in the example: 1.00 mm).
– Install output shaft and tighten nuts for the bearing support in
the clutch housing to tightening torque ⇒ page 131 .
2. Output shaft 143

FABIA II 2007 ➤
3 Reverse shaft
3.1 Disassembling and assembling the re‐

verse shaft
♦ Pressure spindle -MP3-423 (VW407)-
♦ Centering mandrel -MP3-463 (12-551)-
♦ Interior extractor 14.5...18.5 mm e.g. -Kukko 21/2-
Note
Always replace the needle bushing from the clutch housing or from the reverse shaft support after removing ⇒

FABIA II 2007 ➤
1 - Clutch housing
2 - Needle bushing
Parts
3 - Reverse pinion
4 - Circlip
Parts
❑ carefully fit on new cir‐
clip
❑ do not over-extend
5 - Reverse gear sliding gear
❑ remove circlip Pos. 4
before replacing
❑ the collar points to the
return flow gear pinion
Pos. 3
6 - Reverse shaft
⇒ page 96
7 - Needle bushing
❑ pressing out
⇒ page 146
Catalogue of Original Parts
Removing needle bushing from clutch housing

B - Interior extractor 14.5...18.5 mm , e.g. -Kukko 21/2-
Note
The needle bushing is damaged when removed and must be re‐

3. Reverse shaft 145

FABIA II 2007 ➤
Pressing in needle bushing -A- in the clutch housing
Pressing out needle bushing from the reverse shaft support
Pressing the needle bushing in the reverse shaft support

FABIA II 2007 ➤


ring
♦ Drive bushing -T10160-
♦ Catch pan
Removing

vehicle.
Gr. 66 .
– Unscrew the drive shaft from the flange shaft ⇒ Chassis ⇒
Rep. Gr. 40 .
Fabia II 2007 ?
– Mark the fitting position of the screws -1-.
– Release screws -1- ⇒ Chassis ⇒ Rep. Gr. 40 .
– Unscrew coupling rod -2- from anti-roll bar -arrow- ⇒ Chassis
⇒ Rep. Gr. 40 .
Fabia II 2011 ?

Gr. 40 .

FABIA II 2007 ➤
– Unscrew the nut -1- from the coupling rod -3- ⇒ Chassis ⇒
Rep. Gr. 40 .
wards.
– Remove gasket ring for flange shaft with multi-purpose tool -

MP3-419 (VW 771)- and extraction hook -MP3-419/37
(VW 771/37)- .
Install
ring.
tightening torque.
– Screw drive shaft to flange shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Install coupling rod and steering joint to track control arm ⇒
Chassis ⇒ Rep. Gr. 40 .
– Check gear oil level, if necessary pour in gear oil up to lower
edge of filler hole ⇒ page 85 .
– Install the front left wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Install wheel ⇒ Chassis ⇒ Rep. Gr. 44 .

FABIA II 2007 ➤
Tightening torque
Flange shaft on gearbox (conical screw) ⇒ page 152
1.2 Replace gasket ring for right flange shaft

(gasket ring and bushing are one com‐
ponent)
♦ Drive bushing -T10148-
♦ Catch pan
Removing

-arrows-.
– Unscrew the drive shaft -1- from the flange shaft ⇒ Chassis
⇒ Rep. Gr. 40 .
– Position the catch pan under the gearbox and the engine.
– If necessary, unscrew oil return-flow line for exhaust turbo‐
charger from engine -arrow- ⇒ Engine ⇒ Rep. Gr. 21 .

FABIA II 2007 ➤
– Pull out gasket ring with bushing.

– Position the extraction hook -VW 771/37 (MP3-419/37) - im‐
mediately behind the shoulder.
– Press the extraction hook -VW 771/37 (MP3-419/37)- force‐
Install
– Clean the gasket ring seat in the gearbox.
– Insert gasket ring together with bushing.

A - Screw threaded rod from assembly device -MP3-434 (3066)-
– By turning the nut -B- insert the gasket ring with the bushing
over the pressure plate -T10148- up to the stop.
tightening torque.
– If the oil return line for turbocharger was unscrewed at engine,

install it again -arrow- ⇒ Engine ⇒ Rep. Gr. 21 .
– Install drive shaft -1- on gearbox ⇒ Chassis ⇒ Rep. Gr. 40 .

FABIA II 2007 ➤
– If present, screw on heat shield for drive shaft -arrows-.

– Check gear oil level ⇒ page 85 .
Tightening torques
Flange shaft on gearbox (conical screw) ⇒ page 152
Heat shield for drive shaft to engine ⇒ Chassis ⇒ Rep. Gr. 40

FABIA II 2007 ➤
2 Differential gear

tial gear
♦ Drive bushing -MP3-427 (40-21)-
♦ Thrust plate -MP3-464 (30-205)-
♦ Thrust plate -MP3-467 (40-105)-

♦ Thrust piece -MP3-468 (2007)-
♦ Bushing -MP3-474 (3144)-
♦ Interior extractor 46...58 mm e.g. -Kukko 21/7-
Note
♦ Before installing heat the inner ring of the tapered-roller bearing to 100°C.
♦ Removing and installing differential gear ⇒ page 96 .
♦ When replacing the tapered-roller bearings, the differential housing, the gearbox housing or the clutch
housing, set the differential gear ⇒ page 158 .

FABIA II 2007 ➤
1 - Gearbox housing
⇒ page 158
bearing
bearing
❑ pressing on
⇒ page 155
❑ with gear pinion for final
drive
❑ The hole of the tension‐

ing sleeve is adapted to
the length of the ten‐
sioning sleeve
⇒ page 156
Parts
6 - Drive wheel for speedome‐
ter
❑ if present, place it on the
up to the stop before
pressing on the inner
ring Pos. 7
bearing
9 - Clutch housing
❑ a component
❑ replace gasket ring together with bushing in the event of damage to the gasket ring ⇒ page 149
11 - 25 Nm
❑ screw to threaded connector Pos. 19 to attach the flange shaft
12 - Flange shaft
❑ left - removing and installing ⇒ page 147
❑ right - removing and installing ⇒ page 149
13 - Pressure spring for flange shaft
❑ fitted behind flange shaft

FABIA II 2007 ➤
14 - Thrust washer
❑ Fitting position: Collar towards pressure spring ⇒ page 158
15 - Conical ring
❑ with slots for thrust washer catch
❑ Fitting position: Cone towards differential gear housing
16 - Circlip
❑ holds the conical ring, stop disc and pressure spring in position when the flange shaft is removed
18 - large differential bevel gear
19 - Threaded part
❑ remove in combination with short tensioning sleeve ⇒ page 156
❑ remove in combination with long tensioning sleeve ⇒ page 157

❑ Tensioning sleeves having different lengths are mounted
❑ Difference between the tensioning sleeves ⇒ page 156
❑ short tensioning sleeve: removing and installing ⇒ page 156
❑ long tensioning sleeve: is cut when removing ⇒ page 157
❑ long tensioning sleeve: installing ⇒ page 157
22 - small differential bevel gear
23 - Sealing ring
❑ replace with installed gearbox ⇒ page 147
Press outer ring/tapered-roller bearing out of clutch housing

– First remove gasket ring with bushing for right flange shaft.

FABIA II 2007 ➤

No adjusting washer is fitted at the side of the clutch housing.
Removing inner ring/tapered-roller bearing

– Before fitting the extractor, position the thrust plate -MP3-467
(40-105) - 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 rings/tapered-roller bearings for the gearbox housing

and clutch housing are pressed on with the same special tools.

B - Interior extractor 46...58 mm , e.g. -Kukko 21/7-

FABIA II 2007 ➤

– Position adjusting washer under outside ring.
– Support the gearbox housing with a bushing -MP3-474 (3144)
- directly below the bearing support.
Difference between the tensioning sleeves

Dimension “a” (mm) Distinguishing feature
28.5 (short tensioning sleeve), round slot -arrows-
removing and installing ⇒ page 156
36.0 (long tensioning sleeve), no round slot
remove ⇒ page 157 ,
install ⇒ page 157

Assign differential gear housing

– Check the hole for the tensioning sleeve in the differential gear
housing.
The hole in the differential gear housing was adapted due to the
longer tensioning sleeves.
Bore Length of tensioning sleeve (mm)
-A- 28.5 (short tensioning sleeve)
-A- and -B- 36.0 (long tensioning sleeve)
Tensioning sleeve with round slot (short tensioning sleeve): re‐

moving and installing
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.
Install
– Drive the new tensioning sleeve into the differential gear hous‐
ing up to the stop.

FABIA II 2007 ➤
Remove tensioning sleeve without round slot (long tensioning

sleeve); press out differential bevel gear shaft
When pressing out the tensioning sleeve, it is sheared off during
this procedure.
– Drive the remaining part of the tensioning sleeve out of the
differential gear housing and the differential bevel gear shaft.
Install tensioning sleeve without round slot (long tensioning

sleeve)
– Align the hole in the differential bevel gear shaft to the hole in
the differential gear housing.
– Drive in the new tensioning sleeve with a drift -1- to the di‐
mension -a- = 3.0 mm.
• When turning, the tensioning sleeve must not come in contact

with the housing wall of the clutch housing when the differential
gear is installed.
Install differential bevel gears and differential gear shaft

flange shaft).
– Insert and swivel the small differential bevel gears into position
with a 180° offset.
bevel gears.
Fitting position: Shoulder towards differential bevel gear.
– Drive in the differential gear shaft up to end position and se‐
cure with new tensioning sleeve.

FABIA II 2007 ➤
Fitting position of thrust washer for the conical ring -1-

The collar -arrow- points towards the pressure spring -B-.
The lands -A- are available on certain gearboxes.
The lands -A- point towards the conical ring -1-.

♦ Thrust plate -MP3-464 (30-205)-
♦ Thrust piece -MP3-468 (2007)-
♦ Bushing -MP3-474 (3144)-
♦ Interior extractor 46...58 mm e.g. -Kukko 21/7-
♦ Countersupport e.g. -Kukko 22/2 -
♦ Dial gauge
nents are replaced:
♦ Gearbox housing
♦ Clutch housing
Or the
♦ Tapered-roller bearings of the differential gear

FABIA II 2007 ➤
– Press the outer ring/tapered-roller bearing with pressure plate

-MP3-464 (30-205) - into the clutch housing.
Note
The inner and outer ring of the tapered-roller bearing are paired.
Do not interchange!
– Press outer ring/tapered-roller bearing without adjusting

washer with thrust plate -MP3-464 (30-205)- into the gearbox
housing.
– Insert the differential gear in the clutch housing.
– Position the gearbox housing and tighten 5 screws to torque
25 Nm.

– Move the differential gear up and down, read off and write
down the clearance on the dial gauge (example: 0.70 mm).

washer
The prescribed bearing preload is reached by adding to the es‐
tablished measured value a constant compression value (0,25
mm).
Example:
Thickness of the adjusting washer = 0.95 mm
Example:
0.70 mm 0.95 mm

FABIA II 2007 ➤
– Remove the gearbox housing and pull the outer ring/tapered-

roller bearing out of the gearbox housing.
0,303 … 0,449 0,650
0,450 … 0,499 0,700
0,500 … 0,549 0,750
0,550 … 0,599 0,800
0,600 … 0,649 0,850
0,650 … 0,699 0,900
0,700 … 0,749 0,950
0,750 … 0,799 1,000
0,800 … 0,849 1,050
0,850 … 0,899 1,100
0,900 … 0,949 1,150
0,950 … 0,999 1,200
1,000 … 1,049 1,250
1,050 … 1,099 1,300
1,100 … 1,149 1,350
1,150 … 1,199 1,400
Note

Original Parts .

be fitted.
– Press outer ring/tapered-roller bearing with the determined

adjusting washer (in the example 0.95 mm) again into the
gearbox housing.
– Fit gearbox housing and tighten ⇒ page 89 .

FABIA II 2007 ➤
3 Setting overview
Note
♦ When working on the gearbox it is only necessary to re-set the

drive shaft, output shaft or differential gear if parts were re‐
placed that directly affect the setting of the gearbox.
♦ To avoid unnecessary settings, refer to the following table:
Set:
Drive shaft Output shaft Differential gear
⇒ page 126 ⇒ page 141 ⇒ page 158
Replaced part: Gearbox housing x x
Clutch housing x x x
Drive shaft x
Output shaft x
Differential gear housing x
Tapered-roller bearing for drive shaft x
Tapered-roller bearing for output x
shaft
Tapered-roller bearings for differen‐ x
tial gears.
4th gear pinion x
3. Setting overview 161

Service
Workshop Manual
Fabia II 2011 ➤ , Rapid 2011 ➤ ,
Rapid NH 2013 ➤ , Rapid NH 2014 ➤ ,
Roomster 2006 ➤
Gearbox 02T
Edition 05.2014

Service
Repair Group
00 - Technical data
30 - Clutch
35 - Gears, shafts

Gearbox 02T - Edition 05.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification characters, aggregate assignment, ratios, filling capacities (Fabia II) . . . . . . 1
1.2 Identification characters, aggregate assignment, ratios, filling capacities (Roomster) . . . . 6
1.3 Identification characters, aggregate assignment, ratios, filling capacities (Rapid) . . . . . . . . 10
1.4 Identification characters, aggregate assignment, ratios, filling capacities (Rapid NH) . . . . 11
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1 Clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Summary of components - foot controls (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . 19
1.2 Removing and installing, setting angular clutch pedal switch F36 , (Fabia II 2007 ►; Roomster
2006 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.3 Removing and installing, setting cylindrical clutch pedal switch F36 , (Fabia II 2007 ►;
Roomster 2006 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Removing and installing the crash strut for the clutch pedal (Fabia II 2007 ►; Roomster 2006
►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5 Removing and installing the over-centre helper spring (Fabia II 2007 ►; Roomster 2006 ►)
........................................................................ 24
1.6 Removing and installing the clutch pedal (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . . . . . 27
1.7 Summary of components - foot controls (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013
►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.8 Summary of components - Foot controls (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.9 Removing and installing the bracket with the master cylinder (Fabia II 2011 ►; Roomster 2011
►; Rapid NH 2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.10 Removing and installing the bracket with the master cylinder (Rapid 2011 ►) . . . . . . . . . . 41
1.11 Removing and installing the bracket without the master cylinder (Fabia II 2011 ►; Roomster
2011 ►; Rapid NH 2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.12 Removing and installing the bracket without the master cylinder (Rapid 2011 ►) . . . . . . . . 44
1.13 Removing and installing the clutch pedal with the over-centre helper spring (Fabia II 2011 ►;
Roomster 2011 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.14 Removing and installing the clutch pedal with the over-centre helper spring (Rapid) . . . . 48
1.15 Removing and installing the clutch pedal with the tension spring (Fabia II 2011 ►; Roomster
2011 ►; Rapid NH 2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.16 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH) . . . . . . . . . . . . 51
1.17 Summary of components - Hydraulic (Rapid 2011 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.19 Removing and installing the master cylinder (Fabia II 2007 ►; Roomster 2006 ►) . . . . . . 58
1.20 Removing and installing the master cylinder (Fabia II 2011 ►; Roomster 2011 ►; Rapid NH
2013 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.22 Bleeding the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2 Repairing the clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.3 Summary of components - Gearshift knob with shift lever collar . . . . . . . . . . . . . . . . . . . . 79
1.4 Removing and installing gearshift knob and shift lever collar (Fabia II, Roomster) . . . . . . 79
Contents i
1.5 Remove and install gearshift knob and shift lever collar (Rapid) . . . . . . . . . . . . . . . . . . . . 80
1.6 Remove and install gearshift knob and shift lever collar (Rapid NH) . . . . . . . . . . . . . . . . . . 81
1.9 Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH) . . . . . . . . . . . . . . . . . . . . . . 87
1.10 Remove and install shift mechanism (Fabia II, Roomster, Rapid NH) . . . . . . . . . . . . . . . . 89
1.11 Removing and installing shift mechanism (Rapid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3 Inspect the gear oil level in the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.1 Gearbox - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.4 Detaching and attaching clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.5 Removing and installing the drive shaft, output shaft, differential gear, shift mechanism and
gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.6 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
ii Contents
(SRL000700; Edition 05.2014)
Assignment Fabia II ⇒ page 1 .
Assignment Roomster ⇒ page 6 .
Assignment Rapid ⇒ page 10 .
Assignment Rapid NH ⇒ page 11 .
Identification of materials for the gearbox housing -arrow 2-.

Example: JHN 17 11 6
I I I I
Identifica‐ Day Month Manufac‐
tion charac‐ turing year
ters (2006)
Additional data depend on the manufacturing.
Note

data stickers.
Identification of materials for the gearbox housing

There is lettering on aluminium gearboxes -arrow- -GD TL 023-,
or -AlSi9Cu3- or -AlSi6Cu4-.
One can also use the gearbox identification characters to deter‐
mine whether it is an aluminium or a magnesium gearbox.
1.1 Identification characters, aggregate assignment, ratios, filling capacities

(Fabia II)
Manual gearbox 5 speed 02T
Identification characters JHN LVC JUS LVG


Manufac‐ from 12.06 06.09 01.07 06.09
tured
to 05.09 03.10 05.09 03.10
Assign‐ Engine 1.2 ltr./44 kW 1.2 ltr./51 kW
ment:
Ratio: Final drive 67 : 16 = 4.188
Z2:Z1 1. gear 49 : 13 = 3.769
2. gear 44 : 21 = 2.095
3. gear 43 : 31 = 1.387
4. gear 40 : 39 = 1.026
5. gear 39 : 48 = 0.813 40 : 47 = 0.851
Reverse gear 35 : 24 x 24 : 11 = 3.182
Specification ⇒ Electronic Catalogue of Original Parts
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 90 mm 100 mm 90 mm 100 mm
Note
♦ Vehicles with ABS do not have the sender for speedometer -

G22- .
♦ On gearboxes as of production date 06.09, the springs of the
sliding sleeve with synchronizer body for 3rd, 4th and 5th gear
are changed (the springs are longer), at the same time the
synchronizer ring for 3rd and 4th gear is changed as of this
date ⇒ Electronic Catalogue of Original Parts .

Identification characters LVC LNR
tured
to
Assign‐ Engine 1.2 ltr./55 kW 1.2 ltr./44 kW 1.2 ltr./51 kW
ment:
Z2:Z1 1. gear 49 : 13 = 3.769
2. gear 44 : 21 = 2.095
3. gear 43 : 31 = 1.387 41 : 32 = 1.281
4. gear 40 : 39 = 1.026 38 : 41 = 0.927
5. gear 39 : 48 = 0.813 37 : 50 = 0.74
Reverse gear 35 : 24 x 24 : 11 = 3.182


Drive shaft flange ∅ 100 mm 90 mm
Note

G22- .

Identification characters MFX LMG
tured
to
Assign‐ Engine 1.2 ltr./63 kW TFSI 1.2 ltr./77 kW TFSI
ment:
Z2:Z1 1. gear 49 : 13 = 3.769
2. gear 43 : 22 = 1.955
3. gear 41 : 32 = 1.281
4. gear 38 : 41 = 0.927
5. gear 37 : 50 = 0.74
Reverse gear 35 : 24 x 24 : 11 = 3.182
Note

G22- .

Identification characters JHQ LVE JHL LVA


Manufac‐ from 02.07 06.09 04.07 06.09
tured
to 05.09 05.09 05.10
ment:
Ratio: Final drive 66 : 17 = 3.882 59 : 15 = 3.933
Z2:Z1 1. gear 49 : 13 = 3.769
2. gear 44 : 21 = 2.095
3. gear 43 : 31 = 1.387
4. gear 40 : 39 = 1.026
5. gear 39 : 48 = 0.813
Reverse gear 35 : 24 x 24 : 11 = 3.182
Note

G22- .

Identification characters MAB LNJ
tured
to 01.12 01.11
Assign‐ Engine 1.6 ltr./77 kW
ment:
Z2:Z1 1. gear 38 : 11 = 3.455 49 : 13 = 3.769
2. gear 43 : 22 = 1.955 44 : 21 = 2.095
3. gear 41 : 32 = 1.281
4. gear 37 : 42 = 0.881
5. gear 35 : 52 = 0.673
Reverse gear 35 : 24 x 24 : 11 = 3.182


Note

G22- .

Identification characters NVS
tured
to
ment:
Z2:Z1 1. gear 38 : 11 = 3.455
2. gear 43 : 22 = 1.955
3. gear 41 : 32 = 1.281
4. gear 37 : 42 = 1.881
5. gear 35 : 52 = 0.673
Reverse gear 35 : 24 x 24 : 11 = 3.182
Note

G22- .

Identification characters JQM LVF


tured
to 05.09 09.10
Assign‐ Engine 1.4 ltr./51 kW TDI-PD
ment:
Z2:Z1 1. gear 49 : 13 = 3.769
2. gear 44 : 21 = 2.095
3. gear 43 : 31 = 1.387
4. gear 40 : 39 = 1.026
5. gear 38 : 49 = 0.776
Reverse gear 35 : 24 x 24 : 11 = 3.182
Note

G22- .

(Roomster)
Identification characters HZK JHM JHM LVB
Manufac‐ from 05.06 11.06 01.07 06.09
tured
to 11.06 12.06 05.09 03.10
ment:
Z2:Z1 1st gear 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095
3rd gear 43 : 31 = 1.387
4th gear 40 : 39 = 1.026
5th gear 38 : 49 = 0.776
Reverse gear 35 : 24 x 24 : 11 = 3.182


Filling capacity 2.0 l
Note

G22- .


Identification characters MKG MFX LMG
tured
to
ment: TFSI TFSI
Z2:Z1 1st gear 49 : 13 = 3.769 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095 43 : 22 = 1.955
3rd gear 41 : 32 = 1.281 41 : 32 = 1.281
4th gear 37 : 42 = 0.881 38 : 41 = 0.927
5th gear 35 : 52 = 0.673 37 : 50 = 0.74
Reverse gear 35 : 24 x 24 : 11 = 3.182
Filling capacity 2.0 ltr.
Note

G22- .


Identification characters HZM JHN LVC
Manufac‐ from 05.06 11.06 06.09
tured
to 11.06 05.09
ment:
Z2:Z1 1st gear 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095
3rd gear 43 : 31 = 1.387
4th gear 40 : 39 = 1.026
5th gear 39 : 48 = 0.813
Reverse gear 35 : 24 x 24 : 11 = 3.182
Note

G22- .

Identification characters HXL JHL LVA MAB
Manufac‐ from 05.06 11.06 06.09 06.10
tured
to 11.06 05.09 05.10 01.12
ment:
Z2:Z1 1st gear 49 : 13 = 3.769 38 : 11 = 3.455
2nd gear 44 : 21 = 2.095 43 : 22 = 1.955
3rd gear 43 : 31 = 1.387 41 : 32 = 1.281
4th gear 40 : 39 = 1.026 37 : 42 = 0.881
5th gear 39 : 48 = 0.813 35 : 52 = 0.673
Reverse gear 35 : 24 x 24 : 11 = 3.182
Filling capacity 2.0 l


Note

G22- .

Identification characters NVS
tured
to
ment:
Z2:Z1 1st gear 38 : 11 = 3.455
2nd gear 43 : 22 = 1.955
3rd gear 41 : 32 = 1.281
4th gear 37 : 42 = 0.881
5th gear 35 : 52 = 0.673
Reverse gear 35 : 24 x 24 : 11 =
3.182
Note

G22- .


Identification characters HZL JHP LVD
Manufac‐ from 08.06 11.06 06.09
tured
to 11.06 05.09 03.10
ment:
Z2:Z1 1st gear 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095
3rd gear 43 : 31 = 1.387
4th gear 40 : 39 = 1.026
5th gear 38 : 49 = 0.776
Reverse gear 35 : 24 x 24 : 11 = 3.182
Note

G22- .

(Rapid)
Identification characters MAB NVS
tured
to 03.12
ment:
Z2:Z1 1. gear 38 : 11 = 3.455
2. gear 43 : 22 = 1.955
3. gear 41 : 32 = 1.281
4. gear 37 : 42 = 0.881
5. gear 35 : 52 = 0.673


Reverse gear 35 : 24 x 24 : 11 = 3.182
Note

G22- .

(Rapid NH)
Identification characters MKG MFX LGQ
Manufac‐ from 07.12 07.12 07.12
tured
to
Assign‐ Engine 1.2 ltr./55 kW MPI 1.2 ltr./63 kW TSI
ment:
Z2:Z1 1st gear 49 : 13 = 3.769 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095 43 : 22 = 1.954
3rd gear 41 : 32 = 1.281 41 : 32 = 1.281
4th gear 37 : 42 = 0.881 38 : 41 = 0.927
5th gear 35 : 52 = 0.673 37 : 50 = 0.74
Reverse gear 35 : 24 x 24 : 11 = 3.182

Note

G22- .

Identification characters MAB NVS
tured
to
Assign‐ Engine 1.6 ltr./77 kW MPI
ment:

Z2:Z1 1. gear 38 : 11 = 3.455
2. gear 43 : 22 = 1.955
3. gear 41 : 32 = 1.281
4. gear 37 : 42 = 0.881
5. gear 35 : 52 = 0.673
Reverse gear 35 : 24 x 24 : 11 = 3.182
Note

G22- .

Note
The arrow shows the direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Drive shaft
5 - Output shaft

I - 1. gear
II - 2. gear
III - 3. gear
IV - 4. gear
V - 5. gear
R - Reverse gear
A - Final drive

3 General repair instructions

repair procedures.
the workshop manual - are summarized here. They apply for this
particular workshop manual.
Gearbox
Gearboxes are constructed of aluminium and of magnesium
⇒ page 1 .
♦ Gearbox housing and clutch housing are made of the same
materials.
♦ Bolts and other attachments that come into direct contact with
the gearbox can have varying finishes depending on whether
the gearbox is made of aluminium or magnesium.
♦ On gearboxes which are made of magnesium, the screws
must always be replaced for the following screw connections:
Cover for gearbox housing at gearbox housing and clutch
housing at gearbox housing.
♦ The use of substitute components causes contact corrosion.
This will result in damage to the gearbox.
♦ When installing, ensure the dowel sleeves are correctly loca‐
ted between the engine and gearbox.
♦ When replacing the gearbox, pour in gear oil up to lower edge
of filler hole.
♦ Filling capacity and specification (Fabia II) ⇒ page 1 .
♦ Filling capacity and specification (Roomster) ⇒ page 6 .
♦ Filling capacity and specification (Rapid) ⇒ page 10 .
♦ Filling capacity and specification (Rapid NH) ⇒ page 11 .
Gaskets and seals
♦ Clean contact surfaces thoroughly and apply sealant -
AMV 188 200 03- .
♦ Apply sealant evenly - not too thickly.
♦ Replace O-rings.
♦ Replace radial shaft seals.

Before installing
Lightly lubricate the outside diameter of the gasket ring. Fill half
the space between the sealing lips -arrow- with grease - G 052
128 A1- .
After installing
Check gear oil level, if necessary pour in oil up to lower edge of
filler hole ⇒ page 112 , specification:
♦ Fabia II ⇒ page 1 .
♦ Roomster ⇒ page 6 .
♦ Rapid ⇒ page 10 .
♦ Rapid NH ⇒ page 11 .
Locking elements
♦ Replace circlips.

♦ Replace roll pins. Fitting position: Slot longitudinal to power
flow -arrow-.

Nuts and bolts

♦ Slacken and tighten fixing screws and nuts of covers and
♦ Do not twist particularly sensitive parts - e.g. clutch pressure
plates - slacken and tighten diagonally across in stages.
screws.
♦ Always replace the self-locking screws and nuts ⇒ Electronic
♦ Clean all threaded holes into which self-locking bolts were
screwed in, using a suitable thread tap to remove old locking
agent residues. Otherwise there is the risk that the self-locking
screw will shear when removing.
Bearings
♦ New taper roller bearings are fitted as supplied and do not
require any additional lubrication.
♦ Fit needle bearings to the gearbox with some gearbox fluid.

♦ Replace all taper roller bearings belonging to one shaft at the
same time. As far as possible use bearings of the same make.
ing plate or with the hot-air blower , e.g. -V.A.G 1416- , to
to the stop.
ing instrument.
♦ Do not exchange the outer and inner rings of bearings of the
same size. The bearings are matched in pairs.
♦ Position needle bearing with the lettered side (thicker end) to‐
wards the drift pin.
Shims

washer very precisely ⇒ electronic catalogue of original parts .
♦ Inspect washers for burrs and damage.
Synchronizer rings


of Original Parts .
♦ When installing the intermediate ring -B-, check outer contact
surface -arrow 2- and inner contact surface -arrow 3- for
grooves, blue coloring (caused by overheating) and other
damages.
♦ Insert moist with some gearbox fluid.
Pinions
♦ Clean and heat on a heating plate or with the hot-air blower ,
e.g. -V.A.G 1416- to approx. 100°C before pressing on.
ing instrument.
Clutch control
tach the hoses.
control must be bled ⇒ page 65 (further measures
⇒ page 57 ).
Safety precautions for vehicles with start-stop system
WARNING

♦ On vehicles with activated start-stop system (recogniza‐
ble by a message in the dash panel insert), the engine can
start automatically if required.
♦ It is therefore necessary to ensure that the start-stop sys‐
tem is deactivated when carrying out work on the vehicle
(ignition switched off; if required switch ignition on again).

30 – Clutch
1 Clutch control
Summary of components - foot controls (Fabia II 2007 ►; Room‐
ster 2006 ►) ⇒ page 19 .
Removing and installing, setting angular clutch pedal switch -
F36- , (Fabia II 2007 ►; Roomster 2006 ►) ⇒ page 20 .
Removing and installing, setting cylindrical clutch pedal switch -
F36- , (Fabia II 2007 ►; Roomster 2006 ►) ⇒ page 21 .
Removing and installing the crash strut for the clutch pedal (Fabia
II 2007 ►; Roomster 2006 ►) ⇒ page 22 .
Removing and installing the over-centre helper spring (Fabia II
2007 ►; Roomster 2006 ►) ⇒ page 24 .
Removing and installing the clutch pedal (Fabia II 2007 ►; Room‐
ster 2006 ►) ⇒ page 27 .
Summary of components - foot controls (Fabia II 2011 ►; Room‐
ster 2011 ►; Rapid NH 2013 ►) ⇒ page 29 .
Summary of components - Foot controls (Rapid) ⇒ page 36 .

Removing and installing the bracket with the master cylinder (Fa‐
bia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)
⇒ page 38 .
Removing and installing the bracket with the master cylinder
(Rapid 2011 ►) ⇒ page 41 .
Removing and installing the bracket without the master cylinder
(Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)
⇒ page 43 .
Removing and installing the bracket without the master cylinder
(Rapid 2011 ►) ⇒ page 44 .
Removing and installing the clutch pedal with the over-centre
helper spring (Fabia II 2011 ►; Roomster 2011 ►) ⇒ page 46 .
Removing and installing the clutch pedal with the over-centre
helper spring (Rapid) ⇒ page 48 .
Removing and installing the clutch pedal with the tension spring
(Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►)
⇒ page 49 .
Summary of components - Hydraulic (Fabia II ►; Roomster ►;
Rapid NH ►) ⇒ page 51 .
Summary of components - Hydraulic (Rapid 2011 ►)
⇒ page 54 .
Removing and installing the master cylinder (Fabia II 2007 ►;
Roomster 2006 ►) ⇒ page 58 .
Removing and installing the master cylinder (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH 2013 ►) ⇒ page 61 .
Remove and install slave cylinder ⇒ page 61 .
Bleed the clutch control ⇒ page 65 .

1.1 Summary of components - foot controls

Note

♦ Grease all bearing points and contact surfaces with grease -
G 000 450 02- .
♦ Prior to working on the foot controls remove the storage area
on the driver's side ⇒ Body Work; Rep. gr. 70 .
1 - Support/Front wall
❑ for master cylinder and
bracket
2 - Gasket
tronic Catalogue of
Original Parts
3 - Bearing bracket
4 - Screw
6 - 28 Nm
tronic Catalogue of
Original Parts
clutch pedal switch
⇒ page 20
❑ assign according to the
⇒ Electronic catalogue
of original parts .
⇒ page 20 angular
clutch pedal switch
clutch pedal switch
⇒ page 24
9 - Bushing
10 - Bearing pins
11 - Clutch pedal
12 - Support
13 - 28 Nm
❑ test tightness ⇒ page 57
15 - Spring strap clamp
16 - Supply hose
❑ out of rubber
❑ as of 12.05 on certain vehicles out of plastic ⇒ page 54
❑ if the return hose is made out of plastic, do not use hose clamp - MP7-602-
17 - Bearings
18 - Screw
❑ Pedal stop on bracket -Pos. 3-

19 - Pedal stop
❑ screw with screw -Pos. 18- onto bracket -Pos. 3-
20 - 25 Nm
Difference between clutch pedal switch -F36-

♦ -A- Switch with angular housing
Removing and installing ⇒ page 20
♦ -B- Switch with cylindrical housing
1.2 Removing and installing, setting angular

clutch pedal switch - F36- , (Fabia II
2007 ►; Roomster 2006 ►)
Note
sure that it has an adequately tight fit in the bracket.

Removing
Rep. gr. 70 .
– Turn clutch pedal switch - F36- 90° to the left and remove it
from the support.
– Remove tappet up to the stop
– Press down the clutch pedal by hand as far as possible.
– Insert clutch pedal switch into the support and turn switch 90°
to the right.
gr. 70 .
1.3 Removing and installing, setting cylin‐

drical clutch pedal switch - F36- , (Fabia

II 2007 ►; Roomster 2006 ►)
Note

Rep. gr. 70 .
– Unplug connector -1- from the clutch pedal switch - F36- .
– Turn clutch pedal switch - F36- -2- in the bracket 45° to the left
Note
The clutch pedal remains in the off position in this case (do not
depress).
– Before installing the clutch pedal switch - F36- pull out tappet
-3- fully.
– Guide the clutch pedal switch - F36- through the assembly
opening, press against the clutch pedal and attach by turning
it 45° to the right.
gr. 70 .

for the clutch pedal (Fabia II 2007 ►;
Roomster 2006 ►)
Removing
Rep. gr. 70 .
Install

Tightening torque
23

helper spring (Fabia II 2007 ►; Roomster
2006 ►)
♦ Pliers - T10005-
Removing
Rep. gr. 70 .
– Remove clutch pedal switch ⇒ page 19 -Pos. 7-, if provided.
– Unlock the actuating rod/master cylinder from the clutch pedal.
follows:

– Press together support and separate the clutch pedal from the
master cylinder.
– Push the over-centre helper spring against the bulkhead

-in the direction of the arrow- and remove from the bracket
from the bottom.
Install
– Insert bearing for over-centre helper spring -arrow 1- in the

bracket holder.
inder -arrow 2-.
– Insert over-centre helper spring in the bearing.
24
– Press over-centre helper spring against the bearing and posi‐

tion on the support of the clutch pedal -arrow-.
– Position the clutch pedal with the master cylinder
⇒ page 27 .
– Install clutch pedal switch ⇒ page 19 -Pos. 7-.
– Install crash strut ⇒ page 22 .

gr. 70 .
25
Tightening torque
Crash strut to steering column ⇒ page 22
26

♦ Pliers - T10005-
Removing
– Remove clutch pedal switch ⇒ page 19 -Pos. 7-, if provided.
– Unscrew nut -A-.
– Slowly turn steering wheel in a suitable position.
– Pull screw out of the bracket.

Install
following points:

– To click in the support push the clutch pedal towards the front
wall -direction of the arrow- and make sure it catches correctly.
27
Tightening torques
Clutch pedal to bracket 1) ⇒ page 19
1) Always replace self-locking nut ⇒ Electronic Catalogue of Original Parts .
28
1.7 Summary of components - foot controls (Fabia II 2011 ►; Roomster 2011

►; Rapid NH 2013 ►)
Note

1 - Front wall
inder
2 - Bushing
in the bracket

3 - Bearing bracket
⇒ page 38
⇒ page 43
4 - 25 Nm
❑ self-locking
❑ 3 pieces
tronic Catalogue of
Original Parts
⇒ page 31
6 - Crash strut
❑ is attached to the steer‐
ing column
❑ different versions ⇒
electronic catalogue of
original parts
7 - Screw
❑ for crash strut -Pos. 6- at steering column
❑ Tightening torque:
♦ Version with two screws - 9 Nm
♦ Version with one screw - 20 Nm
29
8 - Stop
9 - Bearing bolt
11 - Clutch pedal
12 - Bushing
❑ is inserted on the bracket -Pos. 3- and on the clutch pedal
14 - Cap
15 - Support
17 - Clamp
18 - Gasket
19 - Supply hose
20 - Clutch position sender - G476-
❑ can be checked in the “targeted fault finding” ⇒ Vehicle diagnostic tester
30
Removing and installing tension spring

– Removing and installing with hook - 3438- .

switch - F36-
Note
Removing
Rep. gr. 80 .
Note

Install
out.
Parts .
31

gr. 80 .
1.7.2 Removing and installing crash strut

The crash strut for the clutch pedal, which is installed on the
steering column, is offered in two versions.
Version with two fixing screws
Removing
Rep. gr. 70 .
Install
32
Tightening torque
Crash strut to steering column (2 screws) 9 Nm
33
Version with one fixing screw

Removing
Rep. gr. 70 .
– Unclip the crash strut from the steering column.
Install
34
Tightening torque
Crash strut to steering column (1 screw) 20 Nm
35
1.8 Summary of components - Foot controls (Rapid)
Note

1 - Front wall
inder
2 - Bushing
in the bracket
3 - Bearing bracket
⇒ page 41
⇒ page 44
4 - 25 Nm
❑ self-locking
❑ 3 pieces
tronic Catalogue of
Original Parts
⇒ page 37
6 - Stop
7 - Bearing bolt
9 - Clutch pedal
10 - Bushing
11 - Cap
12 - Support
36
14 - Clamp
15 - Gasket
16 - Supply hose


switch - F36-
Note
pedal.
Removing
Rep. gr. 80 .
Note
37

Install
out.
Parts .

gr. 80 .

the master cylinder (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH 2013 ►)
1.9.1 Removing
Note

– If necessary, remove engine cover ⇒ Engine; Rep. gr. 10 .

– Remove air filter housing ⇒ Engine; Rep. gr. 23 , or ⇒ Engine;
Rep. gr. 24 .
38

control unit from the front wall ⇒ Engine; Rep. gr. 23 or ⇒
suitable tool, e.g. closing tool - T10249/1- .
Note
♦ Do not use the hose clamp - MP7-602- , otherwise the return

longitudinal member or gearbox. If this is the case, these
stop.
Note

out from the side.

– Unclip clutch position sender - G476- at master cylinder
– Remove the clutch position sender with fitted electrical plug
connectors from the master cylinder.
Note
When performing work in the footwell, put cloths on the carpet to

protect it from possible brake fluid spills.

Rep. gr. 87 .
– If present, remove crash strut ⇒ page 32 .
– Remove clutch pedal switch - F36- -1- ⇒ page 31 .

-3-.
39

1.9.2 Install
following points:
Note
Position self-locking nuts -1- and -2- for bracket -3- on front wall.
– Install the clutch pedal switch - F36- ⇒ page 31 .

– If present, install the crash strut ⇒ page 32 .
gr. 87 .

– Insert the clutch position sender - G476- with fitted electrical
plug connectors up to the stop on the master cylinder.
Engine; Rep. gr. 23 or ⇒ Engine; Rep. gr. 24 .
– Install battery ⇒ Electrical System; Rep. gr. 27 .
– Install air filter housing ⇒ Engine; Rep. gr. 23 or ⇒ Engine;
Rep. gr. 24 .
40
Tightening torques
Bracket/clutch pedal to front wall 1) ⇒ page 29 -Position 4-

Master cylinder to front wall 1) ⇒ page 29 -Position 4-

the master cylinder (Rapid 2011 ►)
1.10.1 Removing

Note
♦ Do not use the hose clamp - MP7-602- , otherwise the return

longitudinal member or gearbox. If this is the case, these

stop.
inder.
Note
When performing work in the footwell, put cloths on the carpet to

protect it from possible brake fluid spills.

Rep. gr. 87 .

-3-.
41

1.10.2 Install
following points:
Note
and tighten.

gr. 87 .
– Press in tube-hose line -C- onto the connection of the master
cylinder, until the locking clip -B- is heard to click into position.
– Fit return hose -A- on the master cylinder.
Tightening torques
Bracket/clutch pedal to front wall 1) ⇒ page 36 -Position 4-
42
Master cylinder to front wall 1) ⇒ page 36 -Position 4-


without the master cylinder (Fabia II
2011 ►; Roomster 2011 ►; Rapid NH
2013 ►)
♦ Pliers - T10005-
Removing
Rep. gr. 87 .

– Remove clutch pedal switch - F36- -1- ⇒ page 31 .
-3-.

follows:
T10005- -arrows-.

Install
following points:
43
Note

gr. 87 .

without the master cylinder (Rapid 2011
►)
♦ Pliers - T10005-
Removing
Rep. gr. 87 .
-3-.
44

follows:
T10005- -arrows-

Install

following points:
Note
and tighten.

gr. 87 .
45

with the over-centre helper spring (Fa‐
bia II 2011 ►; Roomster 2011 ►)
Note
♦ Install clutch pedal with new bearing bolt.


♦ Pliers - T10005-
Removing
Rep. gr. 87 .
– Remove clutch pedal switch - F36- ⇒ page 31 .

as follows:
T10005- -arrows-.
– Remove the bearing bolt for the clutch pedal.

-in direction of arrow-, for this purpose use the hexagon socket
wrench -1-, wrench size 8 mm.
While doing so, the catches -A- are destroyed.
Then the bolts -B- are positioned horizontally.
can be pulled out.
Install
• Install the clutch pedal with a new bearing bolt.
46
master cylinder.


– Press on the clutch pedal slightly and insert a new bearing bolt.
– Position the bolts -A- horizontally.
– Turn the bearing bolt to the right -in direction of arrow-, for this
purpose use the hexagon socket wrench -1-, wrench size
8 mm.
Then the bolts -A- are positioned vertically.
gr. 87 .
47

with the over-centre helper spring (Rap‐
id)
Note
Install the clutch pedal with a new bearing bolt.

♦ Pliers - T10005-
Removing
– Remove mounting bracket without master cylinder
⇒ page 44 .
Then the bolts -B- are positioned horizontally to the fitting position.
can be pulled out.
Install


48
master cylinder.
– Press on the clutch pedal slightly and insert a new bearing bolt.
8 mm.
– Install bracket without master cylinder ⇒ page 44 .

with the tension spring (Fabia II 2011 ►;
Roomster 2011 ►; Rapid NH 2013 ►)
Note
♦ Install the clutch pedal with a new bearing bolt.

⇒ page 51 .

♦ Hook - 3438-
♦ Pliers - T10005-
Removing
Rep. gr. 87 .
– Remove clutch pedal switch - F36- ⇒ page 31 .
49
– Unhook the tension spring e.g with hook - 3438- .
Note

follows:
T10005- -arrows-.

can be pulled out.
Install

• The support -2- must be located on the actuating rod -1- of the
master cylinder.
– Insert a new bearing bolt in the bracket and the clutch pedal.
50

8 mm.

gr. 87 .
1.16 Summary of components - Hydraulic (Fabia II ►; Roomster ►; Rapid NH)
51

❑ test tightness
⇒ page 57
2 - Supply hose
❑ out of rubber
❑ as of 12.05 on certain
vehicles out of plastic
⇒ page 54
MP7-602-
❑ test tightness
⇒ page 57
3 - Master cylinder
ster 2006 ►)
⇒ page 58
ster 2011 ►; Rapid NH
2013 ►) ⇒ page 61
clutch control
⇒ page 65
❑ test tightness
⇒ page 57
4 - Locking clip
line -Pos. 9- pull out of
the master cylinder
-Pos. 3- up to the stop
5 - Support
❑ only replace if the master cylinder -Pos. 3- has been removed
6 - Clutch pedal
7 - 28 Nm
8 - O-ring
❑ always replace
❑ Difference between the O-rings ⇒ page 53
❑ assign according to the ⇒ Electronic catalogue of original parts .
❑ moisten with brake fluid before installing
9 - Tube-hose line
10 - Support
❑ at front left frame side rails
52
11 - Support
❑ holds the tube-hose line -Pos. 9- on the gearbox
12 - 20 Nm
13 - Locking clip
❑ to remove the tube-hose line -Pos. 9- pull out of the slave cylinder -Pos. 16- up to the stop
14 - Dust cap
15 - Vent valve
❑ Bleeding the clutch control ⇒ page 65
16 - Slave cylinder
17 - Gearbox


Difference between the O-rings

-arrow 3-, O-rings must be inserted into the slots.
53
As of 12.05 on certain vehicles plastic return hose -1-:

♦ Do not use hose clamp - MP7-602-
1.17 Summary of components - Hydraulic (Rapid 2011 ►)

3 - Supply hose
4 - Master cylinder
⇒ page 61
clutch control
⇒ page 65
5 - Support
ter cylinder -Pos. 4- has
been removed
6 - Clutch pedal
7 - Clamp
line -Pos. 14- pull it out
of the master cylinder up
to the stop
8 - 25 Nm
❑ self-locking
tronic Catalogue of
Original Parts
9 - Brake lines
10 - Support
❑ attached to the vehicle
body
❑ for tube-hose line
-Pos. 14-
11 - Support
❑ for tube-hose line -Pos. 14-
12 - Support
54
14 - Tube-hose line
15 - Support
16 - Support
❑ for tube-hose line -Pos. 14- on the gearbox
17 - Screw, 20 Nm
18 - Dust cap
19 - Vent valve
❑ Bleeding the clutch control ⇒ page 65
20 - Screw, 20 Nm
21 - Slave cylinder
22 - Clamp
❑ to remove the tube-hose line -Pos. 14- pull it out of the slave cylinder up to the stop
23 - Gearbox
55


-arrow 3-, O-rings must be inserted into the slots.
56
Note
♦ If the master cylinder and/or slave cylinder must be replaced

due to the predetermined fault, first of all check the hydraulic
clutch control.
-arrow 1-.
in the system.
♦ Traces of brake fluid on or below the gearbox, as well as on
the noise insulation under the gearbox is a result, amongst
others, of an external leak.

♦ In case of leakage, the corresponding component must be re‐
♦ Check the correct routing of the tube-hose line between the
master and slave cylinder. The line must not be kinked or trap‐
ped.
♦ The brake pedal return must not be obstructed by moved or
Inspect the complete hydraulic system for leaks.

– Carry out a visual inspection of the following components of
the hydraulic clutch control for leaks:
♦ Check brake fluid level in the brake fluid reservoir.
♦ Return hose between brake fluid reservoir and master cylin‐
der.
♦ Master cylinder.
♦ Tube-hose line between master cylinder and slave cylinder.
visible area.
♦ Slave cylinder.
– Remove the slave cylinder (do not open the line system) and
check if no brake fluid drips out of the bellows, to do so remove
the bellows from the rod -arrow-.
– If necessary, bleed the clutch control ⇒ page 65 .
– Then depress the clutch pedal carefully, at the same time hold
the pedal in five different positions for approx. 20s over the
entire distance the pedal has to travel and check that the pedal
does not fall through on its own while being held (in five posi‐
tions). While doing so, a second mechanic must check if fluid
is leaking from the other components of the hydraulic clutch
control ⇒ page 57 .
57

►)
♦ Pliers - T10005-
♦ Hose clamp - MP7-602 (3094)-
1.19.1 Removing
Note



– Remove air filter ⇒ Engine; Rep. gr. 23 or ⇒ Engine; Rep.
gr. 24 .
gr. 27 .
– Pinch off return hose -A- to master cylinder with hose clamp -
MP7-602 (3094)- (if the return hose is made out of plastic, do
not use the hose clamp - MP7-602- , otherwise the return hose
can get damaged).
– Release the return hose -A- to the brake fluid reservoir and
shut it off in a suitable manner.
– Pull locking clip -B- out of the master cylinder.
inder.
Rep. gr. 70 .
– Remove crash strut for clutch pedal (if present) ⇒ page 22 .
– Remove clutch pedal switch, if provided, ⇒ page 19 ,-Pos. 7-.
Note

clutch pedal.
58

follows:
master cylinder.
– Unscrew the nuts -arrows 1- and remove the clutch controls

– Unscrew pedal stop ⇒ page 19 ,-Pos. 19-.
1.19.2 Install
following points:
wall in the -direction of the arrow-; while doing so make sure
it catches correctly.
⇒ page 65 .
59
Tightening torques
60

►; Rapid NH 2013 ►)
♦ Pliers - T10005-
Removing
– Remove bracket with master cylinder:
♦ Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►
⇒ page 38 .
♦ Rapid 2011 ► ⇒ page 41 .
- T10005- .
– Remove master cylinder from mounting bracket.
Install


– Install bracket with master cylinder:
♦ Fabia II 2011 ►; Roomster 2011 ►; Rapid NH 2013 ►
⇒ page 38 .
♦ Rapid 2011 ► ⇒ page 41 .

der
♦ Hose clamp - MP7-602 (3094)-
♦ Grease - G 000 100-
61
Note
♦ If the slave cylinder must be replaced due to a predetermined

fault, first of all check the hydraulic clutch control ⇒ page 57 .
1.21.1 Removing
Note


– If present, remove engine cover ⇒ Engine; Rep. gr. 10 .
gr. 24 .
gr. 27 .
– Remove circlip -arrow 1- for shift cable from gearbox shift lever
-A-.
Vehicles Fabia II and Roomster up to 05.07 and vehicles Rapid
(metal relay lever)
-B-.
relay lever.
Vehicles Fabia II and Roomster as of 06.07 and vehicle Rapid NH
(plastic relay lever)
-arrow 4-.
62

-arrows-.
Note
Make sure no brake fluid comes into contact with the gearbox. If
this is the case, this point must be cleaned thoroughly.
– Pinch off the tube-hose line to the master cylinder with the
hose clamp - MP7-602 (3094)- (if the tube-hose line to the
master cylinder is made out of plastic, do not use the hose
clamp - MP7-602- ).
– Pull retaining clip -A- for tube-hose line out of the slave cylinder
up to the stop.
– Pull tube-hose line out of the support -C-.
– Pull tube-hose line -B- out of the slave cylinder and close

opening in a suitable manner.
– Unscrew slave cylinder -arrows- and take out.
Note
1.21.2 Install
following points:
– Grease tappet head with grease - G 000 100- .
– Install slave cylinder and tighten screws -arrows- to the given
tightening torque.
– Insert tube-hose line -B- into the slave cylinder up to the stop.
– Press in retaining clip -A- for attaching the tube-hose line up
to the stop.
– Press tube-hose line up to the stop into the support -C- at the
gearbox.
⇒ page 65 .
er:
♦ For vehicles Fabia II, Roomster and Rapid NH ⇒ page 89 .
♦ For vehicles Rapid ⇒ page 94 .
gr. 27 .
– Install air filter ⇒ Engine; Rep. gr. 23 or ⇒ Engine; Rep. gr.
24 .
27 .
63
Tightening torques
Slave cylinder to gearbox Fabia II, Roomster, Rapid NH ⇒ page 51
Rapid ⇒ page 54
64
1.22 Bleeding the clutch control

♦ Brake filling and bleeding device , e. g. -VAS 5234-
Note

longitudinal member or gearbox.
Brake fluid specification ⇒ Chassis; Rep. gr. 00 .

gr. 24 .
gr. 27 .
– Connect the brake filling and bleeding device.
– Fit the bleeder hose -A- on the vent valve of the slave cylinder
-arrow- and open the valve.
– Activate system with a brake fluid pressure of 0.2 MPa.
– Rapidly operate pedal from stop to stop 10 to 15 times.
pedal repeatedly.
– Disconnect bleeding device.
65
2 Repairing the clutch release mecha‐

nism
♦ Grease - G 000 100-
1 - Clutch release bearing

❑ Do not wash the bear‐
ing, just wipe clean
of Original Parts
⇒ page 67
❑ remove and install to‐
gether with the clutch re‐
lease lever -Pos. 3- and
guide bushing -Pos. 5-
⇒ page 67

❑ grease contact points
on the clutch release
lever with grease - G
000 100-
2 - 5 Nm + 90° further
tronic Catalogue of
Original Parts
lease lever -Pos. 1- and
guide bushing -Pos. 5-
⇒ page 67
❑ Original grease must be
removed from the con‐
tact surface of the clutch
release lever
❑ Grease contact surface
on the ball stud with
grease - G 000 100-
5 - Guide bushing for clutch release bearing
❑ remove and install together with the clutch release lever -Pos. 3- and clutch release bearing -Pos. 1-
⇒ page 67
❑ Grease guide bushing in the area of the release lever with grease - G 000 100-
❑ Original grease must be removed from the contact surface of the clutch release lever
❑ grease with grease - G 000 100-
66
8 - Gearbox
9 - 20 Nm
10 - Support
11 - Slave cylinder
❑ Grease tappet head with grease - G 000 100-
Remove and install the clutch release lever together with the re‐
lease bearing and guide bushing
– Separate the clutch release lever together with the release
bearing and guide sleeve from the drive shaft and ball stud.
Removing and installing the guide sleeve

– Rotate the guide bushing -3- opposite the release bearing
-2- by approx. 90° in the -direction of the arrow- until the catch
pegs of the guide bushing are aligned with the slots -4- of the
release bearing.
– In this position remove the guide sleeve from the release bear‐
ing.

– Press the catch pegs -arrows- together and remove clutch re‐
lease bearing -A- from the clutch release lever.
– To install press clutch release bearing -A- into the clutch re‐
lease lever until the catch pegs -arrows- lock into position.
2. Repairing the clutch release mechanism 67

3 Repairing clutch
Fault finding power transmission - problems with the clutch and
clutch control ⇒ page 70 .
♦ Centering mandrel - T10086-
♦ Centering mandrel - MP3-475A (3190A)-
♦ Grease - G 000 100-
(Gearbox removed)
Note
- problems with the clutch and clutch control ⇒ page 70 .

♦ Clean the drive shaft serration and hub serration on used clutch discs. Remove corrosion and only apply a
very thin layer of grease -G 000 100- on the drive shaft serration.
♦ Subsequently move the clutch disc up and down on the drive shaft until the hub fits smoothly on the shaft.
♦ Remove all excess grease.
♦ 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 installed, there are problems with the gearshift and the clutch or the gearbox is
loud.
68
1 - Flywheel
pins are correctly fitted
and grease
❑ Removing and Installing
⇒ Engine; Rep. gr. 13
2 - Clutch disc
Parts
❑ Fitting position: The
wards the pressure
plate
❑ centering for vehicles
with 1.2 ltr and 1.4 ltr en‐
gines ⇒ page 70
❑ centring for vehicles
with 1.4 ltr (TDI) and 1.6
ltr engines ⇒ page 70
ration
Note
Clean the drive shaft serration and

hub serration on used clutch discs,
remove corrosion. Apply a very thin
layer of grease - G 000 100- onto the
serration. Subsequently move the
clutch disc up and down on the drive
shaft until the hub fits smoothly on
the shaft. Remove all excess
grease.
3 - Pressure plate
❑ removing and installing for vehicles with 1.2 ltr and 1.4 ltr engines ⇒ page 70
❑ removing and installing for vehicles with 1.4 ltr (TDI) and 1.6 ltr engines ⇒ page 70
❑ Check the extremities of the membrane spring ⇒ page 70
4 - Screw M6 - 13 Nm; screw M7 - 20 Nm
❑ loosen or tighten gradually and crosswise
Centering the clutch disc and removing and installing the pressure
plate for vehicles with 1.2 ltr and 1.4 ltr engines
– When removing inverse the position of the pressure pad -
MP1-223 (3067)- .
Note
lining must fully rest against the flywheel.
♦ Tighten the screws crosswise and uniformly so as not to dam‐
age the centering holes on the pressure plate and the center‐
ing pins of the flywheel.
plate for vehicles with 1.4 ltr (TDI) and 1.6 ltr. engines

MP1-223 (3067)- .
Note
lining must fully rest against the flywheel.
♦ Tighten the fixing screws crosswise and uniformly so as not to
damage the centering holes on the pressure plate and the
centering pins of the flywheel.


Note
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.
70
Complaint Fault description Measure

♦ Line system, master or slave – Replace defective component,
cylinder leaking. vent air from the line system; top
up with brake fluid.
♦ Release bearing is tilted on the – Replace guide bushing and re‐
guide bushing, seizured. lease bearing.

sure plate broken.

♦ The clutch release force has in‐ – Inform customer (higher release
creased through the wear of the force with increased wear).
clutch lining.
– Replace the clutch disc if the
distance base of the rivet is be‐
low 0.1 mm.
♦ Release bearing is tilted on the – Replace defective components.
guide bushing, seizured.

parts .
♦ Mechanical fault at the pressure – Replace defective components.
plate or the clutch disc.
♦ Clutch disc on the serration – Check the hub for damage

sluggish/jams. (burrs), if necessary replace
clutch disc.

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.

Noises when operating the clutch. ♦ Release bearing defective, – Always replace noisy release
guide of clutch release bearing bearing.
not in order, contact surface
drained off. – Replace damaged guide bush‐
ing.
♦ Contact surface of the pressure – Replace pressure plate.
plate defective (tips of mem‐
brane spring bent, broken). Re‐ – Check release bearing and
lease bearing is off-center. guide bushing, replace if neces‐
sary.
– Check position of clutch release

lever.

gearbox.
♦ Clutch disc installed the wrong – Correct installation.

way up.

parts .

out operation.
is leaking, line is leaking. top up with brake fluid, bleed
system.
under the foot controls), clutch is
not fully depressed.
♦ The pressure plate is bent due – Check components, if necessa‐

to incorrect installation, the ry replace, make sure the cen‐
clutch disc is deformed due im‐ tering pins are correctly fitted.
proper handling.
– If scratching still occurs, check
the serration of the clutch disc
on the drive shaft for ease of
movement, if necessary repair
the gearbox.
bearing moves off-center). – Check release bearing and
guide bushing, replace if neces‐
sary.

parts .
♦ Deposit of corrosion adhering to – Slightly rub down friction surfa‐
the flywheel (long immobiliza‐ ces of the clutch linings or re‐
tion time, high humidity). place completely the severely
corroded parts.
72

♦ Clutch disc on the serration – Check the hub for damage, if
sluggish/jams. Corrosion on the necessary replace the clutch
hub, damage during the assem‐ disc.
bly. Hub profile knocked out on
one side. – Remove corrosion from the hub
and the shaft as well as residues
of lubricant. Grease shaft with
clutch disc - G 000 100- .



place if necessary.
parts .
replace.
speeds).
long a time.

Load change jolts when throttle is ♦ Assembly bracket too soft. – Inform customer. Assign hanger
depressed and sudden reduction of via the ⇒ Electronic catalogue
the engine speed. of original parts .
♦ Irregular engine running. – Check engine power, correct.


gearbox. necessary.

Clutch slips through, no or bad pre‐ ♦ Wrong clutch disc fitted, wrong – Assign the clutch disc and pres‐
drive. pressure plate installed. sure plate via the ⇒ Electronic

♦ Clutch disc worn out, burnt, – Replace clutch disc.
grooves, pressure plate de‐ – Replace pressure plate.
formed through incorrect as‐
sembly, compressive force of – Inform customer.
the pressure plate too low, driv‐
ing error, natural wear.

wheel - oily. Radial shaft seal of
the engine or the gearbox de‐ – Clean contact surfaces of pres‐
fective. Grease on the contact sure plate and flywheel.
surface through excess greas‐
ing of the hub. – Replace radial shaft seal, re‐
move excess grease from the
drive shaft.
♦ Clutch disc installed the wrong – Correct installation, check
way up. clutch disc, replace if necessary.
– Inspect clutch disc and pressure


ness.

♦ Engine does not run clean. – Check engine power, correct.
♦ Driving error, starting speed is – Inform customer.

too low.

parts .
original parts .
♦ Clutch lining, contact surface of – Check radial shaft seal of the
pressure plate and flywheel oily drive shaft for clutch or check
(oil leakage from the clutch crankshaft, if necessary re‐
housing). place.

guide bushing (seizured) guide bushing.
membrane spring of the pres‐ – Check control elements and
sure plate). bearing for control elements.
74

plate if necessary.
♦ Pressure plate housing de‐
formed when installed. Contact – Replace release bearing and
surface of the pressure plate lifts guide bushing.
off only unilaterally.
♦ Drive schaft too heavily greased – Remove grease from pressure

(traces of grease on the clutch plate and flywheel, replace if
disc, pressure plate and fly‐ damaged (traces of wear, traces
wheel). of overheating, grooves).

clutch disc - G 000 100- .



Acoustic knock »klack« when cou‐ ♦ Carrier earth/drive shaft is ac‐ – Inform customer.
pinions in mesh knocks, this
noise is increased for clutch
discs with noise insulation as the
damping reaches the stop.

Noises in idle. ♦ Torsional damper spring kinked. – Replace clutch disc.
♦ Clutch disc fitted without pre‐ – Assign clutch disc via the ⇒
damper (idle rattling). Electronic catalogue of original
parts .
♦ Pressure plate deformed, imbal‐ – Replace pressure plate.
ance.
♦ Irregular engine running. – Check engine power, correct if

necessary.
missing).

dowel sleeves.
1 Shift mechanism
Installation position - selector mechanism ⇒ page 76 .
Summary of components - Gearshift mechanism ⇒ page 78 .
Summary of components - Gearshift knob with shift lever collar
⇒ page 79 .
Remove and install gearshift knob and shift lever collar (Fabia II,
Roomster) ⇒ page 79 .
Remove and install gearshift knob and shift lever collar (Rapid)
⇒ page 80
Remove and install gearshift knob and shift lever collar (Rapid
NH) ⇒ page 81 .
Summary of components - Shift lever and shift housing
⇒ page 82 .
Summary of components - Control cables ⇒ page 84 .
Plastic relay lever as of 06.07 (Fabia II, Roomster, Rapid NH)
⇒ page 87 .
Remove and install shift mechanism (Fabia II, Roomster, Rapid
NH) ⇒ page 89 .
Removing and installing shift mechanism (Rapid) ⇒ page 94 .
Setting the shift mechanism ⇒ page 96 .
1.1 Installation position - selector mecha‐

nism
Arrow A - Shift movement
Arrow B - Selector movement

A - Shift cable
B - Selector cable
C - Heat shield
the shift mechanism
1 - Gearshift lever
2 - Reversing lever
Note
♦ If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System;
Rep. gr. 27 .
♦ Remove shift mechanism for replacing the control cables:
♦ Fabia II, Roomster, Rapid NH ⇒ page 89 .
Gearshift knob with shift lever
collar ⇒ page 79
II - Assembly overview - shift

1.3 Summary of components - Gearshift knob with shift lever collar
1 - Gearshift knob
❑ with collar
❑ it can be different in
shape on individual
models
❑ It is not possible to sep‐
arate the gearshift knob
from the collar
of Original Parts
❑ removing and installing:
♦ Fabia II, Roomster
⇒ page 79
♦ Rapid ⇒ page 80
♦ Rapid NH ⇒ page 81
can be separated from
the gearshift knob e.g.
with a screwdriver (2011
►)
2 - Centre console
1.4 Removing and installing gearshift knob

and shift lever collar (Fabia II, Room‐
ster)
♦ Disassembly wedge - 3409- (2 pieces)
– Lever off the collar with two disassembly wedges - 3409- out
of the surround of the centre console in -direction of arrow-.

Install

shift lever collar (Rapid)
♦ Release tool - T30098- (2 pieces)

– Lever off the collar frame with the disassembly wedge -

T30098- out of the surround for the centre console in
– For this step, press on the frame -arrows- and at the same time
raise the frame.

Install
– Fit the frame with its catch pegs into the rear part of the centre
console.
– Lock the frame into the cover of the centre console in the front
part.

shift lever collar (Rapid NH)
♦ Hose strap pliers , e.g. -V.A.G 1275 A-
– Lever the collar frame out of the centre console. To do so, fit
the release tool - T30098- between the collar frame and the
cover of the centre console in the middle of the front side
-arrow 1- and press it forwards in -direction of arrow 2-.
– Open clamp -arrow- and pull off gearshift knob together with
the collar.
Install
Note
When inserting the gearshift knob on the selector lever the gear‐
shift knob must be pressed in up to the stop.
it with a new open warm-type clamp -arrow- by pressing it to‐
gether.
– Fit the frame of the collar onto the pegs in the rear part of the
centre console.
– Press the frame onto the cover of the centre console until it
locks into the pegs in the front part.

Note

1 - Lock washer
⇒ page 84
2 - Pressure spring
3 - Gasket
and body
❑ self-adhesive
housing
4 - Shift lever
5 - Damping
⇒ page 84
6 - Shift housing
round slot -arrow- at the
shift lever -Pos. 4-
8 - Gasket
Parts
9 - Cover
ing
Parts
10 - Bush
11 - Selector cable
❑ pressed onto selector angle plate
12 - Shift cable
❑ pressed onto the shift lever guide
13 - 23 Nm
❑ 4 pieces

the -direction of the arrow B-.
Note


– Press the pressure spring arm -A- as far as possible to the left
until it is located outside the damping -arrow-.
• After installing the damping, the pressure spring arms -A- and
-B- must rest on the damping -Pfeil-.

Note

1 - Shift cable
shift mechanism
shift mechanism
-Pos. 11-
⇒ page 76
mechanism
⇒ page 96
2 - Selector cable
shift mechanism
mechanism
❑ at selector angle plate
-Pos. 10-
⇒ page 76
mechanism
⇒ page 96
3 - Bush
4 - Lock washer
when removing
5 - Shift housing
6 - Cable support
❑ can be made out of plastic or metal
7 - Bush
8 - Spacer bush
9 - 20 Nm
❑ 3 pieces
❑ for cable support
10 - Cable lock
❑ for selector cable ⇒ page 86
11 - Cable lock
❑ for shift cable ⇒ page 86
12 - Lock washer
❑ it is not necessary, if it is a plastic relay lever
13 - Bush
14 - Selector lever
❑ as of 06.07 the relay level is made of plastic
❑ If the relay lever is made of plastic, neither the bushings -Pos. 13- nor the lock washer -Pos. 12- are
required
15 - Sliding shoe
17 - 20 Nm
18 - Lock washer
❑ is not required on cable locks for selector cable at relay lever, if relay lever is made of plastic
Assign cable locks

Cable lock Dimension “a”


Fitting location of gearbox shift lever

Fitting location of relay lever

1 - Gearbox shift lever -1- with balancing weight
2 - The relay lever -2- is inserted over the sliding shoe -arrow- into
the guiding nut of the gearbox shift lever
1.9 Plastic relay lever as of 06.07 (Fabia II,

Roomster, Rapid NH)
Removing
• Before removing the gearbox shift lever the cable lock must
be separated from the selector cable in order to avoid damage
to the selector cable.

– Press the relay lever towards the front in the

Relay lever with a catch

– Carefully press down the pin detent -arrow 1- as far as the
stop.
– Carefully take the relay lever -A- together with the cable lock
-B- out of its bearing point.

Relay lever with clip

– Remove clip -arrow°1-.
– Carefully take the relay lever together with the cable lock out
of its bearing point.
Continued for all versions
Install
Note
Before installing, grease bearing points and friction surfaces with

grease - G 000 450 02- .

– Insert relay lever together with cable lock up to the stop in its
bearing point.

• The pin detent or the clip -arrow 1- secures the relay lever.
Lever off cable lock for selector cable from plastic relay lever
– Position a cross-head screwdriver -A- between bushing -B-
and relay lever.
Press on cable lock

-arrow-.
• The cable lock must be located behind the pin detent
⇒ page 89 .
1.10 Remove and install shift mechanism

♦ Disassembly wedge - 3409- (2 pieces) (Fabia II, Roomster)

♦ Release tool - T30098- (Rapid NH)
♦ Grease - G 000 450 02-
1.10.1 Removing
Note


gr. 24 .
gr. 27 .
Metal relay lever
Plastic relay lever

-arrows-.
– Remove gearshift knob and shift lever collar:
♦ Fabia II and Roomster ⇒ page 79 .
– Remove the centre console cover ⇒ Body Work; Rep. gr. 68 .



-arrows-.

Vehicles Rapid NH
– Remove bracket for retaining straps of middle silencer from
the body.

1.10.2 Install
Installation is carried out in the reverse order. However, pay at‐
– Always replace lock washers -3- and -4- after each disassem‐
bly ⇒ Electronic Catalogue of Original Parts .
– The relay lever and the cable lock must be mounted together
⇒ page 87 .
sides.
24 .
– Connect earth strap of battery while paying attention to the
notes in the ⇒ Electrical System; Rep. gr. 27 .

Tightening torques
Bracket for the exhaust system ⇒ Engine; Rep. gr. 26
93

nism (Rapid)
♦ Release tool - T30098- (2 pieces)
♦ Grease - G 000 450 02-
1.11.1 Removing
Note


gr. 27 .
gr. 24 .

– Pull off the selector cable from the stud -arrow-.

– Remove gearshift knob and shift lever collar ⇒ page 80 .

94

-arrows-.


1.11.2 Install
following points:
The holes in the cable locks have different diameters ⇒ page 84
95
-2-.
– Always replace lock washers -3- and -4- after each disassem‐
bly ⇒ Electronic Catalogue of Original Parts .
sides.
24 .

gr. 27 .
Note

Tightening torques
Bracket for pre-exhaust pipe ⇒ Engine; Rep. gr. 26

♦ Rig pin - T10027A-
♦ Disassembly wedge - 3409- (2 pieces - Fabia II, Roomster)
♦ Release tool - T30098- (2 pieces - Rapid, 1 piece - Rapid NH)
Note
nism:
• Gearbox, clutch and clutch control in perfect condition.

• Selector mechanism must move freely.
• Control elements and transmission elements of the shift mech‐
anism are in perfect condition.
96
Note


gr. 24 .
gr. 27 .

-direction of arrow 2- and at the same time press it in carefully
until it locks into the gearshift shaft.
– Remove shift lever collar:
♦ Fabia II, Roomster ⇒ page 79
♦ Rapid ⇒ page 80
♦ Rapid NH ⇒ page 81
– Guide shift lever in Neutral position to the left into the 1st/2nd
gear gate via the leg.
– Guide locking pin - T10027A- through hole -A- into hole -B-.
97


Note
and must point vertically upwards.

– Pull locking pin - T10027A- out of holes -A- and -B-.

⇒ page 98 .
24 .
gr. 27 .
1.12.1 Operation
• The shift lever must be positioned in Neutral position in the
selector gear gate of the 3rd/4th gear.
– Depress clutch.
98

Removing the gearbox ⇒ page 99 .
Installing the gearbox ⇒ page 108 .
Tightening torques ⇒ page 109 .

♦ Adjusting plate - 3282/31-
♦ Engine and gearbox jack , e.g. -V.A.G 1383/A-
♦ Gearbox attachment device - MP3-478 (3336)-
♦ Cap - MP9-200/3 (10-222A/3)-
♦ Surface - T30099/1-
♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)-

♦ Grease - G 000 100-
Note

gr. 24 .
gr. 27 .

-A-.
Metal relay lever
-B-.
relay lever.
Note
Plastic relay lever

• In order to avoid damage at the selector cable, the catch must
be seperated from the selector cable before removal.
-arrow 4-.
100

– Pull the tube-hose line -A- out of the bracket -B- (if present) on
the gearbox.
– Remove slave cylinder -B-, lay aside and secure with wire. Do
not open line system.
Note

Vehicles with petrol engines

available).
Vehicles with diesel engines

available).

– Remove the earth strap from the engine/gearbox connecting

screw -1- (on certain types of engines the earth strap is not
connected).
– Unplug connector -2-.
– Remove the earth strap for starter -3-.
– Lay aside all electrical cables.
– Remove fixing screw for starter at the top.
Supporting devices for vehicles with 1.2/63; 77 kW TFSI engines
– Install supporting device - MP9-200 (10-222A)- ⇒ Engine;
Rep. gr. 15 .
Supporting device for vehicles with engines with both engine lift‐
ing eyes at the front
– Install supporting device - MP9-200 (10-222A)- with adapter -

MP9-200/3 (10-222A/3)- .

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 of the engine to avoid damaging them.
Supporting devices for vehicles (one front engine lifting eye, one
rear engine lifting eye)
Shorten the original spindle -I- of the supporting device - MP9-200

(10-222A)- by 100 mm:
Note

MP9-200 (10-222A)- not to touch the engine hood, it must be
shortened to the dimension -x- (100 mm).

engine lifting eye for the supporting device - MP9-200
102

the support for the engine hood -arrow 2- as shown.
eye.
– Position the shortened spindle -B- on the adapter - 10-222 A/
3- .
– Hook the rear left shackle - 10-222 A/12- into the engine lifting
eye.
Caution

-arrows-.
– Then connect the shackle - 10-222 A/12- with the shortened

Supporting device for vehicles Rapid NH
– Remove wiper arms ⇒ Electrical System; Rep. gr. 92 .
66 .
– Remove plastic covers for upper shock absorber mounting.
– Install supporting device - T30099- with base - T30099/1- and

hook for MP9-200 and T30099 - MP9-200/10- .
Note

lock carrier.

– Take up the weight of the engine/gearbox unit at the spindle.


vehicle:
♦ ⇒ Maintenance ; Booklet Fabia II .
♦ ⇒ Maintenance ; Booklet Roomster .
♦ ⇒ Maintenance ; Booklet Rapid .
♦ ⇒ Maintenance ; Booklet Rapid NH
gr. 50 .
gr. 66 .
– Disconnect plug -1- from the reversing light switch .

– Unscrew bracket -2- from the gearbox -arrow- and lay aside
together with the lines.
– Unscrew heat shield (if present) for inside right steering joint
boot -arrows-.
– Disconnect the drive shafts from the flange shafts, turn steer‐
ing wheel to the left.
Note
If only a one-piece intermediate plate is installed behind the en‐

gine flywheel, which prevents separating the complete gearbox
from the engine, the right flange shaft must be removed from the
gearbox ⇒ page 154 .
104
– Release the nuts -arrows- for the left steering joint ⇒ Chassis;
Rep. gr. 40 (on certain vehicles release the screws, see fig.
S39-0142).
– Release screws -1-.

with e.g. wire.
– Separate plug connection -2-.
Note

– Release the screws -arrows- and remove the fan shroud

downwards (on newer models, the screws are no longer
present and the fan shroud is only clipped in at the radiator,
see fig. N19-10333).
– Unclip the fan shroud e.g. using a screwdriver and remove ⇒

– Detach gearbox mounting bracket -A- from the gearbox.

Remove the fixing screws -arrows- for the gearbox mounting
bracket as follows:
Note

– Unscrew the engine/gearbox connecting screw above the right

flange shaft.
– Insert engine mount - 3282- into engine and gearbox jack , e.g.
-V.A.G 1383/A- .
Complete engine/gearbox jack with gearbox mount - 3282- , ad‐
justing plate - 3282/31- for gearbox “02T” and support elements:
– Position adjusting plate - 3282/31- on gearbox mount - 3282-
( adjusting plate fits in only one position).
adjusting plate .
106
– Screw in the mounting elements -A- as shown on adjusting

plate .
– Position engine/gearbox jack below vehicle, ⇒ Abb. S34-0340,

arrow symbol -B- on adjusting plate points in the direction of
travel/vehicle.
mounts at gearbox.
– Remove the bottom fixing screws for the engine/gearbox.

carrier.
For vehicles fitted with a 1.4 ltr./51 kW engine
– When lowering the gearbox, if necessary remove the inserted

intermediate piece -arrow-.
– Push the engine forwards (2nd mechanic).
– Screw down gearbox suspension device - MP3-478 (3336)-


– Adjust supporting arm at slide with locking pin.

Number of visible holes -arrow- = 5.
– Lift gearbox using workshop crane and gearbox lifting tackle -
MP3-478 (3336)- .

– Before installing, unscrew plug for gearbox oil inspection and
if necessary top up with gear oil ⇒ page 112 .
– Capacity and specification:
The gearbox is installed in the reverse order for removal. Observe
– Always replace lock washers -1-, -2- and -3- after each disas‐
sembly ⇒ electronic catalogue of original parts .
– After installing, check gear oil level ⇒ page 112 .
Note
♦ Clean splines of drive shaft and apply a thin film of grease -

G 000 100- .
♦ The clutch plate must slide freely up and down the drive shaft.
♦ If the gearbox is replaced, ensure the intermediate plate be‐
♦ Assemble exhaust system free of stress ⇒ Engine; Rep. gr.
26 .
♦ Installing starter and electrical cables ⇒ Electrical System;
Rep. gr. 27 .
108

Gearbox to 1.2/44 kW, 1.2/47 kW, 1.2/51 kW and 1.2/55 kW en‐
gine (Fabia II, Roomster, Rapid NH)
Pos. Screw Piece Nm
Pos. not as‐ M12 x 60 1 80
signed1)
1 M12 x 60 1 80
22) M12 x 135 2 80
3 M12 x 60 1 80
42) M10 x 55 1 40
5 M10 x 60 1 40
6 M12 x 80 1 80
1)
On certain types of engines, this position can be assigned by
means of the screw, see table.
Gearbox to 1.2/63 kW and 1.2/77 kW engine (Fabia II, Roomster,

Rapid NH)
Pos. Screw Piece Nm
1 M12 x 60 2 80
21) M12 x 135 1 80
31) M12 x 135 1 80
4 M12 x 60 1 80
5 M10 x 30 2 40
6 M12 x 80 1 80
Gearbox to 1.4 ltr./63 kW engine (Fabia II, Roomster)

Pos. Screw Piece Nm
1 M12 x 60 1 80
21) M12 x 135 2 80
3 M12 x 60 1 80
4 M10 x 35 2 40
5 M12 x 80 1 80

Gearbox to 1.6 ltr./77 kW engine (Fabia II, Roomster)

Pos. Screw Piece Nm
1 M12 x 60 2 80
21) M12 x 135 1 80
31) M12 x 150 1 80
4 M12 x 60 1 80
5 M10 x 50 2 40
6 M12 x 80 1 80
Gearbox on 1.6 ltr./77 kW engine (Rapid)

Pos. Screw Piece Nm
1 M12 x 50 2 80
21) M12 x 125 1 80

31) M12 x 125 1 80
4 M12 x 60 1 80
5 M10 x 30 2 40
6 M12 x 70 1 80
1) Screw with threaded pin M8 x 12.
Gearbox to 1.4/51 kW TDI PD engine (Fabia II, Roomster)

Pos. Screw Piece Nm
1 M12 x 70 2 80
21) M12 x 150 2 80
31) M10 x 70 1 40
4 M10 x 65 1 40
5 M12 x 80 1 80
Pendulum support
Note


110

Fixing screws of gearbox mount1) 40 Nm + 90°
Cover plate for flywheel 10 Nm
Noise insulation bracket ⇒ Engine; Rep. gr. 15
Pre-exhaust pipe with catalytic converter and clamping ⇒ Engine; Rep. gr. 26
sleeve
Screen cap for drive shaft on engine ⇒ Chassis; Rep. gr. 40

1)Always replace these screws ⇒ Electronic Catalogue of Orig‐

inal Parts .

3 Inspect the gear oil level in the gear‐

box
♦ Socket wrench insert - T30023 (3357)-
Gearbox oil specification:
gr. 50 .
– Tighten oil filler plug -arrow- to tightening torque
⇒ page 112 .
If re-filling, do the following
– Unscrew oil filler plug -arrow-.
– Pour in gear oil up to lower edge of the filler hole.
about 2 minutes.
– Switch off engine and unscrew oil drain plug -arrow-.
– Pour in gear oil again up to lower edge of the filler hole.
– Tighten oil filler plug -arrow- to tightening torque
⇒ page 112 .
Different versions of oil filler plug or oil drain plug

I - Oil filler plug and oil drain plug with internal serration: 24 Nm
II - Oil filler plug and oil drain plug with hexagon socket head: 32
Nm
112

gearbox
Gearbox - Summary of components ⇒ page 113 .
Summary of components ⇒ page 114 .
Removing and installing gearbox housing cover and 5th gear
⇒ page 115 .
Detaching and attaching clutch housing ⇒ page 116 .
Removing and installing the drive shaft, output shaft, differential
gear, shift mechanism and gearshift forks ⇒ page 117 .
Mounting sequence ⇒ page 118 .
4.1 Gearbox - Summary of components
1 - 1. gear
2 - 2. gear
3 - 3. gear
4 - 4. gear
5 - 5. gear
⇒ page 115
7 - Gearbox housing
8 - Reverse gear
9 - Shift mechanism
❑ Gearshift forks
⇒ page 117
10 - Clutch housing
11 - Drive shaft
⇒ page 117
12 - Output shaft
⇒ page 117
⇒ page 117


gear ⇒ page 115
II - Detaching and attaching
clutch housing ⇒ page 116
differential gear, shift mecha‐
nism and gearshift forks
⇒ page 117
114
Mounting sequence ⇒ page 118 .
1 - Gearbox housing
❑ is made out of alumini‐
um or magnesium
Parts
2 - 5th gear pinion
⇒ page 118
⇒ page 124
3 - Lock washer
tronic Catalogue of
Original Parts
⇒ page 125
4 - Gasket
Note
If the gearbox housing cover is fitted

with the gearbox mounted, inspect
the gear oil level, if necessary top up
with oil ⇒ page 112 .
tronic Catalogue of
Original Parts
7 - Lock washer
❑ with sliding sleeve and stop ring
11 - Needle bearing
❑ 5. gear
❑ replace together with bushing -Pos. 12-
12 - Bushing
❑ replace together with needle bearing -Pos. 11-
❑ press off with bearing support for grooved ball bearing ⇒ page 135


14 - Bolt
❑ for 5th gear shift fork
4.4 Detaching and attaching clutch housing

♦ Sealant - AMV 188 200 03-
1 - Conical screw, 25 Nm
spring
⇒ page 118
tronic Catalogue of
Original Parts
4 - Clutch housing
um or magnesium
⇒ page 1
Parts
5 - Gearbox housing
um or magnesium
⇒ page 1
Parts
❑ with guide bushing and
clutch release bearing
⇒ page 118
116
4.5 Removing and installing the drive shaft, output shaft, differential gear, shift
mechanism and gearshift forks
2 - Gearbox housing
um or magnesium
⇒ page 1
❑ on gearboxes made out
of aluminium as of pro‐
duction date 12.06 the
adjusting washer S1 for
outer ring/tapered-roller
bearing is not fitted
⇒ page 159
❑ Bearing pedestal for
bearing is adapted
Parts
3 - Oil drain plug
❑ different versions:
Oil drain plug with inter‐
nal serration - 24 Nm
Oil drain plug with hexa‐

gon socket head - 32 Nm

spring
⇒ page 118
❑ self-locking
❑ to secure the bearing support for grooved ball bearing with the drive shaft and output shaft -Pos. 16-
7 - 23 Nm
❑ for gearshift mechanism -Pos. 15-
❑ self-locking
8 - O-ring
9 - Bearing pins
10 - 5 Nm + 90° further
11 - Gearshift shaft with cover

12 - 5 Nm + 90° further
13 - 5 Nm
14 - Transmission neutral sender - G701-
15 - Reversing light switch - F4- , 20 Nm
16 - Sealing ring
❑ if present, replace ⇒ Electronic Catalogue of Original Parts
❑ Gearshift forks
18 - Drive shaft and output shaft with bearing support for grooved ball bearings
❑ Always replace bearing support after removing ⇒ Electronic Catalogue of Original Parts
❑ pressing off and on bearing support ⇒ page 135
❑ Disassembling and assembling the drive shaft ⇒ page 135
❑ Disassembling and assembling the output shaft ⇒ page 144

19 - Reverse shaft support
❑ with support
20 - Reverse gear
21 - Screw
❑ for reverse shaft support -Pos. 17-
❑ M6: 5 Nm + 90° further
❑ M8: 25 Nm + 45° further
4.6 Mounting sequence

ing, gearshift shaft with gearshift cover, drive shaft, output shaft,
differential gear and gearshift mechanism
Note
On gearboxes as of production date 06.09, the springs of the

sliding sleeve with synchronizer body for 3rd, 4th and 5th gear are
changed (the springs are longer), at the same time the synchron‐
izer ring for 3rd and 4th gear is changed as of this date ⇒

♦ Guide bolt - T10079-
♦ Gearbox mount - T30012 (3221)-
♦ Insert base - T10083-
♦ Washer - T10083/1-
118

♦ Sealant - AMV 188 200 03-
Change gearbox holder -T30012-
Drill a new hole in the gearbox holder - T30012 (3221)- to attach
the Gearbox 02T.
Dimensions in mm.
– Drill a hole ∅ 11.0 mm -arrow-.
4.6.1 Removing
– Secure gearbox to the assembly stand -arrows-.
– Position catch pan underneath.
– Drain out gear oil.
– Remove the clutch release lever together with the release

bearing and guide bushing.
bearing and guide sleeve from the drive shaft and ball stud.
– Removing the right flange shaft.

– To this end insert two screws in the flange and counterhold the
flange shaft using a tyre iron.
– Pull out the flange shaft with pressure spring, stop disc and
conical ring.

– Unscrew the cover -arrow- for the gearbox housing.
– Pull out the bearing bolt -1- for the 5th gear shift fork -2- and
remove gearshift fork.
– Remove circlip -3- for 5th gear synchronizer body.
– Remove circlip -4- for 5th gear pinion.
– Remove gear pinions and 5th gear synchronizer body.
– Release the fixing screws -A- for the bearing support of the
drive shaft and output shaft.
– Unscrew nut -B- for the reverse gear shift fork.
– Remove left flange shaft -C-.
– Turn the gearbox in the assembly stand so that the clutch
housing is at the top.
– Release the connecting screws for the clutch housing and the
gearbox housing.
– Carefully release the clutch housing from the projecting hous‐
ing lands and make sure the sealing surfaces are not damaged
in the process.
Note
When removing, pay attention that the clutch housing does not tilt
so that the roller bearings of the drive shaft and the output shaft
do not get damaged.
– Remove the differential gear from the gearbox housing.

On gearboxes of vehicles with the start-stop system
120
– Remove transmission neutral sender - G701- -arrow-.

Continued for all gearboxes
– Remove the gearshift shaft with cover -A-; to do this, put the
gearshift shaft in idle position. Subsequently unscrew screws
-arrows- and remove the gearshift shaft from the gearbox
housing.
– Remove the bearing pins -B- at the top of the gearbox.
– Unscrew the reversing lights switch - F4- -C-.
– Unscrew screw -A- for reverse shaft support.

– Remove the bearing pins -B- at the bottom of the gearbox.
Note
Do not remove the cover -arrow- to disassemble the gearbox.
– Press off the drive shaft and output shaft together with the
bearing support, shift forks and reverse gear.
Note
♦ Position the gearbox housing on the pressure plates -

MP3-406 (VW 401)- and -MP3-407 (VW 402)- in such a way
that the dowel sleeves in the gearbox housing are not dam‐
aged.
♦ During the pressing off procedure request the assistance of
second mechanic to prevent components from falling.
♦ Always replace bearing support for grooved ball bearing after
removing ⇒ Electronic Catalogue of Original Parts
– Pressing off the drive and output shaft from the bearing sup‐
port for grooved ball bearings ⇒ page 135 .
4.6.2 Install
– Pressing the drive and output shaft into the new bearing sup‐

– Pressing the sleeve of the 5th gear sliding gear needle bearing
onto the drive shaft ⇒ page 135 .
– Place the drive shaft -2- and output shaft -1- with bearing sup‐
port for grooved ball bearing in the pressure plate -T10085- .
– Insert the gearshift mechanism (shift forks) -4- in the sliding
sleeves of the shaft.
– Insert the shaft for reverse gear -3- with the reverse gear.
– Screw the guide bolt -T10079- onto the reverse shaft support
-arrow-.
– Insert the components together into the gearbox housing, by

passing the guide bolt -T10079- through the fixing holes of the
gearshift mechanism in the gearbox housing.
– Unscrew -T10079- guide bolt.
– Check before pressing on the bearing support:
♦ To click in the shift forks into the sliding sleeves correctly.

♦ Dimension -a- of the output shaft serration.
Note
♦ The drive shafts of the individual gearboxes have different

lengths due to the different heights of the serration, dimension
-a-.
♦ In order to press in the drive shaft and the output shaft at the
same time, a 3 mm thick washer - T10083/1- must be posi‐
tioned onto the drive shaft, if necessary.
♦ Therefore, the dimension -a- of the output shaft serration must
be measured.
• Dimension -a- = 30.6 mm
122
– Fit the washer - T10083/1- onto the drive shaft and carefully
press in the bearing support together with the drive shaft and
the output shaft up to the stop.
– Carefully press on the bearing support with the drive and out‐
put shaft up to the arrester.
– Screw in screw -A- for reverse shaft support.

– Install the bearing pins -B- at the bottom of the gearbox.
– Screw on the reversing lights switch - F4- -C-.

– Install the bearing pins -B- at the top of the gearbox.
– Put the gearshift forks into Neutral.
faces of the cover.
– Install the gearshift shaft with cover -A-. Tighten screws
-arrows-.
On gearboxes of vehicles with the start-stop system

– Remove transmission neutral sender - G701- -arrow-.

– Screw in new screws -A- and tighten the bearing support of

the drive shaft and output shaft.
Note
Gradually tighten the screws according to the corresponding tor‐

que starting from the middle and crosswise ⇒ page 117 .

– Tighten hexagon nut -B- for the gearshift mechanism (shift
forks) ⇒ page 117 .
faces.
– Screw down the clutch housing onto the gearbox housing.
– Turn the gearbox in the assembly stand with the clutch hous‐
ing upwards.
– Fit the 5th gear pinion -1-.

Fitting position of 5th °gear pinion:
The high collar -arrow- points to the gearbox housing cover.
– Mount the synchronizer body 5th gear together with sliding
sleeve and stop ring.
124
– Insert the 5th gear shift fork -2- and push the bearing pin -1-
up to the stop.
– Determine the new circlips -arrow-
.
– For the drive shaft -3- and output shaft -4- select the thickest
possible circlip that may be installed, and fit.
The following circlips are available
Thickness (mm) Part number
2.00 085 311 187
2.10 085 311 187 A
2.20 085 311 187 B
Assign the circlips via the ⇒ Electronic catalogue of original
parts .
– Mount cover for gearbox housing ⇒ page 115 .
conical rings.
– Install the clutch release lever together with the release bear‐
ing and guide bushing ⇒ page 66 .


clutch housing
♦ Distance sleeve - MP3-458/2-
♦ Centering mandrel - MP3-463 (12-551)-
♦ Thrust piece - MP3-484 (30-555)-
♦ Gearbox mount - T30012 (3221)-
♦ Socket wrench insert - T30023 (3357)-
♦ Separating device 12 - 75 mm, , e.g. -Kukko 17/1-
♦ Extractor, , e.g. -Kukko 18/1-
♦ Sealant - AMV 188 200 03-
♦ Grease - G 000 100-
1 - Clutch housing
um or magnesium
⇒ page 1
❑ when used: Adjusting
differential gear
⇒ page 159
Parts
driver
❑ grease with grease - G
000 100-
4 - Sealing ring
5 - Bushing
❑ for gasket ring
6 - Screw
⇒ page 128
Oil filler plug or oil drain
plug with internal serra‐
tion - 24 Nm
126
Oil filler plug or oil drain plug with hexagon socket head - 32 Nm
7 - O-ring
❑ only on vehicles without ABS
8 - Speedometer sender -G22-
10 - Adjusting washer S2
❑ if the bearing is replaced, set the differential gear ⇒ page 159

12 - 5 Nm + 90° further
❑ if the bearing is replaced, set the differential gear ⇒ page 159
❑ always 1 mm thick
❑ on gearboxes made out of aluminium as of production date 12.06 the adjusting washer S1 for outer ring/
tapered-roller bearing is not fitted ⇒ page 159
❑ Bearing pedestal for outer ring/tapered-roller bearing is adapted
15 - Fitting sleeve
❑ (2 pieces)
❑ is made out of aluminium or magnesium ⇒ page 1
❑ when used: Adjusting differential gear ⇒ page 159
❑ on gearboxes made out of aluminium as of production date 12.06 the adjusting washer S1 (-Pos.14-) for
outer ring/tapered-roller bearing is not fitted ⇒ page 159
17 - Oil drain plug
❑ different versions: ⇒ page 128
Oil filler plug or oil drain plug with internal serration - 24 Nm
18 - Sealing ring

19 - Bushing
❑ for gearshift shaft
20 - Magnet
21 - Screw cap
❑ Before screwing down cover sealing surface with sealant - AMV 188 200 03-
22 - Circlip
❑ inserted in the cylinder roller bearing groove -Pos. 25-
23 - Circlip
❑ inserted in the cylinder roller bearing groove -Pos. 24-
24 - Cylindrical-roller bearing
❑ for drive shaft

26 - Plug
❑ inserted in the hole in the clutch housing

I - Oil filler plug and oil drain plug with internal serration: 24 Nm
II - Oil filler plug and oil drain plug with hexagon socket head: 32
Nm
Install gasket ring for drive shaft
128
Remove bushing for gasket ring

– Position the distance sleeve - MP3-458/2- and thrust piece -
MP3-484 (30-555)- on the differential gear.
A - Puller , e.g. -Kukko 18/1-
B - Separating device 12 to 75 mm , e.g. -Kukko 17/1-
Insert bushing for gasket ring

A - Threaded rod from assembly device - MP3-434 (3066)-
– Screw threaded rod from assembly device - MP3-434 (3066)-
– By turning the nut -B- install the bushing over the pressure
plate - MP3-420 (3124)- up to the stop.
Note
If the gearbox is disassembled press the bushing with pressure

plate - MP3-420 (3124)- up to the stop.
Remove the bushing -A- for the shiftgear shaft
Insert the bushing -A- for the shiftgear shaft


1 - Bushing
❑ pressing in and pressing
out ⇒ page 126
❑ replace jointly
3 - Locking bolt
mechanism
4 - Reversing lever
⇒ page 84
❑ as of 06.07 the relay lev‐
el is made of plastic
plastic relay lever to‐
gether with cable lock
⇒ page 87
❑ If the relay lever is made
of plastic, neither the
bushings -Pos. 5- nor
the lock washer
-Pos. 10- are required
5 - Bushing
❑ is not required, if the re‐
lay lever is made of plas‐
tic
6 - Sealing ring
driver
7 - Cap
8 - Gearshift lever
9 - 20 Nm
❑ self-locking
10 - Lock washer
130
Remove locking bolt -A- from gearshift cover

– Remove the outer part of the locking bolt.
– Then lever out locking bolt carefully with a screwdriver.
Drive locking bolt -A- into gearshift cover

Fitting position
The marking -1- points towards the marking -2- on the gearshift
cover.
Press in the gasket -A- up to the stop


gearshift forks
♦ Driver - MP1-304 (10-206)-
♦ Distance sleeve - MP3-458 (VW 472)-
♦ Removal tool for inner lining of the door panel - MP8-602/1-
Note
The gearshift fork group with shift rails (-Pos. 1-) must not be disassembled for the disassembly and assembly
of the shift segments, clamping plates and angular ball bearings.


shift rails
❑ Identification
⇒ page 133
ment freely once fitted
❑ 4 pieces
❑ pressing off
⇒ page 134
4 - Circlip
tronic Catalogue of
Original Parts
❑ Identification
⇒ page 133
❑ Gearshift fork with shift
segments
6 - 5th gear shift fork with shift
segments
❑ Shift segments are con‐
nected inseparably with
the gearshift fork
132
7 - Bearing bolt
Identification of shift segments and 5th gear shift fork with shift
segments
Dimension -a-
1 - Shift segments 1st/2nd gear = 10.2 mm
2 - 3rd/4th gear shift segment = 78.6 mm
3 - 5th gear shift fork with shift segments = 79.5 mm
1st/2nd gear shift fork with shift segments

Dimension -a- = 75 mm


Fitting the circlip

segment.
Note
A - Handle wrench, wrench size 10

B - Protective jaws
Pressing off angular ball bearing
Note

134
1 Drive shaft
Disassembling and assembling the drive shaft ⇒ page 135

drive shaft

♦ Flywheel type belt pulley fitting tool - MP9-400-
♦ Cap - T10080-
♦ Insert base - T10083-
♦ Pressure plate - T10084A-
♦ Separating tool , e.g. -Kukko 17/1-
♦ Puller , e.g. -Kukko 18/1-
Note
When installing new pinions observe the technical data:
1. Drive shaft 135

Note
♦ Insert all bearings, gears and synchronizer rings in the gear‐

box with gear oil.
♦ Do not interchange the synchronizer rings, if re-used always
assign to the original sliding gear.
1 - Circlip
tronic Catalogue of
Original Parts
⇒ page 115

2 - Sliding sleeve with 5th gear
synchronizer body
⇒ page 115
❑ disassembling
⇒ page 143
❑ Assembling sliding
sleeve/5th gear syn‐
chronizer body
⇒ page 143 and
⇒ page 140
❑ on gearboxes as of pro‐
duction date 06.09, the
springs -Pos. 27- are
changed
❑ check for wear
⇒ page 140
5 - Needle bearing
❑ 5. gear
❑ replace together with
-Pos. 6-
Parts
6 - Bushing
❑ for 5th gear needle
bearing
❑ replace together with -Pos. 5-

7 - Gearbox housing
8 - Bearing support for grooved ball bearing
❑ Always replace grooved ball bearing together with the bearing support
❑ If the bearing support is released from the gearbox housing, it must always be replaced
9 - Drive shaft
10 - Needle bearing
❑ for 3rd gear
❑ on gearboxes as of production date 06.09, the synchronizer ring for 3rd and 4th gear is changed ⇒
Electronic Catalogue of Original Parts
❑ press off with 3rd gear sliding gear ⇒ page 139

❑ Assemble sliding sleeve/synchronizer body ⇒ page 140 and ⇒ page 140
❑ on gearboxes as of production date 06.09, the springs (-Pos. 23-) are changed
❑ on gearboxes as of production date 06.09, the synchronizer ring for 3rd and 4th gear is changed ⇒
16 - Bushing
17 - Needle bearing
❑ for 4th gear
18 - Thrust washer
19 - Inner ring
❑ for cylindrical-roller bearing
❑ pull off with 4th gear sliding gear ⇒ page 139
20 - Circlip
❑ with circlip
1. Drive shaft 137

❑ Fitting position: The circlip in the bearing points towards the drive shaft
22 - Clutch housing
23 - Spring
❑ on gearboxes as of production date 06.09, the springs of the sliding sleeve with synchronizer body for
3rd, 4th and 5th gear are changed (the springs are longer)
24 - Sliding sleeve 3rd and 4th gear
25 - Synchronizer body for 3rd and 4th gear
26 - Arresters for synchronizer body
❑ (3 pieces)
27 - Spring
❑ on gearboxes as of production date 06.09, the springs of the sliding sleeve with synchronizer body for
3rd, 4th and 5th gear are changed (the springs are longer)
❑ (3 pieces)
31 - Supporting ring
❑ prevents the arresters from wandering
Pull out the cylindrical-roller bearing from the clutch housing

– When removing compress circlip -arrow- of the cylindrical-roll‐
er bearing with pliers -C-.
B - Interior extractor 30 up to 37 mm , e.g. -Kukko 21/5-
Press the cylindrical-roller bearing into the clutch housing

– Support the clutch housing by positioning pipe section -
MP3-450 (VW 415 A)- (not visible in figure) directly under the
bearing support.
– When inserting compress circlip -arrow- of the cylindrical-roller
bearing with pliers -A-.
– Remove pliers before the cylindrical-roller bearing is in fitting
position. The circlip must lock into the clutch housing slot.

Press out the bearing support for grooved ball bearing

– Move the sliding sleeve for 1st and 2nd gear to 2nd gear.
– Slide the pressure plate - T10084A- sideways up to stop onto
the drive shaft.
– Insert centering pins in pressure plate - T10081- in the holes
of the drive shaft and output shaft.
Note
Always replace bearing support for grooved ball bearing.
Remove the bushingof the cylindrical-roller bearing with the 4th

gear sliding gear
– Removing the circlip.
– Insert separating device -A- behind the running gearing (not
the engaging gearing) of the 4th gear and press off.
A - Separating device 12 to 75 mm , e.g. -Kukko 17/1-

Install the bushing of the cylindrical-roller bearing/4th gear sliding

gear
– Partly pressing on bushing -A-.
– Position cylindrical-roller bearing -Pos. 17- and 4th gear slid‐
ing gear.
– Press down sleeve -A- with thrust washer -Pos. 18- and inner
ring/cylindrical-roller bearing -Pos. 19-.
Press off sliding sleeve and synchronizer body for the 3rd and 4th
gear
– After removing the circlip jointly press off the 3rd gear sliding
gear and the sliding sleeve/synchronizer body.
1. Drive shaft 139


1 - Spring (as of production date 06.09 the springs are longer) ⇒
2 - Sliding sleeve
The deeper recesses -arrow A- of the arresters in the synchron‐
izer body and the recesses -arrow B- in the sliding sleeve must
be positioned above one another.
Assembling the sliding sleeve/3rd, 4th and 5th gear synchronizer

body
The sliding sleeve is drawn over the synchronizer body.

– Insert the arresters in the deeper recesses -arrows- and mount
the springs by turning them 120°.
The angled end of the springs must grip into the hollow arrester
of the synchronizer body.

body
The groove on the front side -arrow- points towards the 4th gear.
Check 3rd, 4th and 5th gear synchronizer rings for wear
3.,4. and 5th gear Installation dimen‐ Wear limit
sion
Clearance -a- 1.1 to 1.7 mm 0.5 mm

sleeve
Press on the inner ring -A- for the cylindrical-roller bearing

– Insert the circlip.
Determining the circlip thickness

– Insert circlip with a thickness of 2.0 mm in the slot of the drive
shaft and push upwards.
– Measure the dimension between the inner ring of the taper
roller bearing and the positioned circlip using a feeler gauge.
– Remove the circlip used to take the measurement.
– Determine thickness of circlip according to the table.
Note
Assign the circlips via the ⇒ Electronic catalogue of original parts .
The following circlips are available:

Measured value Circlip thickness Axial play (mm)
(mm) (mm)
0.05…0.14 2.0 0.05…0.15
0.15…0.24 2.1 0.05…0.15
0.25…0.34 2.2 0.05…0.15
0.35…0.44 2.3 0.05…0.15
0.45…0.51 2.4 0.05…0.10
Press the bearing support for grooved ball bearings onto the input
and output shafts
1. Drive shaft 141

Note
♦ The drive shafts of the individual gearboxes have different

lengths due to the different heights of the serration, dimension
-a-.
♦ In order to press in the bearing support evenly onto the shafts,
it is necessary that the shafts are also positioned evenly on
the insert base - T10083- .
♦ A 3 mm thick washer - T10083/1- must be inserted in the fas‐
tening opening of the drive shaft, if necessary ⇒ page 142 .
♦ Therefore, the dimension -a- of the output shaft serration must
be measured.
• Dimension -a- = 30.6 mm
Insert washer - T10083/1-
Press on the bearing support for grooved ball bearing

– Before pressing on the bearing support heat it to approximate‐
ly 100 °C.
Press on the bushing -A- for the 5th gear needle bearing

Remove supporting ring

– Unclip the hook -A- of the supporting ring from the synchron‐
izer body with a screwdriver.
Disassembling and assembling the sliding sleeve/5th gear syn‐

chronizer body
1 - Spring (as of production date 06.09 the springs are longer) ⇒
3 - Synchronizer body; fitting position: The groove on the front
side -arrow A- and the wide collar -arrow B- point towards the 5th

gear.
4 - Sliding sleeve
5 - Supporting ring
The deeper recesses -arrow C- of the arresters in the syn‐
chronizer body and the recesses -arrow D- in the sliding sleeve
must be positioned above one another.
– Insert the arresters in the deeper recesses and mount the
springs by turning them 120°.
Install supporting ring

– Place the supporting ring onto the flywheel type belt pulley fit‐
ting tool -MP9-400- .
– Insert the supporting ring together with the fitting tool in the
synchronizer body/5th gear sliding sleeve (Observe fitting po‐
sition ⇒ page 143 ). Lock the hooks -arrow 1- in the recesses
-arrow 2- of the synchronizer body arresters.
– Push the supporting ring down until the hooks click into posi‐
tion.
1. Drive shaft 143

2 Output shaft
Disassembling and assembling the output shaft ⇒ page 144

put shaft
♦ Interior extractor, e.g. -Kukko 21/5-

Note
When installing new pinions or a new output shaft observe the

technical data:
Note

box with gear oil.
assign to the original gear.

1 - Clutch housing
❑ with circlip
❑ Fitting position: The cir‐
clip in the bearing points
towards the output shaft
3 - Output shaft
❑ if an inner ring is fitted as
a bearing assembly for
the cylindrical-roller
bearing -Pos. 2-, it can‐
not be removed from the
output shaft
❑ Inspect bearing assem‐
bly or inner ring for cy‐
lindrical-roller bearing
for scoring and damage
❑ Replace output shaft
and cylindrical-roller
bearing together if there
is scoring or damage on
the bearing assembly or
inner ring
4 - 4th gear pinion
points to the 3rd gear
⇒ page 148
5 - Circlip
tronic Catalogue of
Original Parts
6 - Circlip
7 - 3rd gear pinion
❑ Fitting position: Collar points to the 4th gear ⇒ page 148
8 - Circlip
10 - Needle bearing
❑ 2. gear
11 - Inner ring for 2nd gear
❑ place onto the inner ring -Pos. 11-
2. Output shaft 145


❑ press off together with 2nd gear sliding gear ⇒ page 147
15 - Circlip
❑ pushing out ⇒ page 147
❑ insert in such a way that the recesses lock into the arresters of the sliding sleeve -Pos. 14-
❑ position in the synchronizer ring -Pos. 16-, fitting position ⇒ page 150
18 - Inner ring for 1st gear
19 - Needle bearing
❑ 1. gear
❑ replace after each removal
❑ Fitting position: collar points towards the cover of the gearbox housing ⇒ page 115
24 - Circlip
25 - Spring
26 - Sliding sleeve
❑ (3 pieces)


– When removing compress circlip of the cylindrical-roller bear‐
ing -arrow- with pliers -C-.

bearing support.
– When pressing in, the cylindrical-roller bearing compress the
circlip -arrow- with pliers -A-.

Press the circlip -1- out of the slot

A - Protective glove
WARNING
Prevent uncontrolled ejection of the circlip.
Press off the sliding sleeve and the synchronizer body for the 1st
and 2nd gear from the drive shaft
– After removing the circlip, at the same time press off the drive
shaft from the synchronizer body as well as from the 2nd gear
sliding gear.
2. Output shaft 147

Fitting position 3rd gear pinion and 4th gear pinion.

– Place the 4th gear pinion -A- on the output shaft.
Fitting position:
The collar -arrow 1- points towards the 3rd gear pinion -B-.
– Insert circlips -1- and -2-.
– Place the 3rd gear pinion -B- on the output shaft.
Fitting position:
The collar -arrow 2- points towards the 4th gear pinion -A-.
– Insert circlip -3-.

1. and 2nd gear Installation dimen‐ Wear
sion limit
Check 1st and 2nd gear synchronizer ring for wear

feeler gauge -1-.
1. and 2nd gear Installation dimen‐ Wear
sion limit
Fitting position of the inner ring, outer ring and 2nd gear syn‐
chronizer ring
– Position the inner ring -A- on the 2nd gear sliding gear.
Lock the lands -arrow 2- in the recesses -arrow 3- of the sliding
gear.
Lock the recesses -arrow 4- in the lands -arrow 1- of the inner
ring -A-.


1 - Spring
2 - Sliding sleeve
Fitting position:
After assembly the groove on the front side -arrow A- and the
higher collar -arrow B- of the synchronizer body point towards the
outer serration of the sliding sleeve -arrow C-.
The deeper recesses -arrow D- of the arresters in the synchron‐
izer body and the recesses -arrow E- in the sliding sleeve must
Assembling the sliding sleeve and 1st and 2nd gear synchronizer
body

The angled ends of the springs must grip into the recesses of
the arresters for the synchronizer body.

Fitting position:
The slot for the shift fork in the sliding sleeve points towards the
1st gear, the serration of the reversing gear points towards the
2nd gear.
2. Output shaft 149

Insert the circlip

– Rotate the synchronizer ring in such a way that the slots are
flush with the arresters.
– Insert the 1st gear synchronizer ring in the sliding sleeve/syn‐
chronizer body.
Fitting position of the 1st gear outer ring

The pegs -arrows- point towards the reversing gear serration
-A-.
Fitting position for 1st gear inner ring -A-

chronizer ring -B-.
Fitting position 1st gear sliding gear

The higher collar -A- points towards the 2nd gear -B-. The re‐
cesses in the collar -arrows- are pushed onto the pegs of the outer
ring ⇒ page 150 .


Removing ⇒ page 151 .
Installing ⇒ page 152 .
♦ Inertia extractor - MP9-501-
♦ Gasket ring extractor - MP3-419/37-
♦ Drive bushing - MP3-489 (3158)-
♦ Sealing grease - G052 128 A1-
1.1 Removing
For left gasket ring
– Fit the left front wheel ⇒ Chassis; Rep. gr. 44 .

– Turn steering to full left lock and raise the vehicle.
– If present, remove the sound dampening system ⇒ Body work;
Rep. gr. 50 .
– Remove the wheelhouse liner from the left wheelhouse ⇒
Body Work; Rep. gr. 66 .
– Remove drive shaft from flange shaft ⇒ Chassis; Rep. gr. 40 .
– Release the nuts -arrows- for the left steering joint ⇒ Chassis;
Rep. gr. 40 (on certain vehicles release the screws, see fig.
S39-0142).

For right gasket ring
– If present, remove the sound dampening system ⇒ Body work;
Rep. gr. 50 .

– If present, remove heat shield for drive shaft -arrows-.

– Remove drive shaft from flange shaft ⇒ Chassis; Rep. gr. 40 .
Proceed as follows for both gasket rings
– Release fixing screw for flange shaft; while doing so prevent
flange shaft from turning along.
– Remove the gasket ring of the flange shaft.
Note
♦ Do not damage the bushing for the right gasket ring as this will
cause leaks.
♦ replace bushing if damaged ⇒ page 126 .
1.2 Install
ring.
– Drive the new gasket ring into the bushing up to the stop, do
not twist the gasket ring.
– Fill half the space between the sealing and dust lip with sealing
grease -G 052 128 A1- .
The further installation occurs in reverse order, while paying at‐
– Check gear oil level, if necessary fill up to lower edge of filler
hole ⇒ page 112 .
– Check the axial measurement of the vehicle ⇒ Chassis; Rep.
gr. 44 .
Tightening torques
Flange shaft to gearbox ⇒ page 154


Wheel bolts to wheel hub ⇒ Chassis; Rep. gr. 44

2 Differential gear
Disassembling and assembling differential gear ⇒ page 154 .
Setting the differential gear ⇒ page 159 .

tial gear
♦ Press-on sleeve - MP3-412 (VW 455)-
♦ Pressure pipe - MP6-408 (30-14)-

♦ Pipe - MP6-419 (3259)-
♦ Tube for wheel bearing - T30019 (3345)-
♦ Interior extractor - Kukko 21/7-
♦ Countersupport - Kukko 22/2-
Note
♦ Before installing, heat the inner ring/tapered-roller bearing with the hot-air blower - V.A.G 1416- to 100°C.
♦ When replacing the tapered-roller bearing of the differential gear housing, gearbox housing and clutch
housing adjust the differential gear ⇒ page 159 .

❑ screw into threaded
piece -Pos. 8-
2 - Right flange shaft
❑ do not interchange, the
left and right flange
shafts are different
3 - Pressure spring for flange
shaft
❑ fitted behind flange
shaft
4 - Thrust washer
for compression spring
5 - Conical ring
❑ Fitting position: Cone for
6 - Circlip
❑ holds the conical ring,
stop disc and pressure
spring in position when
the flange shaft is re‐
moved
7 - Large differential bevel gear
8 - Threaded part
❑ when removing, the ten‐
sioning sleeve
-Pos. 18- is cut out
⇒ page 159
10 - Small differential bevel gear
❑ on certain gearboxes the stop disc compound was provided with a land ⇒ page 159
12 - Flange shaft left
❑ with rubber bowl
❑ do not interchange, the left and right flange shafts are different
13 - Sealing ring
❑ diameter of left and right differ
❑ on gearboxes made out of aluminium as of production date 12.06 the adjusting washer S1 for outer ring/
tapered-roller bearing is not fitted ⇒ page 159

❑ with riveted pinion
❑ is paired with the output shaft, replace together
❑ is cut when removing ⇒ page 159

22 - Sealing ring
❑ on gearboxes made out of aluminium as of production date 12.06 the adjusting washer S1 -Pos. 14- for
outer ring/tapered-roller bearing is not fitted ⇒ page 159
24 - Clutch housing



– If necessary, position adjusting washer S1 always 1 mm thick,
under outer ring.
Note
On gearboxes made out of aluminium as of production date 12.06

the adjusting washer S1 for outer ring/tapered-roller bearing is not
fitted The bearing pedestal for outer ring/tapered-roller bearing in
the gearbox housing is adapted. Difference between the housings
⇒ page 160 .
– Support the gearbox housing with pipe - MP6-419 (3259)- and

pressure pipe - MP6-408 (30-14)- directly below the bearing
support.
Remove inner ring/tapered-roller bearing on the side of the dif‐

ferential cage
– Before fitting the extractor, position distance sleeve -
MP3-458/2- and thrust piece - MP3-431 (3002)- on the differ‐
ential gear housing.
Press on inner ring/tapered-roller bearing on the side of the dif‐

ferential cage
WARNING
– Before pressing on, heat the inner ring/tapered-roller bearing

with the hot-air blower - V.A.G 1416- to approx. 100°C.
– Support the opposite side of the inner ring with an insertion
bushing - MP3-412 (VW 455)- .

Remove inner ring/tapered-roller bearing on the side of the gear

pinion
– Before fitting the extractor, position distance sleeve -
MP3-458/2- and thrust piece - MP3-431 (3002)- on the differ‐
ential gear housing.
Press on inner ring/tapered-roller bearing on the side of the gear

pinion
bushing - MP3-412 (VW 455)- .
Press the outer ring/tapered-roller bearing -A- out of the clutch

housing
– While doing so tighten the interior extractor behind the outer
ring/tapered-roller bearing.

– Support the clutch housing with a pipe for wheel bearing -
T30019 (3345)- directly below the bearing support.

Press out differential bevel gear shaft

The tensioning sleeve is cut during pressing out.
– Remove the remaining parts of the tensioning sleeve out of
the differential gear housing and the differential bevel gear
shaft.
On certain gearboxes the stop disc compound was provided with

lands -A- in the area of the openings.
Therefore the differential gear housing was provided with a round
slot -B-.
– Insert the stop disc compound in such a way that it locks into
the slot -B- in the differential gear housing.

Install differential bevel gears

flange shafts).
– Insert both small differential bevel gears with a 180° offset.
bevel gears.
– Insert the differential bevel gear shaft up to stop and secure
with new -Spannhülse- .

♦ Pressure pipe - MP6-408 (30-14)-
♦ Pipe - MP6-419 (3259)-
♦ Tube for wheel bearing - T30019 (3345)-


♦ Thrust plate - MP3-464 (30-205)-
♦ Dial gauge
nents are replaced:
♦ Gearbox housing
♦ Clutch housing
or
♦ tapered-roller bearings of the differential gear.
On gearboxes made out of aluminium as of production date 12.06
the adjusting washer S1 for outer ring/tapered-roller bearing is not
fitted
Bearing pedestal for outer ring/tapered-roller bearing is adapted.
– Measure the depth of the bearing pedestal for the outer ring/
tapered-roller bearing in the clutch housing.

Clearance “a” Adjusting washer S1

15.2 mm no
16.2 mm yes

– Press the outer ring/tapered-roller bearing (on the riveted pin‐
ion side of the differential housing) with adjusting washer S1
(always 1mm thick) into the clutch housing made out of mag‐
nesium or without adjusting washer into the clutch housing
made out of aluminium.
Note
The inner and outer rings of the tapered-roller bearing are paired
- do not interchange.
– Press the outer ring/tapered-roller bearing (opposite side)

without adjusting washer into the clutch housing.
– Insert the differential gear housing together with the installed
inner rings/tapered-roller bearings into the gearbox housing.
– Position the clutch housing and tighten 5 screws to the given


A - Dial gauge extension 30 mm
– Set the dial gauge to “0” with 1 mm bias.
– Move the differential gear up and down in the direction of the
axle, read off and write down the clearance on the dial gauge
(example: 1.50 mm).
Note
Do not turn the differential gear while measuring as otherwise the

bearings will settle and the measuring result will be inaccurate.
2.2.1 Determining the thickness of adjusting

washer S2
The prescribed bearing preload is reached by adding S2 to the
established measured value a constant compression value (0.25
mm and where necessary 0.35 mm).

Example:
For housing made out of magnesium:
+ pressure (const. value) 0.35 mm
Thickness of the adjusting washer S2 = 1.85 mm
For housing made out of aluminium:

+ pressure (const. value) 0.25 mm
– Remove the clutch housing and press out the outer ring/ta‐
pered-roller bearing -A-.
-B- Interior extractor 46 to 58 mm, e.g. -Kukko 21/7-
– Insert adjusting washer S2 with the required thickness (in our
example 1.75 or 1.85 mm) and press the outer ring/tapered-
roller bearing back into the clutch housing.
Original Parts .
If the measured washer thickness is greater than the thickest
washer listed in the spare parts catalogue, 2 washers corre‐
sponding to the measured value may be fitted.
– Position the clutch housing and tighten the screws to the given

Service
Workshop Manual
FABIA II 2007 ➤
Gearbox 02T
Edition 12.06

Service
Repair Group
00 - Technical data
30 - Clutch
35 - Wheels, shafts

FABIA II 2007 ➤
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification characters, aggregate assignment, ratios, capacities . . . . . . . . . . . . . . . . . . 1
3 General repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 removing and installing, setting angular clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . 12
1.3 removing and installing, setting cylindrical clutch pedal switch F36 . . . . . . . . . . . . . . . . . . 12
1.4 Removing and installing the crash strut for the clutch pedal; Fabia II 2007 ? . . . . . . . . . . 13
1.5 Removing and installing the over-centre helper spring; Fabia II 2007 ? . . . . . . . . . . . . . . 15
1.6 Removing and installing the clutch pedal; Fabia II 2007 ? . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.8 Removing and installing the bracket with the master cylinder; Fabia II 2011 ? . . . . . . . . . . 23
1.9 Removing and installing the bracket without the master cylinder; Fabia II 2011 ? . . . . . . . . 26
1.10 Removing and installing the clutch pedal with the over-centre helper spring; Fabia II
2011 ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.11 Removing and installing the clutch pedal with the tension spring; Fabia II 2011 ? . . . . . . 30
1.12 Summary of components - Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.17 Bleed the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Repairing the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Repairing the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
34 - Control, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.3 Summary of components - Gearshift knob with gearshift lever cover . . . . . . . . . . . . . . . . 57
1.4 Remove and install gearshift knob and gearshift lever cover . . . . . . . . . . . . . . . . . . . . . . . . 57
1.7 Plastic relay lever as of 06.07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3 Inspect the gear oil level in the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.4 Detaching and attaching clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
FABIA II 2007 ➤
4.5 Removing and installing the drive shaft, output shaft, differential, shift mechanism and
gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.6 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5 Repairing the gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6 Repairing the gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
35 - Wheels, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.1 Disassembling and assembling the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ii Contents
FABIA II 2007 ➤
Assignment ⇒ page 1
Identification of materials for the gearbox housing -arrow 2-.

Example: JHN 17 11 6
I I I I
Identifica‐ Day Month Manufac‐
tion charac‐ turing year
ters (2006)
Additional data depend on the manufacturing.
Note

data stickers.
Identification of materials for the gearbox housing

There is lettering on aluminium gearboxes -arrow- -GD TL 023-,
or -AlSi9Cu3- or -AlSi6Cu4-.
One can also use the gearbox identification characters to deter‐
mine whether it is an aluminium or a magnesium gearbox.
1.1 Identification characters, aggregate assignment, ratios, capacities

Identification characters JHN LVC JUS LVG
Manufac‐ from 12.06 06.09 01.07 06.09
tured
to 05.09 03.10 05.09 03.10
ment:
Ratio: Final drive 67 : 16 = 4,188

FABIA II 2007 ➤

Z2:Z1 1st gear 49 : 13 = 3,769
2nd gear 44 : 21 = 2,095
3rd gear 43 : 31 = 1,387
4th gear 40 : 39 = 1,026
5th gear 39 : 48 = 0,813 40 : 47 = 0,851
Reverse gear 35:24 x 24:11 = 3.182
Filling capacity 2.0 litres
Drive shaft flange ∅ 90 mm 100 mm 90 mm 100 mm
Note

G22- .

Identification characters LVC LNR
tured
to
ment:
Z2:Z1 1st gear 49 : 13 = 3,769
2nd gear 44 : 21 = 2,095
3rd gear 43 : 31 = 1,387 41 : 32 = 1,281
4th gear 40 : 39 = 1,026 38 : 41 = 0,927
5th gear 39 : 48 = 0,813 37 : 50 = 0,74
Reverse gear 35:24 x 24:11 = 3.182

FABIA II 2007 ➤
Note

G22- .

Identification characters MFX LMG
tured
to
Assign‐ Engine 1.2 ltr./63 kW TFSI 1.2 ltr./77 kW TFSI
ment:

Z2:Z1 1st gear 49 : 13 = 3,769
2nd gear 43 : 22 = 1,955
3rd gear 41 : 32 = 1,281
4th gear 38 : 41 = 0,927
5th gear 37 : 50 = 0,74
Reverse gear 35:24 x 24:11 = 3.182
Note

G22- .

Identification characters JHQ LVE JHL LVA
Manufac‐ from 02.07 06.09 04.07 06.09
tured
to 05.09 05.09 05.10
ment:

FABIA II 2007 ➤

Ratio: Final drive 66 : 17 = 3,882 59 : 15 = 3,933
Z2:Z1 1st gear 49 : 13 = 3,769
2nd gear 44 : 21 = 2,095
3rd gear 43 : 31 = 1,387
4th gear 40 : 39 = 1,026
5th gear 39 : 48 = 0,813
Reverse gear 35:24 x 24:11 = 3.182

Note

G22- .

Identification characters MAB LNJ
tured
to
ment:
Ratio: Final drive 68 : 15 = 4,533 59 : 15 = 3,933
Z2:Z1 1st gear 38 : 11 = 3,455 49 : 13 = 3,769
2nd gear 43 : 22 = 1,955 44 : 21 = 2,095
3rd gear 41 : 32 = 1,281
4th gear 37 : 42 = 0,881
5th gear 35 : 52 = 0,673
Reverse gear 35:24 x 24:11 = 3.182

FABIA II 2007 ➤
Note

G22- .

Identification characters JQM LVF
tured
to 05.09 09.10
ment:

Z2:Z1 1st gear 49 : 13 = 3,769
2nd gear 44 : 21 = 2,095
3rd gear 43 : 31 = 1,387
4th gear 40 : 39 = 1,026
5th gear 38 : 49 = 0,776
Reverse gear 35:24 x 24:11 = 3.182
Note

G22- .

FABIA II 2007 ➤
Note
The arrow shows the direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Drive shaft
5 - Output shaft/input shaft

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

FABIA II 2007 ➤
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
workshop manual.
Gearbox
Gearboxes are constructed of aluminium and of magnesium
⇒ page 1 .
♦ Gearbox housing and clutch housing are made of the same
materials.
♦ Bolts and other attachments that come into direct contact with
the gearbox can have varying finishes depending on whether
the gearbox is made of aluminium or magnesium.
♦ On magnesium gearboxes, the screws must always be re‐
placed at the following screw connections: Gearbox housing
cover to gearbox housing and clutch housing to gearbox hous‐
ing.
♦ The use of substitute components causes contact corrosion.
This will result in damage to the gearbox.
♦ When installing, ensure the dowel sleeves are correctly loca‐
ted between the engine and gearbox.
♦ When replacing the gearbox, pour in gear oil up to the lower
edge of the filler hole.
♦ Capacity and specification ⇒ page 1 .
Gaskets, seals
♦ Clean contact surfaces thoroughly and apply sealant -
AMV 188 200 03- .
♦ Apply sealant evenly - not too thickly.
♦ Replace O-rings.
♦ Replace radial shaft seals.
Before installing:
Oil outer diameter slightly. Fill half the space between the sealing
lips -arrow- with grease -G 052 128 A1- .
After installing:
Check gear oil level, if necessary pour in up to lower edge of filler
hole ⇒ page 86 , specification ⇒ page 1 .
Locking elements

FABIA II 2007 ➤
♦ Replace circlips.
♦ Replace roll pins. Fitting position: Slot longitudinally to power
flow -arrow-.
Screws, nuts
♦ Do not twist particularly sensitive parts - e.g. clutch pressure
plates - and slacken and tighten diagonally across in stages.
♦ Always replace the self-locking screws and nuts ⇒ Electronic
♦ Clean all threaded holes into which self-locking bolts were
screwed in, using a suitable thread tap to remove old locking
agent residues. Otherwise there is the risk that the self-locking
screw will shear when removing.
Bearings
♦ New taper roller bearings are fitted as supplied and do not
require any additional lubrication.
♦ Fit needle bearings to the gearbox with some gearbox fluid.
♦ Replace all taper roller bearings belonging to one shaft at the
same time. As far as possible use bearings of the same make.
♦ Before installing, heat the inner races of the bearings on a
heating plate or with the hot-air blower -V.A.G 1416- to approx.
100°C, when installing press in axial and play-free up to the
stop.
♦ Temperature can be checked with a temperature measuring
instrument.
♦ Do not exchange the outer and inner rings of bearings of the
same size - bearings go in pairs.
♦ Always position needle bearing with the lettered side (thicker
end) towards the drift pin.
Shims

FABIA II 2007 ➤

washer very precisely ⇒ electronic catalogue of original parts .
♦ Inspect for burrs and damage.
♦ Install only shims which are in perfect condition.
Synchronizer rings

izer rings to the same gear.
of Original Parts .
♦ Check slots -arrow 1- on synchronizer ring -A-, or check the
inside of the ring for flattened parts (slots worn).
♦ When installing the intermediate ring -B-, outer -arrow 2- and
inner -arrow 3- check contact surface for grooves, blue color‐
ing (caused by overheating) and other damages.
♦ Insert moist with some gearbox fluid.
Pinions
♦ Clean and heat on a heating plate or with the hot-air blower -
V.A.G 1416- to approx. 100°C before pressing on.
♦ Temperature can be checked with a temperature measuring
instrument.
Clutch control
tach the hoses.
♦ Do not tilt the clutch pressure plate, release or tighten in small
stages crosswise
system must be bled (further measures ⇒ page 35 ).
thoroughly clean the clutch bell as well as the flywheel and the
engine on the side of the gearbox.

FABIA II 2007 ➤
30 – Clutch
1 Clutch control
1.1 Summary of components - foot controls;

Fabia II 2007 ?
Note

♦ Grease all bearing and contact surfaces with grease -G 000
450 02- .
♦ Prior to working on the foot controls remove the storage area
on the driver's side ⇒ Body Work ⇒ Rep. Gr. 70 .
1 - Support/Front wall
❑ for master cylinder and
bracket
2 - Gasket
tronic Catalogue of
Original Parts
3 - Bracket
4 - Screw
6 - 28 Nm
tronic Catalogue of
Original Parts
clutch pedal switch
⇒ page 11
❑ assign according to the
⇒ Electronic catalogue
of original parts .
⇒ page 12 angular
clutch pedal switch
clutch pedal switch
⇒ page 15

FABIA II 2007 ➤
9 - Bushing
10 - Bearing pins
11 - Clutch pedal
12 - Support
13 - 28 Nm
16 - Tubing
❑ out of rubber
❑ as of 12.05 on certain vehicles out of plastic ⇒ page 35
❑ if the return hose is made out of plastic, do not use hose clamp -MP7–602-
17 - Bearings
❑ insert in bracket
18 - Screw
❑ Pedal stop on bracket - Pos. 3
19 - Pedal stop
❑ screw with screw - Pos. 18 onto bracket - Pos. 3
20 - 25 Nm
Difference between clutch pedal switch -F36-

♦ -A- Switch with angular housing
♦ -B- Switch with cylindrical housing
FABIA II 2007 ➤
1.2 removing and installing, setting angular

clutch pedal switch -F36-
Note
Removing
⇒ Rep. Gr. 70 .
– Turn clutch pedal switch -F36- 90° to the left and remove it
from the support.
– Remove tappet up to the stop
– Press down the clutch pedal by hand as far as possible.

– Insert clutch pedal switch into the support and turn switch 90°
to the right.
Rep. Gr. 70 .
1.3 removing and installing, setting cylindri‐

cal clutch pedal switch -F36-
Note

⇒ Rep. Gr. 70 .
– Unplug connector -1- from the clutch pedal switch -F36- .
– Turn clutch pedal switch -F36- -2- in the bracket 45° to the left
Note
The clutch pedal remains in the off position in this case (do not
depress).

FABIA II 2007 ➤
– Before installing the clutch pedal switch -F36- pull out the
plunger -3- completely.
• The clutch pedal -4- is in the off position.
– Guide the clutch pedal switch -F36- through the assembly
opening, with pressure against the clutch pedal and attach by
turning it 45° to the right.
Rep. Gr. 70 .

for the clutch pedal; Fabia II 2007 ?
Removing
⇒ Rep. Gr. 70 .

Install
FABIA II 2007 ➤
Tightening torque
14
FABIA II 2007 ➤

helper spring; Fabia II 2007 ?
♦ Pliers -T10005-
Removing
⇒ Rep. Gr. 70 .
– Remove clutch pedal switch ⇒ Item 7 (page 10) , if provided.
follows:
master cylinder.
– Push the over-centre helper spring against the partition panel

-in the direction of the arrow- and remove from the bracket
from the bottom.
Install
– Insert bearing for over-centre helper spring -arrow 1- in the

bracket holder.
inder -arrow 2-.
– Insert over-centre helper spring in the bearing.
15
FABIA II 2007 ➤
– Press over-centre helper spring against the bearing and posi‐

tion on the support of the clutch pedal -arrow-.
– Position the clutch pedal with the master brake cylinder
⇒ page 18 .
– Installing the clutch pedal switch ⇒ Item 7 (page 10) .
– Install crash strut ⇒ page 13 .

Rep. Gr. 70 .
16
FABIA II 2007 ➤
Tightening torque
17
FABIA II 2007 ➤
1.6 Removing and installing the clutch ped‐

al; Fabia II 2007 ?
♦ Pliers -T10005-
Removing
– Remove clutch pedal switch ⇒ Item 7 (page 10) , if provided.
– Unscrew nut -A-.
– Slowly turn steering wheel in a suitable position.
– Pull screw out of the bracket.

Install
following points:

wall -direction of the arrow- and make sure it catches correctly.
18
FABIA II 2007 ➤
Tightening torques
19
FABIA II 2007 ➤
1.7 Summary of components - foot controls; Fabia II 2011 ?
Note

♦ Grease all bearing and contact surfaces with Polycarbamide Grease -G 052 142 A2- .
1 - Front wall
❑ with mount for bracket
and master cylinder
2 - Bushing
❑ for top location hole in
the bracket
3 - Bracket
⇒ page 23
⇒ page 26
4 - 25 Nm
❑ self-locking
❑ 3 pieces
tronic Catalogue of
Original Parts
⇒ page 22
6 - Crash strut
❑ secured to steering col‐
umn
7 - 9 Nm
❑ for crash strut Pos. 7 at
steering column
8 - Stop
9 - Bearing bolt
❑ depending on the equipment version, a tension spring or an over-centre helper spring is mounted
❑ Assign components via the ⇒ Electronic catalogue of original parts .
20
FABIA II 2007 ➤
11 - Clutch pedal
❑ Removing and installing the over-centre helper spring ⇒ page 28
12 - Bushing
❑ depending on the equipment version, a tension spring or an over-centre helper spring is mounted
❑ is inserted on the bracket 3 and on the clutch pedal
14 - Cap
15 - Support
17 - Clamp

18 - Gasket
❑ stick onto master cylinder
19 - Tubing
20 - Clutch position sender -G476-
❑ for vehicles with the start-stop system
❑ can be checked in the “guided fault detection system” with the Vehicle diagnosis, measurement and
information system -VAS 5051-
removing and installing tension spring

21
FABIA II 2007 ➤

switch -F36-
Note
Removing
Gr. 80 .
Note

– Turn the clutch pedal switch in the bracket by 45° in

Install
• The bolt -A- of the clutch pedal switch must not be pulled out.
• Grease the bolt head -arrow-.
Parts .
bly, the clutch pedal must only be touched by means of the
bolt head -arrow- of the clutch pedal switch .

– Insert the clutch pedal switch into the support on the bracket
and turn it by 45° in -direction of arrow-.
Gr. 80 .
22
FABIA II 2007 ➤

the master cylinder; Fabia II 2011 ?
♦ Closing tool -T10249-
1.8.1 Removing
Note

– If necessary, remove engine cover ⇒ Engine ⇒ Rep. Gr. 10 .

– Remove air filter ⇒ Engine ⇒ Rep. Gr. 23 or ⇒ Engine ⇒
Rep. Gr. 24 .
control unit from the front wall ⇒ Engine ⇒ Rep. Gr. 23 or ⇒
– Lay a cloth below the master cylinder.
Note

stop.
Note
out from the side.
23
FABIA II 2007 ➤
Vehicles with the start-stop system:

– Unclip clutch position sender -G476- at master cylinder
– Remove the clutch position sender with fitted plugs from the
master cylinder.
Note

Gr. 87 .

-A-.


– Unscrew top fixing nut -arrow- for bracket. To do so, position
an extension on the nut through the opening between the dash
panel -2- and the bottom steering column trim panel -3-.
– Unscrew the two bottom fixing nuts -arrows-.

1.8.2 Install
following points:
24
FABIA II 2007 ➤
Note
– If present, install the crash strut -A-. To do so, tighten the fixing
screws -arrows- ⇒ Item 7 (page 20) to the specified tightening
torque.
Gr. 87 .
Vehicles with the start-stop system:

– Position the clutch position sender -G476- with fitted plugs on
the master cylinder up to the stop.
– Check the clutch position sender for tight connection by pulling
on it -arrow B-.
– Fit the tube-hose line -3- onto the connection of the master
– Fit return hose -1- on master cylinder.
– Check the line for tight connection by pulling on it.
Engine ⇒ Rep. Gr. 23 or ⇒ Engine ⇒ Rep. Gr. 24 .
– Install battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Install air filter housing ⇒ Engine ⇒ Rep. Gr. 23 or ⇒ Engine
⇒ Rep. Gr. 24 .
Tightening torques

25
FABIA II 2007 ➤

without the master cylinder; Fabia II
2011 ?
♦ Pliers -T10005-
Removing
Gr. 87 .
-A-.

– Unscrew top fixing nut -arrow- for bracket. To do so, position
an extension on the nut through the opening between the dash
panel -2- and the bottom steering column trim panel -3-.

as follows:
T10005- -arrows-.
26
FABIA II 2007 ➤
– Unscrew the two bottom fixing nuts -arrows-.

• The master cylinder is secured to the bracket.
Install
following points:
Note

torque.
Gr. 87 .
27
FABIA II 2007 ➤

with the over-centre helper spring; Fabia
II 2011 ?
Note

♦ If only the over-centre helper spring is removed, the clutch
pedal must not be separated from the master cylinder.

♦ Pliers -T10005-
♦ 8 mm Allan key, commercially available
Removing
Gr. 87 .
-A-.

as follows:
T10005- -arrows-.
28
FABIA II 2007 ➤
– Remove bearing bolt for clutch pedal.

The catch -A- is destroyed.
– Now move the clutch pedal in order to pull out the bearing bolt.
Install
• Install clutch pedal with new bearing bolt.
master cylinder.

– Insert the over-centre helper spring -A- from below next to the
pin of the master cylinder and next to the clutch pedal.

29
FABIA II 2007 ➤

– Position the bolt -A- horizontally.
– Turn the bearing bolt to the right in -direction of arrow-.
• The catch -B- must click audibly into place.
torque.
Gr. 87 .

with the tension spring; Fabia II 2011 ?
Note

♦ If only the tension spring is removed, one must pay attention
⇒ page 32 .

♦ Hook -3438-
♦ Pliers -T10005-
♦ 8 mm Allan key, commercially available
Removing
Gr. 87 .
-A-.
30
FABIA II 2007 ➤
– Unhook tension spring with e.g hook -3438- .
Note
Only observe the right part in the fig. -arrows- when installing.

as follows:
T10005- -arrows-.
– Remove bearing bolt for clutch pedal.

The catch -A- is destroyed.
– Now move the clutch pedal in order to pull out the bearing bolt.
Install
• Install clutch pedal with new bearing bolt.
master cylinder.
– Insert a new bearing bolt in the bracket and insert the clutch
pedal.
31
FABIA II 2007 ➤
– Position the bolt -A- horizontally.

– Turn the bearing bolt to the right in -direction of arrow-.
• The catch -B- must click audibly into place.
– Secure the clutch pedal with the support to the actuating rod
of the master cylinder.
– Hook in tension spring.

torque.
Gr. 87 .
32
FABIA II 2007 ➤
1.12 Summary of components - Hydraulics

❑ test tightness
⇒ page 35
2 - Tubing
❑ out of rubber
❑ as of 12.05 on certain
vehicles out of plastic
⇒ page 35
MP7–602-
❑ test tightness
⇒ page 35
3 - Master cylinder
⇒ page 36
clutch control
⇒ page 44
❑ test tightness
⇒ page 35
4 - Locking clip
line Pos. 9 pull out of the
master cylinder Pos. 3
up to the stop
5 - Support
been removed
6 - Clutch pedal
7 - 28 Nm
8 - O-ring
❑ always replace
❑ Difference between the O-rings ⇒ page 34
❑ moisten with brake fluid before installing
9 - Tube-hose line
10 - Support
❑ at front left frame side rails
❑ for clipping in the tube-hose line Pos. 9
33
FABIA II 2007 ➤
11 - Support
❑ holds the tube-hose line Pos. 9 at the gearbox
12 - 20 Nm
13 - Locking clip
❑ to remove the tube-hose line Pos. 9 pull out of the slave cylinder Pos. 16 up to the stop
14 - Dust cap
15 - Vent valve
❑ Bleed the clutch control ⇒ page 44
16 - Slave cylinder
17 - Gearbox


Difference between the O-rings

-1- Line connection with circular slot -arrow 1-
-3- Line connection with shoulder -arrow 2- and round
slot -arrow 3-
34
FABIA II 2007 ➤
as of 12.05 on certain vehicles plastic return hose -1-

♦ Do not use hose clamp -MP7–602-
Note
♦ If the master cylinder and/or slave cylinder must be replaced

due to the predetermined fault, first of all check the hydraulic
clutch control.

-arrow 1-.
♦ If there is no or little brake fluid in this chamber, there is a leak
in the system.
♦ In case of leakage, the corresponding component must be re‐
♦ Check the correct routing of the tube-hose line between the
master and slave cylinder. The line must not be bent or jam‐
med at all in a sharp angle.
♦ The pedal actuation must not be obstructed by moved or ad‐
ditional foot mats.
Inspect the complete hydraulic system for leaks.

– Carry out a visual inspection of the following components of
the hydraulic clutch control for leaks:
♦ Check brake fluid level in the brake fluid reservoir
♦ Return hose between brake fluid reservoir and master cylinder
♦ Master cylinder
♦ Tube-hose line between master and slave cylinder
visible area
♦ Slave cylinder
35
FABIA II 2007 ➤
– Remove the slave cylinder (do not open the line system) and
check if no brake fluid drips out of the bellows, to do so remove
the bellows from the rod -arrow-.
– If necessary, bleed the clutch control ⇒ page 44 .
– Then depress the clutch pedal carefully, at the same time hold
the pedal in five different positions for approx. 20s over the
entire distance the pedal has to travel and check that the pedal
does not fall through on its own while being held (in five posi‐
tions). While doing so, a second mechanic must check if fluid
is leaking from the other components of the hydraulic clutch
control ⇒ page 35 .

♦ Pliers -T10005-
♦ Hose clamp -MP7-602 (3094)-
1.14.1 Removing
Note
If the battery earth strap is disconnected and re-connected, carry


Rep. Gr. 24 .
Gr. 27 .
36
FABIA II 2007 ➤
– Pinch off return hose -A- to master cylinder with hose clamp -
MP7-602 (3094)- (if the return hose is made out of plastic, do
not use the hose clamp -MP7–602 - , otherwise the return hose
can get damaged).
– Release return hose -A- to the brake fluid reservoir and shut
it off in a suitable manner.
– Pull locking clip -B- out of the master cylinder.
inder.
⇒ Rep. Gr. 70 .
– Remove crash strut for clutch pedal (if present) ⇒ page 13 .
– Remove clutch pedal switch, if provided ⇒ Item 7 (page 10) .
Note

clutch pedal.

follows:
master cylinder.
– Unscrew the nuts -arrows 1- and remove the clutch controls

– Unscrew pedal stop ⇒ Item 19 (page 11) .
37
FABIA II 2007 ➤
1.14.2 Install
following points:
wall in the -direction of the arrow-; while doing so make sure
it catches correctly.
⇒ page 44 .
38
FABIA II 2007 ➤
Tightening torques
39
FABIA II 2007 ➤

♦ Pliers -T10005-
Removing
Remove bracket with master cylinder ⇒ page 23 .
– Unlock the clutch pedal from the master cylinder with pliers -
T10005- .
– Remove master cylinder from bracket.
Install

Install bracket with master cylinder ⇒ page 23 .

der
♦ Hose clamp -MP7-602 (3094)-
♦ Grease -G 000 100-
Note
♦ If the slave cylinder must be replaced due to the predeter‐

mined fault, first of all check the hydraulic clutch control
⇒ page 35 .
40
FABIA II 2007 ➤
1.16.1 Removing
Note


Rep. Gr. 24 .
Gr. 27 .
-A-.
Vehicles up to 05.07 (metal relay lever)
-B-.
relay lever.
Vehicles from 06.07 (plastic relay lever)
– Pull off the shift cable from the stud.
-arrow 4-.

-arrows-.
Note
Make sure no brake fluid comes into contact with the gearbox. If
this is the case, this point must be cleaned thoroughly.
– Pinch off the tube-hose line to the master cylinder with the
hose clamp -MP7-602 (3094)- (if the tube-hose line to the
master cylinder is made out of plastic, do not use the hose
clamp -MP7–602 - ).
41
FABIA II 2007 ➤
– Pull retaining clip -A- for tube-hose line out of the slave cylinder
up to the stop.
– Pull tube-hose line out of the support -C-.
– Pull tube-hose line -B- out of the slave cylinder and close
opening in a suitable manner.
– Unscrew slave cylinder -arrows- and take out.
Note
1.16.2 Install
following points:
– Grease tappet head with grease -G 000 100- .
– Install slave cylinder and tighten screws -arrows- to the given
tightening torque.
– Insert tube-hose line -B- into the slave cylinder up to the stop.
– Press in retaining clip -A- for attaching the tube-hose line up
to the stop.
– Press tube-hose line up to the stop into the support -C- at the
gearbox.
⇒ page 44 .
er ⇒ page 65 .
Gr. 27 .
– Install air filter ⇒ Engine ⇒ Rep. Gr. 23 , or ⇒ Engine ⇒ Rep.
Gr. 24 .
Gr. 27 .
42
FABIA II 2007 ➤
Tightening torques
43
FABIA II 2007 ➤
1.17 Bleed the clutch control

♦ Brake filling and bleeding device (e.g. -ROMESS S15- or -VAS
5234- )
Note

Brake fluid specification ⇒ Chassis ⇒ Rep. Gr. 00 .


Rep. Gr. 24 .
Gr. 27 .
– Connect the brake filling and bleeding device.
– Insert the bleeder hose -A- on the vent valve of the slave cyl‐
inder -arrow- and open the valve.
– Activate clutch pedal forcefully from stop to stop between 10
and 15 times.
– Allow another approx. 50 cm3 of brake fluid to drain off.
pedal repeatedly.
– Disconnect the brake filling and bleeding device.
44
FABIA II 2007 ➤
2 Repairing the clutch control

♦ Grease -G 000 100-
1 - Clutch release bearing

❑ Do not wash the bear‐
ing, just wipe clean
of Original Parts
⇒ page 46
lease lever Pos. 3 and
guide bushing Pos. 5
⇒ page 46
❑ grease contact points
on the clutch release
lever with grease -G 000
100-
90°
tronic Catalogue of
Original Parts
lease bearing - Pos. 1
and guide bushing -
Pos. 5 ⇒ page 46
❑ Original grease must be
removed from the con‐
tact point of the clutch
release lever
❑ grease contact point on
the ball stud with grease
-G 000 100-
5 - Guide bushing for clutch release bearing
❑ remove and install together with the clutch release lever - Pos. 3 and clutch release bearing - Pos. 1
⇒ page 46
❑ Grease guide bushing in the area of the release lever with grease -G 000 100-
❑ Original grease must be removed from the contact point of the clutch release lever
❑ grease with grease -G 000 100-
2. Repairing the clutch control 45

FABIA II 2007 ➤
8 - Gearbox
9 - 20 Nm
10 - Support
11 - Slave cylinder
❑ grease tappet end with grease -G 000 100-
Remove and install the clutch release lever together with the re‐
lease bearing and guide bushing
bearing and guide bushing from the drive shaft and ball stud.
Removing and installing the guide bushing

– Rotate the guide bushing -3- opposite the release bearing
-2- by approx. 90° in the -direction of the arrow- until the catch
pegs of the guide bushing are aligned with the slots -4- of the
release bearing.
– In this position remove the guide bushing from the release
bearing.

– Press the catch pegs -arrows- together and remove the re‐
lease bearing -A- from the clutch release lever.
46
FABIA II 2007 ➤
3 Repairing the clutch

♦ Centering mandrel -T10086-
♦ Centering mandrel -MP3-475A (3190A) -
♦ Grease -G 000 100-
(Gearbox removed)
Note
- problems with the clutch and clutch control ⇒ page 49 .
♦ Clean the drive shaft serration and hub serration on used clutch discs. Remove corrosion and only apply a
very thin layer of grease -G 000 100- on the drive shaft serration.
♦ Subsequently move the clutch disc up and down on the drive shaft until the hub fits smoothly on the shaft.
♦ Remove all excess grease.
♦ 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 installed, there are problems with the gearshift and the clutch or the gearbox is
loud.
3. Repairing the clutch 47

FABIA II 2007 ➤
1 - Flywheel
pins are correctly fitted
and grease
⇒ Engine ⇒ Rep. Gr.
13
2 - Clutch disc
Parts
❑ Fitting position: the
wards the pressure
plate
❑ centering for vehicles
with 1.2 ltr and 1.4 ltr en‐
gines ⇒ page 49
❑ centring for vehicles
with 1.4 ltr (TDI) and 1.6
ltr engines ⇒ page 49
ration
Note
3 - Pressure plate
for vehicles with 1.2 ltr
and 1.4 ltr engines
⇒ page 49
for vehicles with 1.4 ltr
(TDI) and 1.6 ltr engines ⇒ page 49
❑ Check the extremities of the membrane spring ⇒ page 49
4 - Screw M6 - 13 Nm; screw M7 - 20 Nm
❑ Release or tighten gradually and crosswise
48
FABIA II 2007 ➤
plate for vehicles with 1.2 ltr and 1.4 ltr engines
MP1-223 (3067)- .
Note
inserted.
♦ Tighten the screws crosswise and uniformly so as not to dam‐
age the centering holes on the pressure plate and the center‐
ing pins of the flywheel.
plate for vehicles with 1.4 ltr (TDI) and 1.6 ltr. engines

MP1-223 (3067)- .
Note
inserted.
♦ Tighten the fixing screws crosswise and uniformly so as not to
damage the centering holes on the pressure plate and the
centering pins of the flywheel.


Note
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.

FABIA II 2007 ➤

brake fluid.
♦ Release bearing is tilted on the – Replace guide bushing and re‐
guide bushing, seizured. lease bearing.

sure plate broken.



mm.
♦ Release bearing on the guide – Replace defective parts.

parts .
♦ Mechanical fault of the pressure – Replace defective parts.
plate/clutch disc.

place clutch disc.

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.

Noises when operating the clutch. ♦ Release bearing defective, re‐ – Always replace noisy release
lease bearing cable is not O.K, bearings.
contact surface drained off.
ing.
♦ Contact surface of the pressure – Replace pressure plate.
plate defective (tips of mem‐
brane spring bent, broken). Re‐ – Check release bearing, guide
lease bearing is off-center. bushing, replace if necessary.
– Check position of release lever.
50
FABIA II 2007 ➤

gearbox.
♦ Clutch disc installed the wrong – Correct installation.

way up.

parts .

Scratch noises when the forward or ♦ Air in the system, clutch does – Bleed system; check system,
reverse gear is engaged, gearschift not separate fully. top up with brake fluid.
jams, hooks, is sluggish, shifting
not possible, clutch without opera‐
tion
♦ Master cylinder or slave cylinder – Replace defective part, top up
is leaking, line is leaking. with brake fluid, bleed system.

under the pedal) clutch is not
fully depressed.
♦ Pressure plate uneven due to in‐ – Inspect parts, if necessary re‐

correct installation, clutch disc place, observe position of the
warped due to improper han‐ centering pins.
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.
bearing moves off-center). – Check release bearing, guide
bushing, replace if necessary.

parts .
♦ Deposit of corrosion adhering to – Slightly rub down friction surfa‐
the flywheel (long immobiliza‐ ces of the clutch linings or re‐
tion time, high humidity). place completely the severely
corroded parts.

FABIA II 2007 ➤

G 000 100- .



place if necessary.
parts .
replace.
♦ Linings spalled off because of – Replace clutch disc. Inform cus‐
too high revs (shift back during tomer.
too high speed).
long a time.

Load change jolts when throttle is ♦ Suspension assembly too soft. – Inform customer. Assign hanger
depressed and sudden reduction of via the ⇒ Electronic Catalogue
the engine speed. of Original Parts replace if nec‐
essary.


gearbox. necessary.

52
FABIA II 2007 ➤

♦ Clutch disc worn out, burnt, – Replace clutch disc.
ural wear.

wheel oily. Shaft seals of engine
or gearbox defective. Grease on – Clean contact surfaces of pres‐
the contact surfaces through ex‐ sure plate and flywheel.
cess greasing of the hub.
– Replace shaft seal, remove ex‐
♦ Clutch disc installed the wrong – Correct installation, check
way up. clutch disc, replace if necessary.


ness.

♦ Driving error, starting speed is – Inform customer.

too low.

parts .
♦ Assembly bracket too soft, – Assign the assembly bracket via
knocked out. the ⇒ electronic catalogue of
original parts .
♦ Clutch lining, contact surface of – Check radial shaft seal of the
pressure plate and flywheel oily drive shaft for clutch or check
(oil leakage from the clutch crankshaft, if necessary re‐
housing). place.

guide bushing (seizured) guide bushing.
membrane spring of the pres‐ – Check actuating elements and
sure plate). bearing for actuating elements.

FABIA II 2007 ➤

sure plate lifts off only unilater‐ clutch lining at the flywheel,
bearing. brane spring, replace pressure
plate if necessary.
♦ Housing of the pressure plate
warped when installed. Contact – Replace release bearing and
surface of the pressure plate lifts guide bushing.
off only unilaterally.
♦ 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 (rattle
wheel). markings, traces of overheating,
scoring).

clutch disc -G 000 100- .


Acoustic knock “Klack” when cou‐ ♦ Carrier earth/drive shaft is ac‐ – Inform customer.

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

parts .
♦ Pressure plate deformed, imbal‐ – Replace pressure plate.
ance.

necessary.
missing).

dowel sleeves.
54
FABIA II 2007 ➤
1 Shift mechanism

Arrow A - Shift movement
Arrow B - Selector movement
A - Shift cable
B - Selector cable
C - Heat shield
the shift mechanism
1 - Gearshift lever

2 - Reversing lever
FABIA II 2007 ➤
Note
♦ If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System
⇒ Rep. Gr. 27 .
♦ Remove shift mechanism for replacing control cables ⇒ page 65 .
Gearshift knob with gearshift
lever cover ⇒ page 57
II - Assembly overview - shift

FABIA II 2007 ➤
1.3 Summary of components - Gearshift knob with gearshift lever cover
1 - Gearshift knob
❑ with collar
❑ It is not possible to sep‐
arate the gearshift knob
from the collar
of Original Parts
⇒ page 57
e.g. with a screwdriver
(Fabia II 2011 ?)
2 - Centre console

gearshift lever cover
♦ Disassembly wedge -3409-
FABIA II 2007 ➤
– Lever off the silver cover frame for the collar using a disas‐
sembly wedge -3409- and remove it from the shift lever.
tre console.

Install

FABIA II 2007 ➤
Note
1 - Lock washer
⇒ page 60
2 - Pressure spring
3 - Gasket
and body
❑ self-adhesive
❑ stick onto shift housing
4 - Shift lever
5 - Damping

⇒ page 60
6 - Shift housing
shift lever Pos. 4
8 - Gasket
Parts
9 - Cover
ing
Parts
10 - Bush
11 - Selector cable
❑ pressed onto selector angle plate
12 - Shift cable
❑ pressed onto the shift lever guide
13 - 23 Nm
❑ 4 pieces
FABIA II 2007 ➤
Removing and installing circlip

the -direction of the arrow B-.
Note
♦ Mounting slot in shift lever for circlip must be visible.


– Press the pressure spring arm -A- as far as possible to the left
until it is located outside the damping -arrow-.
• After installing the damping, the pressure spring arms -A- and
-B- must rest on the damping -Pfeil-.


FABIA II 2007 ➤
Note
1 - Shift cable
shift mechanism
shift mechanism
Pos. 11
⇒ page 55
mechanism
⇒ page 71
2 - Selector cable
shift mechanism
mechanism
❑ at selector angle plate
Pos. 10
⇒ page 55
mechanism
⇒ page 71
3 - Bush
4 - Lock washer
when removing
5 - Shift housing
6 - Cable support
❑ made out of plastic or metal
7 - Bush
8 - Spacer bush
9 - 20 Nm
❑ 3 pieces
❑ for cable support
10 - Cable lock
❑ for selector cable ⇒ page 62
FABIA II 2007 ➤
11 - Cable lock
❑ for shift cable ⇒ page 62
12 - Lock washer
13 - Bush
14 - Selector lever
❑ as of 06.07 the relay level is made of plastic
15 - Sliding shoe

17 - 20 Nm
18 - Lock washer
❑ is not required for cable locks for selector cable at relay lever, if relay lever is made of plastic
Assign cable locks

Cable lock for: Clearance “a”


FABIA II 2007 ➤
Fitting location of gearbox shift lever

Fitting location of relay lever

1 - Gearbox shift lever -1- with balancing weight
2 - The relay lever -2- is inserted over the sliding shoe -arrow- into
the guiding nut of the gearbox shift lever
1.7 Plastic relay lever as of 06.07

Removing
• Before removing the gearbox shift lever the cable lock must
be separated from the selector cable in order to avoid damage
to the selector cable.
FABIA II 2007 ➤
– Press the relay lever towards the front in the

Relay lever with a catch

– Carefully press down the pin detent -arrow 1- as far as the
stop.
– Carefully take the relay lever -A- together with the cable lock
-B- out of its bearing point.
Relay lever with clip

– Remove clip -arrow°1-.
– Carefully take the relay lever together with the cable lock out
of its bearing point.
Continued for all versions
Install
Note
Before installing, grease bearing points and friction surfaces with

grease -G 000 450 02- .

– Insert relay lever together with cable lock in its bearing point.
• The pin detent or the clip -arrow 1- secures the relay lever.

FABIA II 2007 ➤
Lever off cable lock for selector cable from plastic relay lever.
relay lever.
Press on cable lock

-arrow-.
• The cable lock must be located behind the pin detent
⇒ page 64 .

nism
♦ Disassembly wedge -3409 -
♦ Grease -G 000 450 02-
1.8.1 Removing
Note


Rep. Gr. 24 .
Gr. 27 .
FABIA II 2007 ➤
Metal relay lever
Plastic relay lever

-arrows-.
tre console.

FABIA II 2007 ➤

– Removing surround for the centre console ⇒ Body Work ⇒
Rep. Gr. 68 .


-arrows-.
FABIA II 2007 ➤


1.8.2 Install
following:

FABIA II 2007 ➤
– Relay lever and cable lock must be installed together
⇒ page 63 .
sides.
bridges ⇒ Engine ⇒ Rep. Gr. 26 .
– Install air filter ⇒ Engine ⇒ Rep. Gr. 23 , or ⇒ Engine ⇒ Rep.
Gr. 24 .
– Connect earth strap of battery while paying attention to the
notes in the ⇒ Electrical System ⇒ Rep. Gr. 27 .
FABIA II 2007 ➤
Tightening torques
Tunnel bridge ⇒ Engine ⇒ Rep. Gr. 26
Bracket for the exhaust system ⇒ Engine ⇒ Rep. Gr. 26
70
FABIA II 2007 ➤

♦ Rig pin -T10027A-
Note
nism:
• Gearbox, clutch and clutch control in perfect condition

• Shift mechanism operates freely
• Control and transmission elements of the shift mechanism are
in perfect condition
• Gearbox in Neutral
Note


Rep. Gr. 24 .
Gr. 27 .

-direction of arrow 2- and at the same time press it in carefully
until it locks into the gearshift shaft.
71
FABIA II 2007 ➤
tre console.
– Guide shift lever in Neutral to the left into the 1st/2nd gear gate.
– Insert rig pin -T10027A- through hole -A- into hole -B-.



Note
up to the stop and must point vertically upwards.
72
FABIA II 2007 ➤
– Pull rig pin -T10027A- out of hole -A- and -B-.

1.9.1 Operation
• The shift lever must be in Neutral, in the gate of 3rd/4th gear.
– Depress clutch.
73
FABIA II 2007 ➤
2.1 Removing
♦ Engine/gearbox jack (e.g. -V.A.G 1383/A- )
♦ Gearbox attachment device -MP3-478 (3336)-
♦ Cap -MP9-200/3 (10-222A/3)-
♦ Hook for MP9-200 and T30099 -MP9-200/10 (10-222A/10)-
♦ Grease -G 000 100-

Note
♦ If the battery earth strap is disconnected and re-connected,
Gr. 27 .

Rep. Gr. 24 .
Gr. 27 .
-A-.
Metal relay lever
-B-.
– Pull off the selector cable from the stud.
relay lever.
Note
74
FABIA II 2007 ➤
Plastic relay lever

• In order to avoid damage at the selector cable, the cable locks
must be seperated from the selector cable before removal.
-arrow 4-.

– Pull the tube-hose line -A- out of the bracket -B- (if present) on
the gearbox.
– Remove slave cylinder -B-, lay aside and secure with wire. Do
not open line system.
Note
Vehicles with petrol engines

FABIA II 2007 ➤

available).
Vehicles with diesel engines

available).
– Remove the earth strap from the engine/gearbox connecting

screw -1- (on certain types of engines the earth strap is not
connected).
– Remove the earth strap for starter -3-.
– Lay aside all electrical cables.
– Remove fixing screw for starter at the top.
Supporting devices for vehicles 1.2/63/77kW TFSI
– Install supporting device -MP9-200 (10-222A)- ⇒ Engine ⇒
Rep. Gr. 15 .
Supporting devices for vehicles (both front engine lifting eyes)
– Install supporting device -MP9-200 (10-222A)- with adapter -

MP9-200/3 (10-222A/3)- .
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 of the engine to avoid damaging them.
Supporting devices for vehicles (one front engine lifting eye, one
rear engine lifting eye)
76
FABIA II 2007 ➤
Shorten the
original spindle -I- of the supporting device -MP9-200 (10-222A)-
by 100 mm:
II - Shortened spindle MP9-200/10 (10-222A/10)
Note

MP9-200 (10-222A)- not to touch the front flap, it must be short‐
ened to the dimension -x- (100 mm).

engine lifting eye for the supporting device -MP9-200

eye.
– Position the shortened spindle -B- on the adapter -10-222 A/
3- .
– Hook the rear left supporting device -10-222 A/12- into the
engine lifting eye.
Caution

-arrows-.
– Then connect the supporting device -10-222 A/12- with the

shortened spindle ⇒ page 77 .
– Take up the weight of the engine/gearbox unit at the spindle.

FABIA II 2007 ➤

– Remove front left wheel and raise vehicle.
– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Gr. 50 .
Gr. 66 .
– Disconnect plug -1- from the reversing light switch .

– Unscrew bracket -2- from the gearbox -arrow- and lay aside
together with the lines.
– Unscrew heat shield (if present) for inside right steering joint
boot -arrows-.
– Remove the drive shafts from the flange shafts, turn steering
to full left lock.
78
FABIA II 2007 ➤
– Release the nuts -arrows- for the left steering joint ⇒ Chassis
⇒ Rep. Gr. 40 (on certain vehicles release the screws, see
fig. S39-0142).

with e.g. wire.
Note

FABIA II 2007 ➤
– Release the screws -arrows- and remove the fan shroud

downwards (on newer models, the screws are no longer
present and the fan shroud is only clipped in, see fig.
N19-10333).

– Detach gearbox mounting bracket -A- from the gearbox.

Remove the fixing screws -arrows- for the gearbox mounting
bracket as follows:
Note

– Unscrew the engine/gearbox connecting screw above the right

flange shaft.
– Insert engine mount -3282 - into engine and gearbox jack , e.g.
-V.A.G 1383/A- .
Complete engine/gearbox jack with gearbox mount -3282- , ad‐
justing plate -3282/31- for gearbox “02T” and support elements:
– Position adjusting plate -3282/31 - on gearbox mount -3282-
( adjusting plate fits in only one position).
adjusting plate .
80
FABIA II 2007 ➤
– Screw in the mounting elements -A- as shown on adjusting

plate .
– Position engine/gearbox jack below vehicle, ⇒ Fig. S34-0340

arrow symbol -B- on adjusting plate points in the direction of
travel/vehicle.
mounts at gearbox.
– Remove the bottom fixing screws for the engine/gearbox.

carrier.
For vehicles fitted with a 1.4 ltr./51 kW engine
– When lowering the gearbox, if necessary remove the inserted

intermediate piece -arrow-.
– Push the engine forwards (2nd mechanic).
– Screw down gearbox suspension device -MP3-478 (3336)-


FABIA II 2007 ➤
– Adjust supporting arm at slide with locking pin.

Number of visible holes (-arrow-) = 5.
device -MP3-478 (3336)- .
2.2 Install
– Before installing, unscrew plug for gearbox oil inspection and
if necessary top up with gear oil ⇒ page 86 .
Capacity and specification ⇒ page 1 .

– Always replace lock washers -1-, -2- and -3- after each disas‐
sembly ⇒ electronic catalogue of original parts .
– After installing, check gear oil level ⇒ page 86 .
Note
♦ Clean splines of drive shaft and apply a thin film of grease -

G 000 100 - .
♦ The clutch plate must slide freely up and down the drive shaft.
♦ If the gearbox is replaced, ensure the intermediate plate be‐
♦ Assemble exhaust system free of stress ⇒ Engine ⇒ Rep.
Gr. 26 .
♦ Installing starter and cables ⇒ Electrical System ⇒ Rep. Gr.
27 .
♦ Top up with coolant ⇒ Engine ⇒ Rep. Gr. 19
♦ If the battery earth strap is disconnected and re-connected,
Gr. 27 .
♦ Check the axial measurement of the vehicle ⇒ Chassis ⇒
Rep. Gr. 44 .
82
FABIA II 2007 ➤

Gearbox to 1.2/44 kW, 1.2/51 kW and 1.2/55 kW engine
Position Screw Pieces Nm
Pos. not as‐ M12 x 60 1 80
signed1)
1 M12 x 60 1 80
22) M12 x 135 2 80
3 M12 x 60 1 80
42) M10 x 55 1 40
5 M10 x 60 1 40
6 M12 x 80 1 80
1)
On certain types of engines, this position can be assigned by
means of the screw, see table.
A: Dowel sleeves for centering

Gearbox to 1.2/63 kW and 1.2/77 kW engine

1 M12 x 60 2 80
21) M12 x 135 1 80
31) M12 x 135 1 80
4 M12 x 60 1 80
5 M10 x 30 2 40
6 M12 x 80 1 80
Gearbox on 1.4 ltr./63 kW engine

1 M12 x 60 1 80
21) M12 x 135 2 80
3 M12 x 60 1 80
4 M10 x 35 2 40
5 M12 x 80 1 80

FABIA II 2007 ➤
Gearbox on 1.6 ltr./77 kW engine

1 M12 x 60 2 80
21) M12 x 135 1 80
31) M12 x 150 1 80
4 M12 x 60 1 80
5 M10 x 50 2 40
6 M12 x 80 1 80
Gearbox on 1.4/51 kW TDI PD Engine

1 M12 x 70 2 80
21) M12 x 150 2 80

31) M10 x 70 1 40
4 M10 x 65 1 40
5 M12 x 80 1 80
Pendulum support
Note


Fixing screws of gearbox mount1) 40 Nm + 90°
Cover plate for flywheel 10 Nm
Fixing screws of engine mount ⇒ Engine ⇒ Rep. Gr. 10
Pendulum support ⇒ Engine ⇒ Rep. Gr. 10
Noise insulation bracket ⇒ Engine ⇒ Rep. Gr. 15
Pre-exhaust pipe with catalytic con‐ ⇒ Engine ⇒ Rep. Gr. 26
verter and clamping sleeve
84
FABIA II 2007 ➤

Screen cap/drive shaft to engine ⇒ Chassis ⇒ Rep. Gr. 40
Wheel bolts ⇒ Chassis ⇒ Rep. Gr. 44
1)Always replace these screws ⇒ Electronic Catalogue of Orig‐

inal Parts

FABIA II 2007 ➤
3 Inspect the gear oil level in the gear‐

box
♦ Socket wrench insert -T30023 (3357)-
Gear oil specification ⇒ page 1 .
– Remove the sound dampening system ⇒ Body Work ⇒ Rep.
Gr. 50 .
– Tighten oil filler plug -arrow- to tightening torque ⇒ page 86
– Unscrew oil filler plug -arrow-.
– Screw in oil drain plug -arrow-.

about 2 minutes.
– Switch off engine and unscrew oil drain plug -arrow-.
– Pour in gear oil again up to lower edge of filler hole.
– Tighten oil filler plug -arrow- to tightening torque ⇒ page 86

I - Oil filler plug or oil drain plug with internal serration: 24 Nm
lI - Oil filler plug or oil drain plug with hexagon socket head: 32
Nm
86
FABIA II 2007 ➤

gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
⇒ page 89
7 - Gearbox housing
8 - Reverse gear wheel

9 - Shift mechanism
❑ Gearshift forks
⇒ page 91
10 - Clutch housing
11 - Drive shaft
⇒ page 91
12 - Output shaft
⇒ page 91
⇒ page 91

FABIA II 2007 ➤

gear ⇒ page 89
II - Detaching and attaching
clutch housing ⇒ page 90
differential, shift mechanism
and gearshift forks
⇒ page 91
Mounting sequence
⇒ page 92
88
FABIA II 2007 ➤
1 - Gearbox housing
um or magnesium
Parts
2 - 5th gear pinion
⇒ page 92
⇒ page 97
3 - Lock washer
tronic Catalogue of
Original Parts
⇒ page 97
4 - Gasket
Note
6 - 5 Nm + torque a further 90°

tronic Catalogue of
Original Parts
7 - Lock washer
tronic Catalogue of
Original Parts
⇒ page 97
8 - Synchronizer body with sliding sleeve and stop ring for 5th gear
11 - Needle bearing
❑ 5th gear
❑ replace together with bushing Pos. 12
12 - Bushing
❑ replace together with needle bearing Pos. 11

FABIA II 2007 ➤
14 - Bolt
4.4 Detaching and attaching clutch housing

♦ Sealant -AMV 188 200 03-
spring
⇒ page 92
tronic Catalogue of
Original Parts
4 - Clutch housing
um or magnesium
Parts
5 - Gearbox housing
um or magnesium
Parts
❑ with guide bushing and
clutch release bearing
⇒ page 93
tronic Catalogue of
Original Parts
90
FABIA II 2007 ➤
4.5 Removing and installing the drive shaft, output shaft, differential, shift mech‐
anism and gearshift forks
2 - Gearbox housing
um or magnesium
❑ on gearboxes made out
of aluminium as of man‐
ufacturing date 12.06
the adjusting washer
S1 for outer ring/ta‐
pered-roller bearing is
not fitted ⇒ page 132
❑ Bearing pedestal for
bearing is adapted
Parts
3 - Oil drain plug
Oil drain plug with inter‐
nal serration - 24 Nm
Oil drain plug with hexa‐

gon socket head - 32 Nm

spring
⇒ page 92
❑ self-locking
❑ to secure the bearing support for grooved ball bearing with the drive shaft and output shaft - Pos. 16
7 - 23 Nm
❑ for gearshift mechanism Pos. 15
❑ self-locking
8 - O-ring
9 - Bearing pins

FABIA II 2007 ➤

13 - Reversing light switch - F4- , 20 Nm
14 - Gasket ring
❑ if present, replace ⇒ Electronic Catalogue of Original Parts
❑ Gearshift forks
16 - Drive shaft and output shaft with bearing support for grooved ball bearing
❑ Always replace bearing support after removing ⇒ Electronic Catalogue of Original Parts
❑ pressing off and on bearing support ⇒ page 108
❑ Disassembling and assembling the drive shaft ⇒ page 108
❑ Disassembling and assembling the output shaft ⇒ page 117
17 - Reverse shaft support
❑ with support
18 - Reverse gear wheel

19 - Screw
❑ for reverse shaft support Pos. 17
❑ M6: 5 Nm + torque a further 90°
❑ M8: 25 Nm + torque a further 45°
4.6 Mounting sequence

ing, gearshift shaft with cover, drive shaft, output shaft, differential
and gearshift mechanism
Note
On gearboxes as of manufacturing date 06.09, the springs of the

sliding sleeve with synchronizer body for 3rd, 4th and 5th gear are
changed (the springs are longer), at the same time the synchron‐
izer ring for 3rd and 4th gear is changed as of this date ⇒

♦ Gearbox mount -T30012 (3221) -
♦ Insert base -T10083-
♦ Pressure plate -T10085-
♦ Sealant -AMV 188 200 03-
92
FABIA II 2007 ➤
Change gearbox holder -T30012-

Drill a new hole in the gearbox holder -T30012 (3221)- to attach
the Gearbox 02T.
Dimensions in mm.
– Drill a hole ∅ 11.0 mm -arrow-.
4.6.1 Removing
– Secure gearbox to the assembly stand -arrows-.
– Position catch pan underneath.
– Drain out gear oil.

– Remove the clutch release lever together with the release

bearing and guide bushing.
bearing and guide bushing from the drive shaft and ball stud.
– Removing the right flange shaft.

– To this end insert two screws in the flange and counterhold the
flange shaft using a tyre iron.
– Pull out the flange shaft with pressure spring, stop disc and
conical ring.

FABIA II 2007 ➤
– Unscrew the cover -arrow- for the gearbox housing.
– Pull out the bearing bolt -1- for the 5th gear shift fork -2- and
remove gearshift fork.
– Remove circlip -3- for 5th gear synchronizer body.
– Remove circlip -4- for 5th gear pinion.
– Remove gear pinions and 5th gear synchronizer body.
– Release the fixing screws -A- for the bearing support of the
drive shaft and output shaft.
– Unscrew nut -B- for the reverse gear shift fork.
– Remove left flange shaft -C-.
– Turn the gearbox in the assembly stand so that the clutch
housing is at the top.
– Release the connecting screws for the clutch housing on the
gearbox housing.
– Carefully release the clutch housing from the projecting hous‐
ing lands and make sure the sealing surfaces are not damaged
in the process.
Note
When removing, pay attention that the clutch housing does not tilt
so that the roller bearings of the drive shaft and the output shaft
do not get damaged.
– Remove the differential gear from the gearbox housing.
– Remove the gearshift shaft with cover -A-; to do this, put the
gearshift shaft in idle position. Subsequently unscrew screws
-arrows- and remove the gearshift shaft from the gearbox
housing.
– Remove the bearing pins -B- at the top of the gearbox.
– Unscrew the reversing lights switch -F4- -C-.
94
FABIA II 2007 ➤
– Unscrew screw -A- for reverse shaft support.

– Remove the bearing pins -B- at the bottom of the gearbox.
Note
Do not remove the cover -arrow- to disassemble the gearbox.
– Press off the drive shaft and output shaft together with the
bearing support, shift forks and reverse gear.
Note
♦ Position the gearbox housing on the pressure plates -

MP3-406 (VW 401)- and -MP3-407 (VW 402)- in such a way
that the dowel sleeves in the gearbox housing are not dam‐
aged.
♦ During the pressing off procedure request the assistance of
second mechanic to prevent components from falling.
♦ Always replace bearing support for grooved ball bearing after
removing ⇒ Electronic Catalogue of Original Parts
– Pressing off the drive and output shaft from the bearing sup‐
4.6.2 Install
– Pressing the drive and output shaft into the new bearing sup‐
– Pressing the sleeve of the 5th gear sliding gear needle bearing
onto the drive shaft ⇒ page 108 .
– Place the drive shaft -2- and output shaft -1- with bearing sup‐
port for grooved ball bearing in the pressure plate -T10085- .
– Insert the gearshift mechanism (shift forks) -4- in the sliding
sleeves of the shaft.
– Insert the shaft for reverse gear -3- with the reverse gear.
– Screw the guide bolt -T10079- onto the reverse shaft support
-arrow-.

FABIA II 2007 ➤
– Insert the components together into the gearbox housing, by

passing the guide bolt -T10079- through the fixing holes of the
gearshift mechanism in the gearbox housing.
– Unscrew -T10079- guide bolt.
– Before pressing the bearing support check whether the shift
forks are properly engaged in the sliding sleeves.
– Carefully press on the bearing support with the drive and out‐
put shaft up to the arrester.
– Screw in screw -A- for reverse shaft support.

– Install the bearing pins -B- at the bottom of the gearbox.
– Screw on the reversing lights switch -F4- -C-.

– Install the bearing pins -B- at the top of the gearbox.
– Put the gearshift forks into Neutral.
faces of the cover.
– Install the gearshift shaft with cover -A-. Tighten screws
-arrows-.
96
FABIA II 2007 ➤
– Screw in new screws -A- and tighten the bearing support of

the drive shaft and output shaft.
Note
Tighten the screws gradually crosswise to the corresponding

– Tighten hexagon nut -B- for the gearshift mechanism (shift

forks) ⇒ page 91 .
– Insert the differential gear.
faces.
– Screw down the clutch housing onto the gearbox housing.
– Turn the gearbox in the assembly stand with the clutch hous‐
ing upwards.
– Fit the 5th gear pinion -1-.

Fitting position of 5th °gear pinion:
The high collar -arrow- points to the gearbox housing cover.
– Mount the synchronizer body 5th gear together with sliding
sleeve and stop ring.
– Insert the 5th gear shift fork -2- and push the bearing pin -1-
up to the stop.
– Determine the new circlips -arrow-
.
– For the drive shaft -3- and output shaft -4- select the thickest
possible circlip that may be installed, and fit.
The following circlips are available ⇒ Electronic Catalogue of
Original Parts
Thickness (mm) Spare part No.
2,00 085 311 187
2,10 085 311 187 A
2,20 085 311 187 B
Assign the circlips via the ⇒ Electronic catalogue of original
parts .
– Mount cover for gearbox housing ⇒ page 89 .

FABIA II 2007 ➤
conical rings.
– Install the clutch release lever together with the release bear‐
ing and guide bushing ⇒ page 45 .
98
FABIA II 2007 ➤
5 Repairing the gearbox housing and

clutch housing
♦ Pressure plate - MP3-420 (3124)-
♦ Thrust piece -MP3-448 (VW 408 A)-
♦ Distance sleeve -MP 3-458/2 -
♦ Centering mandrel -MP3-463 (12-551) -
♦ Pressure plate -MP3-484 (30-555)-
♦ Gearbox mount -T30012 (3221) -
♦ Socket wrench insert -T30023 (3357)-
♦ Separating device 12 - 75 mm for example -Kukko 17/1-
♦ Extractor , e.g. -Kukko 18/1-
♦ Sealant -AMV 188 200 03-
♦ Grease -G 000 100-
1 - Clutch housing
um or magnesium
❑ when replacing: adjust
the differential gear
⇒ page 132
Parts
driver
❑ grease with grease -G
000 100-
4 - Gasket ring
5 - Bushing
❑ for gasket ring
6 - Screw
⇒ page 101
plug with internal serra‐
tion - 24 Nm
5. Repairing the gearbox housing and clutch housing 99

FABIA II 2007 ➤
plug with hexagon socket head - 32 Nm
7 - O-ring
8 - Speedometer sender -G22-
❑ for differential
❑ if the bearing is replaced, set the differential ⇒ page 132

❑ if the bearing is replaced, set the differential ⇒ page 132
❑ on gearboxes made out of aluminium as of manufacturing date 12.06 the adjusting washer S1 for outer
ring/tapered-roller bearing is not fitted ⇒ page 132
15 - Fitting sleeve
❑ (2 pieces)
❑ is made out of aluminium or magnesium
❑ when replacing: adjust the differential gear ⇒ page 132
❑ on gearboxes made out of aluminium as of manufacturing date 12.06 the adjusting washer S1 (Pos.14)
for outer ring/tapered-roller bearing is not fitted ⇒ page 132
17 - Oil drain plug
❑ different versions: ⇒ page 101
Oil filler plug or oil drain plug with internal serration - 24 Nm
18 - Gasket ring
100
FABIA II 2007 ➤
19 - Bushing
20 - Magnet
21 - Screw cap
❑ Before screwing down cover sealing surface with sealant -AMV 188 200 03-
22 - Circlip
❑ insert in the cylinder roller bearing groove Pos. 25
23 - Circlip
❑ insert in the cylinder roller bearing groove Pos. 24
❑ for drive shaft

26 - Plug
❑ inserted in the hole in the clutch housing

I - Oil filler plug or oil drain plug with internal serration: 24 Nm
lI - Oil filler plug or oil drain plug with hexagon socket head: 32
Nm
Install gasket ring for drive shaft
5. Repairing the gearbox housing and clutch housing 101

FABIA II 2007 ➤
Remove bushing for gasket ring

– Position the distance sleeve -MP 3-458/2 - and pressure plate
-MP3-484 (30-555) - on the differential.
A - Extractor , e.g. -Kukko 18/1-
B - Separating device 12 to 75 mm , e.g. -Kukko 17/1-
Insert bushing for gasket ring

A - Threaded rod from assembly device -MP3-434 (3066)-
B - Nut with washer
– Screw threaded rod from assembly device -MP3-434 (3066)-
into the threaded part of the differential.
– By turning the nut -B- install the bushing over the pressure
plate -MP3-420 (3124)- up to the stop.
Note
If the gearbox is disassembled press the bushing with pressure

plate -MP3-420 (3124)- up to the stop.
Remove the bushing -A- for the shiftgear shaft
Insert the bushing -A- for the shiftgear shaft
102
FABIA II 2007 ➤

1 - Bushing
❑ pressing in and pressing
out ⇒ page 99
❑ replace jointly
3 - Locking bolt
mechanism
4 - Reversing lever
⇒ page 61
❑ as of 06.07 the relay lev‐
el is made of plastic
plastic relay lever to‐
gether with cable lock
⇒ page 63
❑ If the relay lever is made
of plastic, neither the
bushings pos. 5 nor the
lock washer pos. 10 are
required
5 - Bushing
❑ it is not necessary, if it is
a plastic relay lever
6 - Gasket ring
driver
7 - Cap
8 - Gearshift lever
9 - 20 Nm
❑ self-locking
10 - Lock washer
6. Repairing the gearshift mechanism 103

FABIA II 2007 ➤
Remove locking bolt -A- from gearshift cover

– Remove the outer part of the locking bolt.
– Then lever out locking bolt carefully with a screwdriver.
Insert locking bolt -A- into gearshift cover

Fitting position
The marking -1- points towards the marking -2- on the gearshift
cover.
Press in the gasket -A- up to the stop
104
FABIA II 2007 ➤

gearshift forks
♦ Driver -MP1-304 (10-206)-
♦ Thrust piece -MP3-448 (VW 408 A)-
♦ Pressure plate -MP3-453 (VW 431) -
♦ Distance sleeve -MP3-458 (VW 472) -
♦ Removal tool for inner lining of the door panel -MP8-602/1-
Note
The gearshift fork group with shift rails (Pos. 1) need not to be disassembled for the disassembly and assembly
of the shift segments, clamping plates and angular ball bearings.


shift rails
❑ Identification
⇒ page 106
ment freely once fitted.
❑ 4 pieces
❑ pressing off
⇒ page 107
4 - Circlip
tronic Catalogue of
Original Parts
❑ Identification
⇒ page 106
❑ Gearshift fork with shift
segments
6 - 5th gear shift fork with shift
segments
❑ Shift segments are con‐
nected inseparably with
the gearshift fork

FABIA II 2007 ➤
7 - Bearing bolt
Identification of shift segments and 5th gear shift fork with shift
segments
Dimension -a-
1 - Shift segments 1st/2nd gear = 10.2 mm
2 - 3rd/4th gear shift segment = 78.6 mm
3 - 5th gear shift fork with shift segments = 79.5 mm
1st/2nd gear shift fork with shift segments

Dimension -a- = 75 mm

106
FABIA II 2007 ➤
Fitting the circlip

segment.
Note
A - Handle wrench, wrench size 10

B - Protective jaws
Press off ball bearing
Note


FABIA II 2007 ➤
1 Drive shaft

drive shaft
♦ Bushing -MP1-316 (30-100) -
♦ Pressure plate -MP3-431 (3002)-

♦ Distance sleeve -MP 3-458/2 -
♦ Flywheel type belt pulley fitting tool -MP 9-400-
♦ Cap -T10080-
♦ Insert base -T10083-
♦ Pressure plate -T10084A-
♦ Separating device , e.g. -Kukko 17/1-
♦ Extractor , e.g. -Kukko 18/1-
♦ Countersupport , e.g. -Kukko 22/1 -
♦ Hot-air blower -V.A.G 1416-
Note
♦ When installing new pinions observe the technical data

⇒ page 1 .
box with gear oil.
assign to the original sliding gear.
♦ On gearboxes as of manufacturing date 06.09, the springs of
the sliding sleeve with synchronizer body for 3rd, 4th and 5th
gear are changed (the springs are longer), at the same time
the synchronizer ring for 3rd and 4th gear is changed as of this

FABIA II 2007 ➤
1 - Circlip
tronic Catalogue of
Original Parts
⇒ page 89
2 - Sliding sleeve with 5th gear
synchronizer body
⇒ page 89
❑ disassembling
⇒ page 115
❑ Assembling sliding
sleeve/5th gear syn‐
chronizer body
⇒ page 115 and
⇒ page 113
❑ on gearboxes as of
manufacturing date
06.09, the springs (Pos.
27) are changed
❑ check for wear
⇒ page 113
5 - Needle bearing
❑ 5th gear
❑ replace together with
Pos. 6
Parts
6 - Bushing
❑ for 5th gear needle
bearing
❑ replace together with Pos. 5
7 - Gearbox housing
❑ If the bearing support is released from the gearbox housing, it must always be replaced
9 - Drive shaft
10 - Needle bearing
❑ for 3rd gear
❑ on gearboxes as of manufacturing date 06.09, the synchronizer ring for 3rd and 4th gear is changed ⇒
1. Drive shaft 109

FABIA II 2007 ➤
❑ press off with 3rd gear sliding gear ⇒ page 112
❑ on gearboxes as of manufacturing date 06.09, the springs (Pos. 23) are changed
❑ on gearboxes as of manufacturing date 06.09, the synchronizer ring for 3rd and 4th gear is changed ⇒
16 - Bushing

17 - Needle bearing
❑ for 4th gear
18 - Thrust washer
19 - Inner ring
❑ for cylindrical-roller bearing
❑ pull off with 4th gear sliding gear ⇒ page 112
20 - Circlip
❑ with circlip
❑ Fitting position: the circlip in the bearing points towards the drive shaft
22 - Clutch housing
23 - Spring
❑ on gearboxes as of manufacturing date 06.09, the springs of the sliding sleeve with synchronizer body
for 3rd, 4th and 5th gear are changed (the springs are longer)
24 - Sliding sleeve 3rd and 4th gear
25 - Synchronizer body for 3rd and 4th gear
❑ (3 pieces)

FABIA II 2007 ➤
27 - Spring
❑ on gearboxes as of manufacturing date 06.09, the springs of the sliding sleeve with synchronizer body
for 3rd, 4th and 5th gear are changed (the springs are longer)
❑ (3 pieces)
31 - Supporting ring
❑ prevents the arresters from wandering

– When removing compress circlip -arrow- of the cylindrical-roll‐
er bearing with pliers -C-.

B - Interior extractor 30 up to 37 mm , e.g. -Kukko 21/5 -

bearing support.
– When inserting compress circlip -arrow- of the cylindrical-roller
bearing with pliers -A-.
Press out the bearing support for grooved ball bearing

– Move the sliding sleeve for 1st and 2nd gear to 2nd gear.
– Slide the pressure plate -T10084A- sideways up to stop onto
the drive shaft.
– Insert centering pins in pressure plate -T10081- in the holes
of the drive shaft and output shaft.
Note
Always replace bearing support for grooved ball bearing.
1. Drive shaft 111

FABIA II 2007 ➤
Remove the bushingof the cylindrical-roller bearing with the 4th

gear sliding gear
– Remove circlip.
– Insert separating device -A- behind the running gearing (not
the engaging gearing) of the 4th gear and press off.
A - Separating device 12 to 75 mm , e.g. -Kukko 17/1 -
Install the bushing of the cylindrical-roller bearing/4th gear sliding

gear
– Partly pressing on bushing -A-.
– Position cylindrical-roller bearing Pos. 17 and 4th gear sliding
gear.
– Press down sleeve -A- with thrust washer Pos. 18 and inner
ring/cylindrical-roller bearing Pos. 19.

Press off sliding sleeve and synchronizer body for the 3rd and 4th
gear
– After removing the circlip jointly press off the 3rd gear sliding
gear and the sliding sleeve/synchronizer body.

1 - Spring (as of manufacturing date 06.09 the springs are longer)
⇒ Electronic Catalogue of Original Parts
2 - Sliding sleeve
The deeper recesses -arrow A- of the arresters in the synchron‐
izer body and the recesses -arrow B- in the sliding sleeve must

FABIA II 2007 ➤
Assembling the sliding sleeve/3rd, 4th and 5th gear synchronizer

body
The sliding sleeve is drawn over the synchronizer body.

body
The groove on the front side -arrow- points towards the 4th gear.
Check 3rd, 4th and 5th gear synchronizer rings for wear
Fitting dimension Wear limit
sleeve
1. Drive shaft 113

FABIA II 2007 ➤
Press on the inner ring -A- for the cylindrical-roller bearing

– Insert the circlip.
Determining the circlip thickness

– Insert circlip with a thickness of 2.0 mm in the slot of the drive
shaft and push upwards.
– Measure the dimension between the inner ring of the taper
roller bearing and the positioned circlip using a feeler gauge.
– Remove the circlip used to take the measurement.
– Determine thickness of circlip according to the table.
Note
Assign the circlips via the ⇒ Electronic catalogue of original parts .
The following circlips are available:

Measured value Circlip thickness Axial play (mm)
(mm) (mm)
0,05…0,14 2,0 0,05…0,15
0,15…0,24 2,1 0,05…0,15
0,25…0,34 2,2 0,05…0,15
0,35…0,44 2,3 0,05…0,15
0,45…0,51 2,4 0,05…0,10
Press on the bearing support for grooved ball bearing

– Before pressing on the bearing support heat it to approximate‐
ly 100 °C.

FABIA II 2007 ➤
Press on the bushing -A- for the 5th gear needle bearing
Remove supporting ring

– Unclip the hook -A- of the supporting ring from the synchron‐
izer body with a screwdriver.
Disassembling and assembling the sliding sleeve/5th gear syn‐

chronizer body
1 - Spring (as of manufacturing date 06.09 the springs are longer)
⇒ Electronic Catalogue of Original Parts
3 - Synchronizer body, fitting position: the groove on the front side
-arrow A- and the wide collar -arrow B- point towards the 5th gear.
4 - Sliding sleeve
5 - Supporting ring
The deeper recesses -arrow C- of the arresters in the syn‐
chronizer body and the recesses -arrow D- in the sliding sleeve
must be positioned above one another.
– Insert the arresters in the deeper recesses and mount the
springs by turning them 120°.
1. Drive shaft 115

FABIA II 2007 ➤
Installing the stop ring

– Place the supporting ring onto the flywheel type belt pulley fit‐
ting tool -MP 9-400- .
– Insert the supporting ring together with the fitting tool in the
synchronizer body/5th gear sliding sleeve (Observe fitting po‐
sition ⇒ page 115 ). Lock the hooks -arrow 1- in the recesses
-arrow 2- of the synchronizer body arresters.
– Push the stop ring down until the hooks click into position.

FABIA II 2007 ➤
2 Output shaft

put shaft
♦ Interior extractor, (e.g. -Kukko 21/5- )
♦ Countersupport, (e.g. -Kukko 22/1- )

Note
♦ When installing new pinions or a new output shaft observe the

technical data ⇒ page 1 .
box with gear oil.
assign to the original gear.
2. Output shaft 117

FABIA II 2007 ➤
1 - Clutch housing
❑ with circlip
❑ Fitting position: the cir‐
clip in the bearing points
towards the output shaft
3 - Output shaft
❑ if an inner ring is fitted as
a bearing assembly for
the cylindrical-roller
bearing Pos. 2, it cannot
be removed from the
output shaft
❑ Inspect bearing assem‐
bly or inner ring for cy‐
lindrical-roller bearing
for scoring and damage
❑ replace output shaft and
cylindrical-roller bearing
together if there is scor‐
ing and damage on the
bearing assembly or in‐
ner ring
4 - 4th gear pinion
points to the 3rd °gear
⇒ page 121
5 - Circlip
tronic Catalogue of
Original Parts
6 - Circlip
7 - 3rd gear pinion
❑ Fitting position: Collar points to the 4th °gear ⇒ page 121
8 - Circlip
10 - Needle bearing
❑ 2nd gear
11 - Inner ring for 2nd gear

FABIA II 2007 ➤

❑ press off together with 2nd gear sliding gear ⇒ page 120
15 - Circlip
❑ pushing out ⇒ page 120
❑ insert in such a way that the recesses lock into the arresters on the sliding sleeve Pos. 14
❑ position in the synchronizer ring Pos. 16, fitting position ⇒ page 123
18 - Inner ring for 1st gear
19 - Needle bearing
❑ 1st gear
❑ replace after each removal
❑ Fitting position: collar points towards the cover of the gearbox housing ⇒ page 89
24 - Circlip
25 - Spring
26 - Sliding sleeve
❑ (3 pieces)
2. Output shaft 119

FABIA II 2007 ➤

– When removing compress circlip of the cylindrical-roller bear‐
ing -arrow- with pliers -C-.

bearing support.
– When pressing in the cylindrical-roller bearing compress the
circlip -arrow- with pliers -A-.

Press the circlip -1- out of the slot

A - Protective glove
WARNING
Prevent uncontrolled ejection of the circlip.
Press off the sliding sleeve and the synchronizer body for the 1st
and 2nd gear from the drive shaft
– After removing the circlip, at the same time press off the drive
shaft from the synchronizer body as well as from the 2nd gear
sliding gear.

FABIA II 2007 ➤
Fitting position 3rd gear pinion and 4th gear pinion.

– Place the 4th gear pinion -A- on the output shaft.
Fitting position:
The collar -arrow 1- points towards the 3rd gear pinion -B-.
– Insert circlips -1- and -2-.
– Place the 3rd gear pinion -B- on the output shaft.
Fitting position:
The collar -arrow 2- points towards the 4th gear pinion -A-.
– Insert circlip -3-.

Fitting dimension Wear
limit
Check 1st and 2nd gear synchronizer ring for wear

feeler gauge -1-.
Fitting dimension Wear
limit
Fitting position of the inner ring, outer ring and 2nd gear syn‐
chronizer ring
– Position the inner ring -A- on the 2nd gear sliding gear.
Lock the lands -arrow 2- in the recesses -arrow 3- of the sliding
gear.
Lock the recesses -arrow 4- in the lands -arrow 1- of the inner
ring -A-.
2. Output shaft 121

FABIA II 2007 ➤

1 - Spring
2 - Sliding sleeve
Fitting position:
After assembly the groove on the front side -arrow A- and the
higher collar -arrow B- of the synchronizer body point towards the
outer serration of the sliding sleeve -arrow C-.
The deeper recesses -arrow D- of the arresters in the synchron‐
izer body and the recesses -arrow E- in the sliding sleeve must
Assembling the sliding sleeve and 1st and 2nd gear synchronizer
body

The angled ends of the springs must grip into the recesses of
the arresters for the synchronizer body.

Fitting position:
The slot for the shift fork in the sliding sleeve points towards the
1st gear, the serration of the reversing gear points towards the
2nd gear.

FABIA II 2007 ➤
Insert the circlip

– Rotate the synchronizer ring in such a way that the slots are
flush with the arresters.
– Insert the 1st gear synchronizer ring in the sliding sleeve and
synchronizer body.
Fitting position of the 1st gear outer ring

The pegs -arrows- point towards the reversing gear serration
-A-.
Fitting position for 1st gear inner ring -A-

chronizer ring -B-.
Fitting position 1st gear sliding gear

The higher collar -A- points towards the 2nd gear -B-. The re‐
cesses in the collar -arrows- are pushed into the pegs of the outer
ring ⇒ page 123
2. Output shaft 123

FABIA II 2007 ➤

♦ Inertia extractor -MP9-501-
♦ Gasket ring extractor -MP 3-419/37-
♦ Drive bushing -MP3-489 (3158)-
♦ Sealing grease -G052 128 A1-
1.1 Removing
– Remove left front wheel ⇒ Chassis ⇒ Rep. Gr. 44 .
– Turn steering to full left lock and raise the vehicle.
– If present, remove the sound dampening system ⇒ Body work

⇒ Rep. Gr. 50 .
– Remove the wheelhouse liner from the left wheelhouse ⇒
Body Work ⇒ Rep. Gr. 66 .
– Remove drive shaft from flange shaft ⇒ Chassis ⇒ Rep. Gr.
40 .
– Release the nuts -arrows- for the left steering joint ⇒ Chassis
⇒ Rep. Gr. 40 (on certain vehicles release the screws, see
fig. S39-0142).

FABIA II 2007 ➤

– If present, remove the sound dampening system ⇒ Body work
⇒ Rep. Gr. 50 .
– Remove drive shaft from flange shaft ⇒ Chassis ⇒ Rep. Gr.
40 .
– Release fixing screw for flange shaft; while doing so prevent
flange shaft from turning along.
– Remove the gasket ring of the flange shaft.
Note
♦ Do not damage the bushing for the right gasket ring as this will
cause leaks.
♦ replace bushing if damaged ⇒ page 99 .
1.2 Install
ring.

FABIA II 2007 ➤
– Drive the new gasket ring into the bushing up to the stop, do
not twist the gasket ring.
– Fill half the space between the sealing and dust lip with sealing
grease -G 052 128 A1- .
The further installation occurs in reverse order, while paying at‐
– Check gear oil level, if necessary pour in up to lower edge of
filler hole ⇒ page 86 .
– Check the axial measurement of the vehicle ⇒ Chassis ⇒
Rep. Gr. 44 .
Tightening torques
Flange shaft to gearbox ⇒ page 127
Wheel bolts to wheel hub ⇒ Chassis ⇒ Rep. Gr. 44

FABIA II 2007 ➤
2 Differential gear
2.1 Disassembling and assembling the dif‐

ferential gear
♦ Pressure plate -MP3-411 (VW 454) -
♦ Press-on sleeve -MP3-412 (VW 455) -
♦ Distance sleeve -MP 3-458/2-
♦ Press-on sleeve -MP3-413 (VW 510) -
♦ Pressure pipe -MP6-408 (30-14)-
♦ Pressure plate -MP3-431 (3002)-

♦ Pipe -MP6-419 (3259)-
♦ Pipe for the wheel bearing -T30019 (3345)-
♦ Interior extractor -Kukko 21/7 -
♦ Countersupport -Kukko 22/2-
♦ Hot-air blower -V.A.G 1416-
Note
♦ Before installing, heat the inner ring/tapered-roller bearing with the hot-air blower -V.A.G 1416- to 100°C.
♦ When replacing the tapered-roller bearing of the differential housing, gearbox housing and clutch housing
adjust the differential ⇒ page 132 .

FABIA II 2007 ➤
❑ screw into threaded
piece Pos. 8
2 - Right flange shaft
❑ do not interchange, the
left and right flange
shafts are different
3 - Pressure spring for flange
shaft
❑ fitted behind flange
shaft
4 - Thrust washer
towards pressure spring
5 - Conical ring
❑ 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 - Differential bevel gear large
8 - Threaded part
❑ when removing, the ten‐
sioning sleeve Pos. 18
is cut out ⇒ page 132
10 - Differential bevel gear small
❑ on certain gearboxes the stop disc compound was provided with land ⇒ page 132
12 - Flange shaft left
❑ with dust guard
❑ do not interchange, the left and right flange shafts are different
13 - Gasket ring
❑ on gearboxes made out of aluminium as of manufacturing date 12.06 the adjusting washer S1 for outer
ring/tapered-roller bearing is not fitted ⇒ page 132

FABIA II 2007 ➤
❑ with riveted pinion for final drive
❑ is paired with the output shaft, replace together
❑ is cut when removing ⇒ page 132

22 - Gasket ring
❑ on gearboxes made out of aluminium as of manufacturing date 12.06 the adjusting washer S1 Pos. 14
for outer ring/tapered-roller bearing is not fitted ⇒ page 132
24 - Clutch housing

FABIA II 2007 ➤


– If necessary, position adjusting washer S1 always 1 mm thick,
under outer ring.
Note
On gearboxes made out of aluminium as of manufacturing date

12.06 the adjusting washer S1 for outer ring/tapered-roller bear‐
ing is not fitted The bearing pedestal for outer ring/tapered-roller
bearing in the gearbox housing is adapted. Difference between
the housings ⇒ page 133 .
– Support the gearbox housing with pipe -MP6-419 (3259)- and

pressure pipe -MP6-408 (30-14)- directly below the bearing
support.
Remove inner ring/tapered-roller bearing on the side of the dif‐

ferential cage
– Before fitting the extractor position distance sleeve -MP
3-458/2- and pressure plate -MP3-431 (3002)- on the differ‐
ential housing.
Press on inner ring/tapered-roller bearing on the side of the dif‐

ferential cage
WARNING
– Before pressing on, heat the inner ring/tapered-roller bearing

with the hot-air blower -V.A.G 1416- to approx. 100°C.
bushing -MP3-412 (VW 455)- .

FABIA II 2007 ➤
Remove inner ring/tapered-roller bearing on the side of the gear

pinion
– Before fitting the extractor position distance sleeve -MP
3-458/2- and pressure plate -MP3-431 (3002)- on the differ‐
ential housing.
Press on inner ring/tapered-roller bearing on the side of the gear

pinion
bushing -MP3-412 (VW 455)- .
Press the outer ring/tapered-roller bearing -A- out off the clutch
housing
– While doing so tighten the interior extractor behind the outer
ring/tapered-roller bearing.

– Support the clutch housing with a pipe for wheel bearing -
T30019 (3345)- directly below the bearing support.

FABIA II 2007 ➤
Press out the differential bevel gear shaft

The tensioning sleeve is cut during pressing out.
– Remove the remaining parts of the tensioning sleeve out of
the differential housing and the differential bevel gear shaft.
On certain gearboxes the stop disc compound was provided with

lands -A- in the area of the openings.
Therefore the differential housing was provided with a round slot
-B-.
– Insert the stop disc compound in such a way that it locks into
the slot -B- in the differential gear housing.

Install the differential bevel gears

flange shafts).
– Insert both small differential bevel gears with a 180° offset.
small bevel gear.
– Insert the threaded parts -arrow B- in the large differential
bevel gears.
– Insert the differential bevel gear shaft up to stop and secure
with new tensioning sleeve .

♦ Gauge block plate - MP 3-405/17-
♦ Pressure washer -MP3-413 (VW 510) -
♦ Pressure pipe -MP6-408 (30-14)-
♦ Pipe -MP6-419 (3259)-
♦ Pipe for the wheel bearing -T30019 (3345)-

FABIA II 2007 ➤

♦ Thrust plate -MP3-464 (30-205)-
♦ Dial gauge
nents are replaced:
♦ Gearbox housing
♦ Clutch housing
or
♦ differential gear tapered-roller bearing.
on gearboxes made out of aluminium as of manufacturing date
12.06 the adjusting washer S1 for outer ring/tapered-roller bear‐
ing is not fitted
Bearing pedestal for outer ring/tapered-roller bearing is adapted.
– Measure the depth of the bearing pedestal for the outer ring/
tapered-roller bearing in the clutch housing.

Clearance “a” Adjusting washer S1

15.2 mm no
16.2 mm yes

– Press the outer ring/tapered-roller bearing (on the riveted pin‐
ion side of the differential housing) with adjusting washer S1
(always 1mm thick) into the clutch housing made out of mag‐
nesium or without adjusting washer into the clutch housing
made out of aluminium.
Note
The inner and outer rings of the tapered-roller bearing are paired
- do not interchange.
– Press the outer ring/tapered-roller bearing (opposite side)

without adjusting washer into the clutch housing.
– Insert the differential housing together with the installed inner
rings/tapered-roller bearings into the gearbox housing.
– Position the clutch housing and tighten 5 screws to the given

FABIA II 2007 ➤

A - Dial gauge extension 30 mm
– Set the dial gauge to “0” with 1 mm bias.
– Move the differential gear up and down in the direction of the
axle, read off and write down the clearance on the dial gauge
(example: 1.50 mm).
Note
Do not turn the differential while measuring as otherwise the

bearings will settle and the measuring result will be inaccurate.
2.2.1 Determining the thickness of adjusting

washer S2
The required bearing preload is reached by adding to the value
measured for S2 (for example:1.50 mm) a constant compression
value (0.25 mm or 0.35 mm).

Example:
For housing made out of magnesium:
+ compression (const. value) 0.35 mm
For housing made out of aluminium:

+ compression (const. value) 0.25 mm
– Remove the clutch housing and press out the outer ring/ta‐
pered-roller bearing -A-.
-B- Interior extractor 46 to 58 mm, e.g. -Kukko 21/7-
– Insert adjusting washer S2 with the required thickness (in our
example 1.75 or 1.85 mm) and press the outer ring/tapered-
roller bearing back into the clutch housing.
Original Parts .
If the measured washer thickness is greater than the thickest
washer listed in the spare parts catalogue, 2 washers corre‐
sponding to the measured value may be fitted.
– Position the clutch housing and tighten the screws to the given

Service
Workshop Manual
Fabia II 2011 ➤ , Octavia II 2004 ➤ ,
Octavia II 2010 ➤ , Octavia III 2013 ➤ ,
Octavia III 2014 ➤ , Rapid 2011 ➤ ,
Rapid NH 2014 ➤ , Roomster 2006 ➤ ,
Superb II 2008 ➤ , Yeti 2010 ➤ ,

Yeti 2011 ➤
Gearbox 09G
Edition 07.2014

Service
Repair Group
00 - Technical data
32 - Torque converter
38 - Gears, control

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 09G - Edition 07.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Information and repair instructions for the automatic gearbox 09G . . . . . . . . . . . . . . . . . . 12
2.1 Information for the automatic gearbox 09G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Draining the torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 Removing and installing gasket ring for torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Checking the torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Installing the torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1 Electric and electronic components, fitting locations of the automatic gearbox . . . . . . . . . . 20
1.1 Summary of components - Electric and electronic components, fitting locations of the
automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2 Removing and installing automatic gearbox control unit J217 . . . . . . . . . . . . . . . . . . . . . . 38
2.1 Assembly overview - shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.4 Check the function of the ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.6 Removing and installing and installing selector lever handle up to 10.2012 . . . . . . . . . . . . 65
2.7 Removing and installing selector lever handle as of 11.2012 . . . . . . . . . . . . . . . . . . . . . . 70
2.8 Installing the lock button at the selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.9 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.10 Removing and installing the selector lever control cable . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.13 Checking the plug connections at the gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . 104
2.14 Emergency release of gearshift mechanism out of position “P” . . . . . . . . . . . . . . . . . . . . 105
3.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.4 Transporting an automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.5 Attaching gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.1 Check the ATF level level and top up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.2 Change ATF or top up after repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5 ATF coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.1 ATF radiator - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.2 Removing and installing ATF radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

1 Removing and installing oil pan, oil filter, slide valve body and internal wiring looms . . . . 165
Contents i
1.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

1.2 Summary of components - oil pan, oil strainer, slide valve body, internal wiring looms . . . . 165
1.3 Components at wiring loom of 8-pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.4 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.5 Removing and installing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.6 Removing and installing the slide valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.7 removing and installing wiring loom with 14-pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.8 Removing and installing wiring loom with 8-pin plug and integrated gearbox oil temperature
sender G93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.9 Removing and installing the gearbox input r.p.m. sender G182 . . . . . . . . . . . . . . . . . . . . 183
1.10 Removing and installing the gearbox output r.p.m. sender G195 . . . . . . . . . . . . . . . . . . . . 184
2 Removing, installing and setting multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . 185
2.1 Removing and installing the multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.2 Setting multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187


2 Replacing the gasket ring for the gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.1 Replacing the gasket ring for the gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
ii Contents
(SRL000705; Edition 07.2014)
⇒ “1.1 Location on the gearbox”, page 1
⇒ “1.2 Identification characters, aggregate assignment, ratios”,
page 2
⇒ “1.3 Contents”, page 10
1.1 Location on the gearbox

The “automatic 6-speed gearbox 09G” is installed in combination
with 4-cylinder engines.
Identification characters and manufacturing date of the gearbox
-arrow 1- and -arrow 2-.
Example:
FXA Gearbox identification characters

02H2T0014 Serial number
4 02 : Production year 2002
H : Production month from A = January to M =
December
2T : Identification of gearbox by the manufactur‐
er, 2T = 09G
00144 : serial number for production month, here
144. Gearboxes in August
09G 300 Part number
035G
AISIN AW Manufacturer: AISIN
Note

data stickers.

1.2 Identification characters, aggregate as‐

signment, ratios
⇒ “1.2.1 Identification characters, aggregate assignment, ratios
(Octavia II)”, page 2
(Fabia II)”, page 6
(Rapid India)”, page 8
(Rapid)”, page 8
(Superb II)”, page 9
(Octavia III)”, page 9
⇒ “1.2.8 Identification characters, aggregate assignment, gear
ratios (YETI)”, page 10
1.2.1 Identification characters, aggregate assignment, ratios (Octavia II)

Identification characters GSY HFS
Manufac‐ from 01.2004 08.2004
Torque con‐ ⇒ Electronic Catalogue of Original Parts
verter
Ratio 1. gear 4.148
2. gear 2.370
3. gear 1.556
4. gear 1.155
5. gear 0.859
6. gear 0.686
Reverse gear 3.394
Intermediate Drive wheel 49
gear Output gear 52
Ratio 1.061
Final drive Output shaft 15
Crown wheel 61
Ratio 4.067

Identification characters GJZ
tured through 09.2004
Assignment Engine 2.0 ltr./110 kW FSI
verter
Ratio 1. gear 4.148


2. gear 2.370
3. gear 1.556
4. gear 1.155
5. gear 0.859
6. gear 0.686
Reverse gear 3.394
gear Output gear 52
Ratio 1.061
Crown wheel 61
Ratio 4.067

Identification characters HFR HFT
Manufac‐ from 11.2004 02.2005

Assignment Engine 1.6 ltr./85 kW FSI 2.0 ltr./110 kW FSI
Torque con‐ ⇒ Electronic Catalogue of Orig‐ ⇒ Electronic Catalogue of Orig‐
verter inal Parts inal Parts
Ratio 1. gear 4.148
2. gear 2.370
3. gear 1.556
4. gear 1.155
5. gear 0.859
6. gear 0.686
Reverse gear 3.394
gear Output gear 52
Ratio 1.061
Crown wheel 61 58
Ratio 4.067 3.867

Identification characters HTN HTM
Manufac‐ from 05.2005 06.2005
Assignment Engine 1.6 ltr./75 kW 1.6 ltr./85 kW FSI
Ratio 1. gear 4.148
2. gear 2.370
3. gear 1.556
4. gear 1.155
5. gear 0.859


6. gear 0.686
Reverse gear 3.394
gear Output gear 52
Ratio 1.061
Crown wheel 61
Ratio 4.067

Identification characters HTP JUH
Manufac‐ from 06.2005 11.2006
Ratio 1. gear 4.148
2. gear 2.370
3. gear 1.556
4. gear 1.155
5. gear 0.859
6. gear 0.686
Reverse gear 3.394
gear Output gear 52
Ratio 1.061
Crown wheel 58
Ratio 3.867

Identification characters JTY JUG
Manufac‐ from 11.2006 11.2006
Assignment Engine 1.6 ltr./75 kW 1.6 ltr./85 kW FSI
Ratio 1. gear 4.148
2. gear 2.370
3. gear 1.556
4. gear 1.155
5. gear 0.859
6. gear 0.686
Reverse gear 3.394
gear Output gear 52


Ratio 1.061
Crown wheel 61
Ratio 4.067

Identification characters KGK KGH
Manufac‐ from 05.2008 05.2008
Ratio 1. gear 4.148
2. gear 2.370
3. gear 1.556

4. gear 1.155
5. gear 0.859
6. gear 0.686
Reverse gear 3.394
gear Output gear 52
Ratio 1.061
Crown wheel 58 61
Ratio 3.867 4.067

Identification characters KGJ KGV
Manufac‐ from 05.2008 11.2011
Assignment Engine 1.6 ltr./75 kW 1.8 ltr./112 kW TFSI
Ratio 1. gear 4.148 4.044
2. gear 2.370 2.371
3. gear 1.556 1.556
4. gear 1.155 1.159
5. gear 0.859 0.852
6. gear 0.686 0.672
Reverse gear 3.394 3.193
Intermediate Drive wheel 49 48
gear Output gear 52 53
Ratio 1.061 0.906
Crown wheel 61


Ratio 4.067
1.2.2 Identification characters, aggregate assignment, ratios (Fabia II)

Manufac‐ from 11.2006 05.2008
verter
Ratio 1. gear 4.148
2. gear 2.370
3. gear 1.556
4. gear 1.155
5. gear 0.859
6. gear 0.686
Reverse gear 3.394
gear Output gear 53
Ratio 0.906
Crown wheel 61
Ratio 4.067

Identification characters MFZ QAW
Manufac‐ from 07.2010 11.2014
Assignment Engine 1.6 ltr./77 kW 1.6 ltr./77 kW
Ratio 1. gear 4.148 4.148
2. gear 2.370 2.370
3. gear 1.556 1.556
4. gear 1.155 1.155
5. gear 0.859 0.859
6. gear 0.686 0.686
Ratio 0.906 0.906
Final drive Output shaft 15 15
Crown wheel 61 61
Ratio 4.067 4.067

1.2.3 Identification characters, aggregate assignment, ratios (Roomster)

Manufac‐ from 11.2006 05.2008
verter
Ratio 1. gear 4.148
2. gear 2.370
3. gear 1.556
4. gear 1.155
5. gear 0.859
6. gear 0.686
Reverse gear 3.394

gear Output gear 53
Ratio 0.906
Crown wheel 61
Ratio 4.067

Manufac‐ from 07.2010 11.2014
Assignment Engine 1.6 ltr./77 kW 1.6 ltr./77 kW
Ratio 1. gear 4.148 4.148
2. gear 2.370 2.370
3. gear 1.556 1.556
4. gear 1.155 1.155
5. gear 0.859 0.859
6. gear 0.686 0.686
Ratio 0.906 0.906
Final drive Output shaft 15 15
Crown wheel 61 61
Ratio 4.067 4.067

1.2.4 Identification characters, aggregate assignment, ratios (Rapid India)

Identification characters MFZ
tured to
Torque con‐ ⇒ Electronic Catalogue of Orig‐
verter inal Parts
Ratio 1. gear 4.148
2. gear 2.370
3. gear 1.556
4. gear 1.155
5. gear 0.859
6. gear 0.686
Reverse gear 3.394
gear Output gear 53
Ratio 0.906
Crown wheel 61
Ratio 4.067
1.2.5 Identification characters, aggregate assignment, ratios (Rapid)

Manufac‐ from 11.2013 11.2013
verter
Ratio 1. gear 4.148
2. gear 2.370
3. gear 1.556
4. gear 1.155
5. gear 0.859
6. gear 0.686
Reverse gear 3.394
gear Output gear 53
Ratio 0.906
Crown wheel 61
Ratio 4.067

Identification characters PLS


tured through
Assignment Engine 1.6 l/81 kW MPI
verter
Ratio 1. gear 4.670
2. gear 2.530
3. gear 1.560
4. gear 1.130
5. gear 0.860
6. gear 0.690
Reverse gear 3.390
gear Output gear 53
Ratio 0.906

Crown wheel 58
Ratio 3.867
1.2.6 Identification characters, aggregate assignment, ratios (Superb II)

Identification characters KGV
tured through
Torque con‐ ⇒ Electronic Catalogue of Orig‐
verter inal Parts
Ratio 1. gear 4.044
2. gear 2.371
3. gear 1.556
4. gear 1.159
5. gear 0.852
6. gear 0.672
Reverse gear 3.193
gear Output gear 53
Ratio 0.906
Crown wheel 61
Ratio 4.067
1.2.7 Identification characters, aggregate assignment, ratios (Octavia III)

Identification characters PAL QNQ


Manufac‐ from 01.2014 03.2014
tured to
verter
Ratio 1. gear 4.670
2. gear 2.530
3. gear 1.556
4. gear 1.130
5. gear 0.859
6. gear 0.686
Reverse gear 3.394
gear Output gear 53
Ratio 0.906

Crown wheel 61
Ratio 4.067
1.2.8 Identification characters, aggregate assignment, gear ratios (YETI)

Identification characters QEM
tured through
verter
Ratio 1. gear 4.460
2. gear 2.510
3. gear 1.560
4. gear 1.140
5. gear 0.850
6. gear 0.670
Reverse gear 3.190
gear Output gear 52
Ratio 1.061
Crown wheel 61
Ratio 4.067
1.3 Contents
Planetary gear
New filling 7 ltr.


Top-up approx. 3 l 1)
Lubricant ⇒ Electronic Catalogue of Original
Parts
1) Filled for life: change the oil following repairs only.
Only ATF available as spare part should be used in the automatic
gearbox 09G ⇒ Electronic Catalogue of Original Parts
Checking ATF level, change ATF if necessary
⇒ “4 ATF”, page 147 .

2 Information and repair instructions for

the automatic gearbox 09G
⇒ “2.1 Information for the automatic gearbox 09G”, page 12
⇒ “2.2 Repair instructions”, page 13
⇒ “2.3 Explanation of the terms used in this workshop manual”,
page 15
2.1 Information for the automatic gearbox

09G
Gearbox
The automatic 6 speed gearbox 09G is equipped with 6 hydraul‐
ically controlled forward gears. When the torque converter lockup
clutch is closed, the 2nd, 3rd, 4th, 5th and 6th forward gears be‐
come mechanically driven gears by bypassing the converter slip.
Torque converter
The torque converter is equipped with a torque converter lockup
clutch. The closing of the torque converter lockup clutch is load
and speed sensitive, and particularly low in vibrations, and without
the converter slip the direct gear clutch drives the 2nd, 3rd, 4th,
5th and 6th forward gears mechanically.
ATF
The ATF is filled for life. The ATF need not be changed within the
scope of servicing.
The ATF oil filling is for the planetary gear and final drive together.
Check and top up ⇒ “4 ATF”, page 147 .
or to failure of the gearbox.
♦ ATF Part No. ⇒ Electronic Catalogue of Original Parts .
Automatic gearbox control unit - J217-
The gear-change point is determined automatically, according to
driving conditions and road resistance.
Advantages:
♦ Fuel-efficient gearshift
♦ maximum engine power output continuously available
♦ gear-change points are adapted to suit particular road condi‐
tions
♦ gear-change points changed as required
gine power output
braking effect of the engine
♦ By directly selecting a gear via the Tiptronic, e.g. for a slope
during trailer operation, the motor braking effect is also fully
used.

2.2 Repair instructions

workshop manual.
Gearbox
♦ Each time a gearbox is installed, basic settings are required.
♦ Do not run the engine or tow the vehicle when the oil pan of
the gearbox has been removed or without ATF filling.
♦ If the automatic gearbox is replaced, check ATF level if nec‐
essary top up with ATF ⇒ “4 ATF”, page 147 . Capacities and
specifications ⇒ “1.3 Contents”, page 10 .
♦ Secure the torque converter against dropping out when the
gearbox is removed.

before releasing.
♦ Place removed parts on a clean surface and cover. Use foil
and paper. Do not use fuzzy cloths!
♦ Only install clean parts. Remove spare parts from their wrap‐
♦ Before installing the gearbox check the fitting position of the
torque converter
⇒ “1.4 Installing the torque converter”, page 18 .
♦ When installing, take care with the correct positions of dowel
sleeves in the engine.
The ATF filler tube -arrow- is no longer available on gearboxes
as of production date 06.2006.

♦ Always replace O-rings, gaskets and gasket rings.

♦ After removing gaskets, examine the contact surface in the
housing or on shafts for burrs or damage, and correct if nec‐
essary.
♦ Depending on location, before fitting a gasket ring, smear the
outer surface and sealing lip thinly with ATF or axle oil.
♦ The open side of the sealing rings faces the side with fluid
filling.
♦ Before inserting the O-rings coat with ATF to prevent the rings
being squashed during installation.
♦ Never use other lubricants in the ATF area.
♦ Radial shaft seals before mounting lightly oil at outside diam‐
eter and fill half the space between the sealing lips -arrow- with
♦ After installation, inspect ATF level and if necessary top up
⇒ “4 ATF”, page 147 .
Locking elements
Screws, nuts
♦ Slacken and tighten screws or fixing nuts of covers and hous‐
ings crosswise.
♦ Do not twist particularly sensitive parts - e.g. the slide valve
body - and slacken and tighten diagonally across in stages.
agent with a wire brush. Next, insert screws using a suitable
locking agent ⇒ Electronic Catalogue of Original Parts .
♦ Clean all threaded holes into which bolts are screwed in with
locking agent , using a thread tap to remove old locking agent
residues. Otherwise there is a risk that the bolts will shear at
the next disassembling.
♦ Replace self-locking nuts and bolts each time they are re‐
moved.
♦ Bolts that still need to be turned at a certain angle after tight‐
ening must always be replaced.
This electrostatic charge can lead to operational problems after
touching the electrical components of the gearbox and the shift
mechanism.
– Touch an earthed object - e.g. a metal water pipe or a lift plat‐
form - before working on the electrical components. Do not
touch the contacts of the plugs and the »open« electrical com‐
ponents.
Before repairing the automatic gearbox 09G, try to determine the
origin of the damage as accurately as possible using the ⇒ Vehi‐
cle diagnostic tester in the “Targeted fault-finding” mode.


workshop manual
These explanations relate solely to this assembly: automatic
gearbox 09G. They do not claim to be valid in all cases.
ATF (Automatic Transmission Fluid)
Gear oil for automatic gearbox.
ATF level
ATF level in the gearbox. To measure the ATF level, see the in‐
structions in the Workshop Repairs Manual.
Brakes
Ensure the individual gears and the reverse gear shift properly
working together with the clutches. As opposed to the clutches
the brakes are supported on the gearbox housing.
Torque converter
Transfers the engine torque into the automatic gearbox and
serves as a hydraulic starting clutch. The torque converter also
includes the torque converter lockup clutch.
Self-diagnosis
The capability of the control unit for the automatic gearbox -J217- :
♦ recognize faults,
♦ react to faults,
♦ store faults,
♦ Determine measured values and to display them in the meas‐
ured value block.
Perform self-diagnosis
– ⇒ Vehicle diagnostic tester connect and perform “Targeted
Fault Finding” or “Vehicle self-diagnosis”.
Clutches
Ensure the individual gears and the reverse gear shift properly
working together with the clutches.
Wiring
Fitting locations of electrical cables and components in the gear‐
box.
Selector lever lock solenoid - N110-
Located in the gearshift mechanism close to the selector lever.
Prevents the (unintentional) shifting of the selector lever from po‐
sitions “P” and “N”, as long as the brake pedal is not pressed.
Solenoid valves
Open and shut the oil galleries to the clutches and brakes.
Multi-function switch - F125-
The multi-function switch -F125- is screwed onto the top of the
gearbox housing to the gearshift shaft. It is an electrical switch,
which transfers the individual gears selected with the selector
lever to the gearbox control unit. It must be correctly set
⇒ “2.2 Setting multi-function switch F125 ”, page 187 .

Parking position
When the vehicle is parked, the selector lever locks the parking
gear in position “P” thereby preventing the vehicle from moving
off (unintentionally). Is not a replacement for the handbrake.
Planetary gear
The mechanical part of the automatic gearbox that is switched via
clutches and brakes and allows a switching without power flow
interruption.
Slide valve body
Located below the gearbox and is surrounded by the oil pan of
the gearbox. Its valves regulate the hydraulic pressure and dis‐
tribute it via the oil galleries to the gearshift elements (clutches
and brakes).
Automatic gearbox control unit - J217-
Control unit -J217- determines the shifting points. The function of
the gearbox is monitored via self-diagnosis. If components or
sensors fail, an emergency running programme is activated to
continuity of vehicle operation.
Torque converter lockup clutch
It mechanically transmits the engine torque directly to the plane‐

tary gear without converter slip.

32 – Torque converter
1 Torque converter
⇒ “1.1 Draining the torque converter”, page 17
⇒ “1.2 Removing and installing gasket ring for torque converter”,
page 17
⇒ “1.3 Checking the torque converter”, page 18
⇒ “1.4 Installing the torque converter”, page 18
1.1 Draining the torque converter

♦ Old oil collecting and suction equipment , e.g. -V.A.G 1782-
If the ATF has been contaminated or if the gearbox has had a
major repair, the torque converter should be drained as follows:
– Suction off the ATF with the old oil collection and suction de‐
vice -V.A.G 1782- from the torque converter.
1.2 Removing and installing gasket ring for

torque converter
♦ Ejection lever - MP3-418 (VW 681)-
Note
♦ Coat gasket rings with ATF. Other types of lubricant will cause
the gearbox hydraulic control system to malfunction.
♦ ⇒ “2.2 Repair instructions”, page 13 .
Removing
– Lever out gasket ring with ejection lever - MP3-418 (VW 681)- .
Install
– Drive in new gasket ring for torque converter with thrust piece
- T10175- up to the stop.
1.3 Checking the torque converter

– Check hub -arrow- of torque converter for traces of wear.
Note
The torque converter is welded and must be replaced completely

if damaged or faults.
1.4 Installing the torque converter

♦ Depth gauge
Work procedure
– Carefully push the torque converter hub through the gasket
ring up to the first stop on the input shaft.
– Press the torque converter by hand into the converter housing
and turn it until the recesses catch into the torque converter
hub in the driver of the inner gear of the ATF pump and the
torque converter locks audibly into place.
18 Rep. gr.32 - Torque converter

– Measure the dimension -a- between the screw-on flange of the

gearbox housing and the contact surface of the threaded
bores of the torque converter using a depth gauge.
• The converter is correctly installed if the dimension -a- is at
least 19.5 mm.
– Absolutely ensure that the dimension -a- is maintained during
further assembly. The torque converter must not slide to the
front.
Caution

When subsequently installing the gearbox, the following point

must be observed.
Caution

Always check before and while tightening the screws on the
flange (engine/gearbox) whether the torque converter behind
the drive plate can be turned. In cases where the torque con‐
verter cannot be turned one must assume that it is not properly
installed and that either the driver plate of the torque converter
or the ATF pump will be destroyed during final tightening of the
bolted connections.
1 Electric and electronic components,
fitting locations of the automatic gear‐
box
⇒ “1.1 Summary of components - Electric and electronic compo‐
nents, fitting locations of the automatic gearbox”, page 20
⇒ “1.2 Removing and installing automatic gearbox control unit
J217 ”, page 38
1.1 Summary of components - Electric and

electronic components, fitting locations
of the automatic gearbox
⇒ “1.1.1 Summary of components - Electric and electronic com‐
ponents, fitting locations of the automatic gearbox (Octavia II,
Superb II, YETI)”, page 20
ponents, fitting locations of the automatic gearbox (Fabia II,
Roomster, Rapid)”, page 26
ponents, fitting locations of the automatic gearbox (Octavia III)”,
page 32
1.1.1 Summary of components - Electric and electronic components, fitting loca‐

tions of the automatic gearbox (Octavia II, Superb II, YETI)


unit - J217-
installing automatic
J217 ”, page 38
❑ Control unit for automat‐
ic gearbox - J217- is
checked using self-di‐
agnosis
driver's footwell
⇒ Fig. ““Diagnostic con‐
nection”“ , page 22
- N110-
❑ Selector lever lock sole‐
noid - N110- is checked
using self-diagnosis

⇒ Fig. ““ Selector lever
lock solenoid -N110- ”“ ,
page 23
❑ The solenoid is installed
firmly in the gearshift
mechanism and cannot
be replaced individually.
❑ The removal and instal‐
lation procedure is only
possible together with
the gearshift mecha‐
nism
stalling selector mecha‐
nism”, page 74 .
❑ Fitting location ⇒ Fig. ““Slide valve body”“ , page 23
❑ ⇒ “1.6 Removing and installing the slide valve body”, page 171
5 - Wiring loom with 8-pin plug and integrated gearbox oil temperature sender - G93-
❑ Fitting location: Wiring harness is fixed to the slide valve body
⇒ Fig. ““Wiring loom with 8-pin plug and integrated gearbox oil temperature sender -G93- -Arrow-”“ , page
23
❑ ⇒ “1.8 Removing and installing wiring loom with 8-pin plug and integrated gearbox oil temperature sender
G93 ”, page 181
❑ Gearbox oil temperature sender - G93- is checked by self-diagnosis
⇒ Fig. ““Wiring loom with 14-pin plug”“ , page 23
❑ ⇒ “1.7 removing and installing wiring loom with 14-pin plug”, page 180
7 - Multi-function switch - F125-
❑ Multi-function indicator - F125- is checked by self-diagnosis
❑ Fitting location ⇒ Fig. ““ Multi-function switch -F125- ”“ , page 24
❑ ⇒ “2.1 Removing and installing the multi-function switch F125 ”, page 185
❑ ⇒ “2.2 Setting multi-function switch F125 ”, page 187
1. Electric and electronic components, fitting locations of the automatic gearbox 21


❑ ⇒ “2.5 Removing and Installing the cover for the shift mechanism”, page 58
❑ the Tiptronic switch - F189- is integrated in the shift mechanism; Fitting location:
⇒ Fig. ““ Switch for Tiptronic -F189- ”“ , page 24
9 - Terminal 50, voltage supply relay - J682-
❑ Fitting location:
♦ Octavia II and Superb II up to 05.2005: E-box in the engine compartment ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations
♦ Octavia II and Superb II as of 06.2005: Additional relay holder under the dash panel ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
10 - Gearbox input r.p.m. sender - G182-
❑ Gearbox input r.p.m. sender - G182- is checked using self-diagnosis
❑ Fitting location ⇒ Fig. ““ Gearbox input r.p.m. sender -G182- ”“ , page 25
❑ ⇒ “1.9 Removing and installing the gearbox input r.p.m. sender G182 ”, page 183
11 - Gearbox output r.p.m. sender - G195-
❑ Gearbox output r.p.m sender - G195- is checked using self-diagnosis

❑ Fitting location ⇒ Fig. ““ Gearbox output r.p.m. sender -G195- ”“ , page 25
❑ ⇒ “1.10 Removing and installing the gearbox output r.p.m. sender G195 ”, page 184
12 - Selector lever position indicator - Y6-
❑ Fitting location ⇒ Fig. ““ Selector lever position indicator -Y6- ”“ , page 25
❑ removing and installing ⇒ Electrical System; Rep. gr. 90
13 - Kick-down switch - F8-
❑ Kick-down switch - F8- is checked by self-diagnosis
❑ Fitting location ⇒ Fig. ““ Kick-down switch -F8- ”“ , page 26
❑ removing and installing accelerator pedal module ⇒ Engine; Rep. gr. 20
14 - Brake light switch - F-
❑ Brake light switch - F- is checked by self-diagnosis
❑ ⇒ Fig. ““ Brake light switch -F- up to production date 05.2010”“ , page 26
❑ ⇒ Fig. ““ Brake light switch -F- as of production date 06.2010”“ , page 26
❑ removing and installing ⇒ Brake systems; Rep. gr. 46
Fitting location: Cover in driver's footwell.


Fitting location: Selector lever lock solenoid - N110- -1- is in the
The solenoid is installed firmly in the gearshift mechanism and
cannot be replaced individually. The removal and installation pro‐
cedure is only possible together with the gearshift mechanism
⇒ “2.9 Removing and installing selector mechanism”,
page 74 .
Slide valve body

ture sender - G93- -Arrow-
Fitting location: Wiring harness is fixed to the slide valve body.



Switch for Tiptronic - F189-

Fitting location: The Tiptronic switch - F189- is integrated in the
printed circuit board -B- of the gearshift mechanism.
The Tiptronic switch - F189- is installed firmly in the gearshift
mechanism and cannot be replaced individually. The removal and
installation procedure is only possible together with the gearshift
mechanism
page 74 .

Gearbox output r.p.m. sender - G195-

body.
Gearbox input r.p.m. sender - G182-

Fitting location: The gearbox input r.p.m sender - G182-
body.
Selector lever position indicator - Y6-

Note
The selector lever position indicator - Y6- can only be replaced


Kick-down switch - F8-

This switch is not available for vehicles with petrol engine. Instead
a certain value from the accelerator pedal position sender - G79- /
accelerator pedal position sender 2 - G185- is stored in the engine
control unit.
Brake light switch - F- up to production date 05.2010

Fitting location: The brake light switch - F- -arrow- is located in the
foot controls.
Note

Brake light switch - F- as of production date 06.2010

Fitting location: Brake light switch - F- -Pos. 3- is located on the
master brake cylinder.

tions of the automatic gearbox (Fabia II, Roomster, Rapid)


unit - J217-
J217 ”, page 38
❑ Control unit is checked
by self-diagnosis
driver's footwell
- N110-
lock solenoid -N110- ”“ ,
page 29
❑ ⇒ “2.12 Removing and
installing selector lever
lock solenoid N110 ”,
page 100
nosis
⇒ Fig. ““Slide valve
body”“ , page 29
❑ ⇒ “1.6 Removing and in‐
stalling the slide valve
body”, page 171
and integrated gearbox oil
temperature sender - G93-
29
G93 ”, page 181
❑ the Tiptronic switch - F189- is built into the shift mechanism; fitting location

9 - Relay for starter interlock switch

❑ Fitting location ⇒ Electrical System; Rep. gr. 97
❑ measures the gearbox output speed
12 - Selector lever position indicator - Y6-
❑ Fitting location ⇒ Fig. ““ Selector lever position indicator -Y6- ”“ , page 31
❑ removing and installing ⇒ Electrical System; Rep. gr. 90
❑ ⇒ Fig. ““ Brake light switch -F- up to MY 2011”“ , page 32
❑ ⇒ Fig. ““ Brake light switch -F- as of MY 2011”“ , page 32
Fitting location: Cover in driver's footwell


Fitting location: Selector lever lock solenoid - N110- -A- is in the
Slide valve body

Fitting location: Wiring harness is fixed to the slide valve body

Fitting location: Wiring harness is fixed to the slide valve body



Fitting location: The Tiptronic switch - F189- is integrated in the
printed circuit board -A- of the gearshift mechanism.
mechanism and cannot be replaced individually.
The removal and installation procedure is only possible together
with the gearshift mechanism
page 74 .


body.

body.

Note


Brake light switch - F- up to MY 2011

Fitting location: The brake light switch - F- -arrow- is located in the
foot controls.
Note

Brake light switch - F- as of MY 2011

Fitting location: Brake light switch - F- -Pos. 3- is located on the
master brake cylinder.

tions of the automatic gearbox (Octavia III)

driver's footwell
unit - J217-
J217 ”, page 38
❑ Control unit for automat‐
ic gearbox - J217- is
checked using self-di‐
agnosis
cator - Y6-
position indicator -Y6-

”“ , page 37
deactivated gearbox
control unit
⇒ Electrical System;
Rep. gr. 90
ic Catalogue of Original Parts
❑ the Tiptronic switch - F189- is integrated in the shift mechanism; Fitting location:
❑ Fitting location ⇒ Fig. ““Slide valve body”“ , page 34
35
G93 ”, page 181

❑ Multi-function indicator - F125- is checked by self-diagnosis
❑ Gearbox output r.p.m sender - G195- is checked using self-diagnosis
❑ Gearbox input r.p.m. sender - G182- is checked using self-diagnosis
❑ Fitting location ⇒ Fig. ““ Brake light switch -F- ”“ , page 37
❑ Brake light switch - F- is checked by self-diagnosis
❑ Kick-down switch - F8- is checked by self-diagnosis
Fitting location: Cover in driver's footwell.
Slide valve body






Fitting location: The Tiptronic switch - F189- is integrated firmly in
the gearshift mechanism and cannot be replaced separately.
mechanism and cannot be replaced individually.
page 74 .

body.

body.


Note

Brake light switch - F-

Fitting location: Brake light switch - F- -1- is located on the master
brake cylinder.

1.2 Removing and installing automatic gear‐

box control unit - J217-
⇒ “1.2.1 Removing and installing automatic gearbox control unit
J217 (Octavia II, Octavia III and Superb II)”, page 38
J217 (Fabia II, Roomster, Rapid)”, page 38
(YETI) J217 ”, page 39
1.2.1 Removing and installing automatic gear‐

box control unit - J217- (Octavia II, Oc‐
tavia III and Superb II)
Fitting location: The control unit is located in the front left wheel‐
house.
Removing
Caution

battery ⇒ Electrical System; Rep. gr. 27 .
Touch an earthed object before working on the electrical com‐
ponents. Do not grab directly at the plug contacts or electronic
components.

– Remove front wheel on the left.
– Remove the left wheelhouse liner ⇒ Body Work; Rep. gr. 66 .
disconnect.
– Take out control unit.
Note
the plug connection is separated. The control unit must re-initial‐
ise these values after the re-connection. During this “initialisation”
the gearshift quality can be worse than usual.
Install
– Installation is carried out in the reverse order.

box control unit - J217- (Fabia II, Room‐
ster, Rapid)
Fitting location: The control unit is located at the battery cover.

Removing
Caution

components.

disconnect.
– Press off locking tabs -arrows- from control unit holder.
– Remove control unit from the top.
Note
the plug connection is separated. The control unit must re-initial‐
ise these values after the re-connection. During this “initialisation”
the gearshift quality can be worse than usual.
Install
– Insert the control unit into the mounting bracket at the battery
cover until it clicks into the position of the locking tabs
-arrows-.
– Mount the plug connection of the gearbox control unit.
27 .

box control unit (YETI) - J217-
Fitting location: The control unit is located at the battery cover in
the engine compartment.
Removing
Caution

components.


– Unlock the plug connection -1- and pull out.

– Unscrew screws -arrow-.
– Undo the mounting bracket with the automatic gearbox control
unit - J217- from the bearing and remove it upwards and out.
– Unlock the catches -arrows- and remove the automatic gear‐

box control unit - J217- from the mounting bracket.
Install
– Installation is carried out in the reverse order.
– Pay attention to the correct locking of the plug connection and
the catches.

WARNING


27 .
Tightening torque
Component Nm
Control unit holder at 5
battery tray


⇒ “2.1 Assembly overview - shift mechanism ”, page 41
⇒ “2.2 Inspecting the gearshift mechanism”, page 54
⇒ “2.3 Inspecting and adjusting the selector lever control cable”,
page 55
⇒ “2.4 Check the function of the ignition key removal lock”,
page 57
⇒ “2.5 Removing and Installing the cover for the shift mechanism”,
page 58
⇒ “2.6 Removing and installing and installing selector lever handle
up to 10.2012”, page 65
⇒ “2.7 Removing and installing selector lever handle as of
11.2012”, page 70
⇒ “2.8 Installing the lock button at the selector lever handle”, page
72
⇒ “2.9 Removing and installing selector mechanism”, page 74

⇒ “2.10 Removing and installing the selector lever control cable”,
page 92
⇒ “2.11 Removing and installing the Tiptronic switch F189 ”, page
100
⇒ “2.12 Removing and installing selector lever lock solenoid N110
”, page 100
⇒ “2.13 Checking the plug connections at the gearshift mecha‐
nism”, page 104
⇒ “2.14 Emergency release of gearshift mechanism out of posi‐
tion P ”, page 105
2.1 Assembly overview - shift mechanism

⇒ “2.1.1 Summary of components - Gearshift mechanism -Octa‐
via II up to 10.2009”, page 41
⇒ “2.1.2 Summary of components - Gearshift mechanism - Oc‐
tavia II as of 11.2009”, page 44
⇒ “2.1.3 Summary of components - Gearshift mechanism -Superb
II”, page 46
⇒ “2.1.4 Summary of components - Shift mechanism up to
10.2011 (Fabia II and Roomster)”, page 47
⇒ “2.1.5 Summary of components - Shift mechanism as of
11.2011 (Fabia II and Roomster)”, page 49
⇒ “2.1.6 Summary of components - Gearshift mechanism (Rap‐
id)”, page 51
⇒ “2.1.7 Summary of components - Gearshift mechanism (Octa‐
via III, Yeti)”, page 53
2.1.1 Summary of components - Gearshift

mechanism -Octavia II up to 10.2009
Note

Ignition key anti-removal lock is not actuated mechanically with

the linkage but electrically with a magnet.
♦ Check the function of the ignition key anti-removal lock
page 57 .

❑ ⇒ “2.5 Removing and In‐
stalling the cover for the
shift mechanism”,
page 58
stalling and installing
selector lever handle up
to 10.2012”, page 65
⇒ “2.14 Emergency re‐
lease of gearshift mech‐
anism out of position P ”,
page 105
2 - Stop buffer for selector lever

❑ clipped into the gearshift
mechanism
3 - Nut
❑ 4 pieces
❑ 10 Nm
4 - Shift mechanism
nism”, page 74
mechanism, do not
touch
Tiptronic switch - F189-
and Selector lever lock
solenoid - N110- , these components can be checked in the “Targeted fault finding” ⇒ Vehicle diagnostic
tester
❑ replace gearshift mechansim if Tiptronic switch - F189- defective
❑ If the selector lever lock solenoid - N110- is faulty, the shift mechanism will need to be replaced
5 - Latch spring
6 - Screw
❑ 3.5 Nm
7 - Catch plate
8 - Screw
❑ 4 pieces
❑ for attaching the catch plate to the gearshift mechanism
❑ 3.5 Nm

9 - Bearing bolt
❑ for selector lever control cable on gearshift mechanism
10 - Lock washer
❑ replace
12 - Nut
❑ self-locking
❑ 4 pieces
❑ 9 Nm
❑ ⇒ “2.3 Inspecting and adjusting the selector lever control cable”, page 55
❑ ⇒ “2.10 Removing and installing the selector lever control cable”, page 92
14 - Nut
❑ for holder Pos. 15 at gearbox
❑ 13 Nm
15 - Support
16 - Screw
❑ 2 pieces
❑ 23 Nm
17 - Cable support

2.1.2 Summary of components - Gearshift mechanism - Octavia II as of 11.2009
Note
The selector lever control cable was replaced as a separate component part up to production date 10.2009.
As of production date 11.2009, this is no longer possible, the selector lever control cable Pos. 10 must not be
removed (separated) from the shift mechanism Pos. 3, it must be replaced together as one component part ⇒
1 - Cover with handle up to

10.2012
shift mechanism”,
page 58
to 10.2012”, page 65

Note
As of 11.2012, the selector handle

was changed, see Pos. 2
page 105
the cover
2 - Cover with handle as of
11.2012
shift mechanism”,
page 58
stalling selector lever
handle as of 11.2012”,
page 70
❑ for the emergency release only the cover needs to be unclipped
⇒ “2.14 Emergency release of gearshift mechanism out of position P ”, page 105
❑ the symbol insert and the circuit board with the lamp for selector lever scale illumination - L101- are
integrated in the cover
❑ tighten using hose binding claw - V.A.G 1275-
4 - Shift mechanism
❑ with selector lever lock solenoid - N110-
❑ ⇒ “2.14 Emergency release of gearshift mechanism out of position P ”, page 105
❑ ⇒ “2.9 Removing and installing selector mechanism”, page 74

❑ ⇒ Fig. ““Remove the shift mechanism together with the selector lever control cable from the shift hous‐
ing”“ , page 45
5 - Screw
❑ 8 Nm
ing”“ , page 45
7 - Nut
❑ 4 pieces
❑ 25 Nm
8 - Gearshift lever
9 - Cable support
10 - Screw
❑ 2 pieces
❑ 23 Nm
❑ when installing in the vehicle, clamp on the gearbox side with the fixing part to the heat shield of the
exhaust system
❑ The selector lever control cable must not be separated from the shift mechanism Pos. 3, it must be
removed together as one component part ⇒ Electronic Catalogue of Original Parts.
ing”“ , page 45
12 - Support
13 - Nut
❑ 13 Nm
-direction of arrow-. To do so, unscrew 4 screws Pos. 5 (fig.
S37-10007) from the shift housing ⇒ Item 5 (page 45) .

2.1.3 Summary of components - Gearshift mechanism -Superb II

10.2012
shift mechanism”,
page 58
to 10.2012”, page 65
Note
As of 11.2012, the selector handle

was changed, see Pos. 2
page 105
the cover
11.2012
shift mechanism”,
page 58
page 70
4 - Shift mechanism
ing”“ , page 47
5 - Screw
❑ 8 Nm


ing”“ , page 47
7 - Nut
❑ 4 pieces
❑ 25 Nm
8 - Gearshift lever
9 - Cable support
10 - Screw
❑ 2 pieces
❑ 23 Nm
exhaust system
removed together as one component part ⇒ Electronic Catalogue of Original Parts .
ing”“ , page 47
12 - Support
13 - Nut
❑ 13 Nm
2.1.4 Summary of components - Shift mech‐

anism up to 10.2011 (Fabia II and
Roomster)
Note
Ignition key anti-removal lock is not actuated mechanically with

the linkage but electrically with a magnet.


shift mechanism”,
page 58
to 10.2012”, page 65
2 - Intermediate piece
3 - Nut
❑ 4 pieces
❑ 25 Nm
4 - Shift mechanism
nism”, page 74
mechanism, do not
touch
Tiptronic switch - F189- ,
this can be checked in
the “Targeted fault find‐
ing” ⇒ Vehicle diagnos‐
tic tester
❑ replace gearshift me‐
chansim if Tiptronic
switch - F189- defective
nism”, page 74
5 - Selector lever lock solenoid - N110-
❑ ⇒ “2.12 Removing and installing selector lever lock solenoid N110 ”, page 100
❑ Selector lever lock solenoid - N110- is checked using self-diagnosis
6 - Retaining clip
❑ replace
8 - Nut
❑ self-locking
❑ 4 pieces
❑ 9 Nm
❑ ⇒ “2.10 Removing and installing the selector lever control cable”, page 92

exhaust system
10 - Nut
❑ 13 Nm
11 - Support
12 - Screw
❑ 2 pieces
❑ 23 Nm
13 - Cable support
2.1.5 Summary of components - Shift mechanism as of 11.2011 (Fabia II and

Roomster)

10.2012
❑ As of 11.2012, the se‐
lector handle was
changed, see Pos. 2
shift mechanism”,
page 58
to 10.2012”, page 65
page 105
the cover
11.2012
shift mechanism”,
page 58
page 70

4 - Shift mechanism
ing”“ , page 51
5 - Screw
❑ 8 Nm
ing”“ , page 51
7 - Nut
❑ 4 pieces
❑ 25 Nm
8 - Gearshift lever
9 - Cable support
10 - Screw
❑ 2 pieces
❑ 23 Nm
exhaust system
ing”“ , page 51
12 - Support
13 - Nut
❑ 13 Nm

2.1.6 Summary of components - Gearshift mechanism (Rapid)

10.2012
❑ As of 11.2012, the se‐
lector handle was
changed, see Pos. 2

shift mechanism”,
page 58
to 10.2012”, page 65
page 105
the cover
11.2012
shift mechanism”,
page 58
page 70

4 - Shift mechanism
ing”“ , page 52
5 - Screw
❑ 8 Nm
7 - Nut
❑ 4 pieces
❑ 25 Nm
8 - Gearshift lever
9 - Cable support
10 - Screw
❑ 2 pieces
❑ 23 Nm
exhaust system
ing”“ , page 52
12 - Support
13 - Nut
❑ 13 Nm

2.1.7 Summary of components - Gearshift mechanism (Octavia III, Yeti)
1 - Shift mechanism
solenoid - N110-
❑ ⇒ “2.14 Emergency re‐
page 105
nism”, page 74
❑ ⇒ “2.3 Inspecting and
adjusting the selector
lever control cable”,
page 55
❑ ⇒ Fig. ““Remove the
shift mechanism togeth‐
er with the selector lever
control cable from the
shift housing”“ ,
page 54
2 - Screw
❑ 8 Nm
❑ ⇒ Fig. ““Remove the
shift mechanism togeth‐
er with the selector lever
control cable from the
shift housing”“ ,
page 54
4 - Nut
❑ 4 pieces
❑ 25 Nm
5 - Gearshift lever
6 - Cable support
7 - Screw
❑ 2 pieces
❑ 23 Nm
exhaust system
ing”“ , page 54

-direction of arrow-. To do so, unscrew 4 screws
⇒ Item 2 (page 53) from the shift housing.
WARNING


the selector lever. The selector lever can be shifted in a driving
position.
moved from position “N” by activating the brake pedal.
Selector lever in position “P” and ignition switched on:
“P”. The selector lever lock solenoid blocks the selector lever.
lever from “P” through “R, N, D, S”; while doing so check whether
the selector lever position in the dash panel insert corresponds
with the actual selector lever position.
Selector lever in position “N” and ignition switched on:
Selector lever in position “D” ignition and light switched on:
• Selector lever in Tiptronic gear leads to:
The lighting up of the “D” symbol in the selector lever position
indicator should go out and the “+” and “-” symbols should light
up.

When the gear selector lever is put into the Tiptronic gate, the
selector lever position display in the dash panel insert should
change from “PRNDS” to “654321”.
– Move selector lever in the Tiptronic gear to “+” and “-”.
When the gear selector lever is put into a higher or a lower driving
position, the selector lever position display in the dash panel in‐
sert should change.
⇒ “2.3 Inspecting and adjusting the selector lever control ca‐
ble”, page 55 .
– Check ignition key anti-removal lock
page 57 .

lever control cable
Inspection
For vehicles Octavia II and Superb II

– Remove air guide hose.
For vehicles Fabia II, Roomster and Rapid
– Remove automatic gearbox control unit - J217- ⇒ page 38 .
gr. 27 .
– Remove intake hose ⇒ Engine; Rep. gr. 24 .
For vehicles Octavia III
gr. 27 .
For the vehicles Yeti
– Remove automatic gearbox control unit - J217- with mounting
bracket
⇒ “1.2.3 Removing and installing automatic gearbox control
unit (YETI) J217 ”, page 39 .
gr. 27 .
lever, e.g. using an open-end wrench -1-.
Note
Ignore position -2- and -4-.
For vehicles Fabia II, Roomster, Rapid, Octavia II and Superb II


– Lever off selector lever control cable in such a way that the
extremity can move freely.
• Do not bend or buckle selector lever control cable.
For vehicles Octavia III and Yeti
– Unlock the quick-release lock -3- at the mounting bracket -2-

and unhook the selector lever control cable -1-.
– Unscrew the screws -arrows-, remove the support for the se‐
lector lever control cable -4- and place it to one side.
Note

♦ Do not remove the circlip -5-.
♦ Do not bend or buckle the selector lever control cable.

– Check front boot on the selector lever cable control for dam‐
age, if necessary replace control cable.
move smoothly when shifting gears. On some vehicles, you
can replace the selector lever control cable separately.
• Selector lever control cable can be replaced as a separate part
or only on the vehicles:
• ⇒ “2.1.1 Summary of components - Gearshift mechanism -
Octavia II up to 10.2009”, page 41 .
• ⇒ “2.1.4 Summary of components - Shift mechanism up to
10.2011 (Fabia II and Roomster)”, page 47 .
– Carefully push the selector lever control cable onto the gear‐
shift lever and insert into the cable support/gearbox.
Setting
The selector lever control cable must be set, if:
♦ the selector lever control cable was removed from the gear‐
box,
♦ the engine was removed and installed or the gearbox was re‐
moved and installed,
removed and installed,
♦ The position of the engine/gearbox was changed, e.g. during
a stress-free assembly of the unit.

control cable -1-.
– Tip selector lever in position “P” slightly to the front and to the
rear, however under no circumstances move out of “P”.
– Position the gearshift lever -3- at the gearbox in “P”, i.e. push
the gearshift lever fully backwards against the direction of
travel.
Note
Locking lever must engage in parking gear, both front wheels are
blocked (cannot be simultaneously turned in one direction).
– Tighten screw -2-.

– Inspect gearshift mechanism
⇒ “2.2 Inspecting the gearshift mechanism”, page 54 .
Tightening torque
Component Nm

Adjusting screw for 13
selector lever control
cable
2.4 Check the function of the ignition key re‐

moval lock
– Switch on the ignition - do not start the engine.
• Shifting the selector lever out of the position “P” when the lock
sible without “jerking”.
• The key cannot be withdrawn from the ignition starter switch
in any other selector lever position except in the position “P”.
• Only withdraw the key from the ignition starter switch if the
selector lever is in position “P”.
• The selector lever cannot be shifted out of position “P” when
the button is pressed and the brake pedal is actuated.
ble”, page 55 .
♦ Inspect the vehicle ⇒ Vehicle diagnostic tester in the function
“Targeted fault finding”.


the shift mechanism
⇒ “2.5.1 Removing and Installing the cover for the shift mecha‐
nism - Fabia II and Roomster”, page 58
nism Superb II”, page 59
nism Octavia II”, page 60
nism Rapid”, page 62
nism Octavia III”, page 62
nism Yeti”, page 63
2.5.1 Removing and Installing the cover for

the shift mechanism - Fabia II and
Roomster
♦ Disassembly wedge - 3409-
Removing
Note
As of 11.2012, the selector lever handle was changed

⇒ “2.1.5 Summary of components - Shift mechanism as of
– Push selector lever into position “N”.

Note
Make sure that the vehicle does not put itself into motion.
– Carefully press the disassembly wedge - 3409- in

-direction of arrow- and subsequently clip the cover -1- out of
the centre console.


tion - L101- .
Install
Installation is carried out in the reverse order. When installing,
observe the following:
Note
When plugging in the plug connection for lamp for selector lever
scale illumination - L101- make sure that the contact pins are not
bent.
– Insert the plug connection -A- for lamp for selector lever scale
illumination - L101- .
Note

When fitting on the cover, make sure that the retaining lugs do
not break off.
– Clip cover for shift mechanism into centre console.

the shift mechanism Superb II
Removing
Note

⇒ “2.1.3 Summary of components - Gearshift mechanism -Superb
II”, page 46 .

Note
– Open ashtray in the centre console.

– Remove cover using the release tool - T30098- . Pull up rear

left and right cover -arrows-.

tion - L101- .
Install
Note
bent.
– Insert the plug connection -C- for lamp for selector lever scale
Note
not break off.

the shift mechanism Octavia II

Removing
Note

tavia II as of 11.2009”, page 44 .

Note

– Release the front right cover -arrow- using the release tool -
T30098- . Then release the rear right and centre cover
-arrow-.


tion - L101- .
Install
Note
bent.
Note
not break off.


the shift mechanism Rapid
Removing
– Carefully press the release tool - T30098- in
-direction of arrow- and subsequently clip the cover out of the
centre console.

tion - L101- .
Install
Note
bent.
– Insert the plug connection -A- for lamp for selector lever scale
Note
not break off.

the shift mechanism Octavia III


– Apply handbrake.
– Shift selector lever into position “D/S”.
– Fit the release tool - T30098- under the cover for shift mech‐
anism and loosen the cover by pressing it in
– Swivel the cover for shift mechanism to the side.
– Disconnect the plug of the display unit -arrow A- and the plugs
for the switches mounted on the cover for the shift mechanism
-arrows B and C-.
– Raise cover for shift mechanism.
– Use a screwdriver to press onto the clips of the protective cov‐

er for the selector lever and separate the protective cover from
the cover for the selector mechanism.
– Remove the cover for the selector mechanism via the loose
protective cover and selector lever handle.
Install

the shift mechanism Yeti
Removing
– Apply handbrake.

– Using the unlocking tool - T30098- lift up the cover on the left
and right -arrow-.

– Detach the plug connection -A- for lamp for selector lever scale
Install
following points:
Note
bent.
– Insert the plug connection -2- for lamp for selector lever scale
Note
♦ When fitting on the cover, make sure that the retaining lugs do
not break off.
♦ Ignore position -1-.

2.6 Removing and installing and installing

selector lever handle up to 10.2012
⇒ “2.6.1 Removing and installing retractor spring Octavia II”, page
65
⇒ “2.6.2 Removing and installing retractor spring Superb II”, page
66
⇒ “2.6.3 Removing and installing retractor spring Fabia II, Room‐
ster”, page 68
⇒ “2.6.4 Removing and installing selector lever handle Rapid”,
page 69
2.6.1 Removing and installing retractor spring

Octavia II
♦ Hose binding claw - V.A.G 1275-
Removing
– Removing the cover for the shift mechanism
⇒ “2.5.3 Removing and Installing the cover for the shift mech‐
anism Octavia II”, page 60 .
– Before removing the handle pull out lock button over its pres‐
sure point and secure it with a cable strap or a suitable wire
-arrow-. This can prevent that the lock button is inadvertently


tion - L101- .
Install
Note
lector lever handle. Then the grip must be secured using a
cable strap -arrow- or with the factory-delivered assembly aid
for the new grip.
♦ If the lock button was not inadvertently secured, it must not be
pulled out of the selector lever grip using mechanical auxiliary
tools if it is pressed in. The lock button can be pressed out if
necessary by positioning the compressed air pistol on the un‐
derside of the grip.
– Insert the selector lever with a new clamp onto the selector
lever fully until the stop.
groove of the selector lever.
• The handle must be rotated with the lock button to the driver.
– Remove the cable strap or the assembly aid. After the remov‐
al, the lock button actuator grips into the vertical groove of the
selector lever, if necessary press the lock button into the se‐
lector lever grip.
Tighten warm-type clamp -arrow- using the hose binding claw .

– Installing the cover for the shift mechanism
anism Octavia II”, page 60 .

Superb II

Removing
anism Superb II”, page 59 .
– Before removing the handle pull out lock button over its pres‐
sure point and secure it -arrow- with a cable strap or a suitable
wire -A-. This can prevent that the lock button is inadvertently

tion - L101- .
Install

Note
for the new grip.
lector lever grip.

anism Superb II”, page 59 .


Fabia II, Roomster
Removing
anism - Fabia II and Roomster”, page 58 .
– Before removing the handle pull out lock button -1- in
-direction of arrow- beyond its pressure point and secure it with
a cable strap or a suitable wire -2-. This can prevent that the
lock button is inadvertently pressed into the handle.
tion - L101- .
Install
Note
for the new grip.
lector lever grip.


anism - Fabia II and Roomster”, page 58 .
2.6.4 Removing and installing selector lever

handle Rapid
Removing
anism Rapid”, page 62 .
– Before removing the handle pull out lock button -1- in
-direction of arrow- beyond its pressure point and secure it with
a cable strap or a suitable wire -2-. This can prevent that the
lock button is inadvertently pressed into the handle.


tion - L101- .
Install
Note
for the new grip.
lector lever grip.

anism Rapid”, page 62 .

handle as of 11.2012
Removing
⇒ “2.5 Removing and Installing the cover for the shift mecha‐
nism”, page 58 .

– Open the warm-type clamp -arrow- below the handle.
– Detach the selector lever handle -1- together with the selector
lever collar from the selector lever towards the top -arrow A-
so that the lock button -2- is not pressed in.
Note
Ignore -arrow B-.

Install

following points:
• The lock button -2- points in direction of travel.
Caution
The shift mechanism can be damaged.

♦ The lock button at the selector lever handle must protrude
when installing. If the lock button is inadvertently pressed
in when removing the selector lever handle, it must be re‐
positioned
⇒ “2.8 Installing the lock button at the selector lever han‐
dle”, page 72 .
♦ If the selector lever handle with pressed in lock button is
installed, the selector lever handle and the control cable
for the selector mechanism will be destroyed.
– Press the selector lever handle -1- onto the selector lever in
-direction of arrow B- in such a way that the lock button -2- is
not touched.
• The selector lever handle must latch into the round slot of the
selector lever.

Note
♦ The selector lever is only correctly secured when the gripper

clamp is under tension. Only then the lock button at the handle
may be pressed on.
♦ The lock button can only show high resistance when it is
pressed on for the first time after installing the selector lever
handle.
– Press the lock button onto the selector lever handle.

nism”, page 58 .
2.8 Installing the lock button at the selector

lever handle

Work procedure
• The lock button -2- on the selector lever handle protrudes
when it is in the installation position.
Note
If the lock button -2- was inadvertently pressed in, it must then be
repositioned in order to fit the selector lever handle.

– Carefully guide the release tool - T40203- fully into the selector
lever handle -1- -arrow-.
Note
The selector lever handle in the illustration is shown without the

protective cover. The protective cover for the selector lever can‐
not be removed from the handle.
• The recess at the release tool - T40203- points to the lock

button and the hook points to the left.
– Hold the selector lever handle -A- and turn the release tool -
T40203- by 180° in -direction of arrow 1-.
– Hold the selector lever handle and carefully pull out the release
tool - T40203- -arrow 2-.
• When pulling out the release tool - T40203- , the lock button
at the selector lever handle -A- is pressed out and locked.
• Do not touch and press in the lock button again before instal‐
ling the selector lever handle.

2.9 Removing and installing selector mech‐

anism
⇒ “2.9.1 Removing and installing shift mechanism Fabia II, Room‐
ster, Rapid”, page 74
⇒ “2.9.2 Removing and installing slave cylinder Octavia II, Superb
II”, page 80
⇒ “2.9.3 Remove and install shift mechanism Octavia IlI”,
page 84
⇒ “2.9.4 Removing and installing shift mechanism (Yeti)”,
page 88
2.9.1 Removing and installing shift mecha‐

nism Fabia II, Roomster, Rapid
Removing

WARNING


Note

– Removing the selector lever handle and cover for the shift
mechanism:
♦ ⇒ “2.6 Removing and installing and installing selector lever
handle up to 10.2012”, page 65 .
♦ ⇒ “2.7 Removing and installing selector lever handle as of
11.2012”, page 70 .
– Remove ashtray or storage area in front of the shift mecha‐
nism ⇒ Body Work; Rep. gr. 68 .
– Disconnect plug from automatic gearbox control unit -J217-
⇒ “1.2.2 Removing and installing automatic gearbox control
unit J217 (Fabia II, Roomster, Rapid)”, page 38 .
gr. 27 .

lever -3-, e.g. using a fixed spanner -2-.
For vehicles Fabia II and Roomster up to 10.2011

For vehicles Fabia II and Roomster as of 11.2011 and Rapid ve‐
hicles

anism.
– Raise vehicle.


– Detach tunnel bridge below the exhaust system ⇒ Engine;
Rep. gr. 26 .
– Disconnect plug connection -1-, remove inserting terminal out

of the bracket -2- and expose wiring to lambda probe heater
downstream of catalytic converter.
– Separate exhaust system at the clamping sleeve -1-.

– Remove the bracket for the pre-exhaust pipe from the assem‐
bly carrier arrows ⇒ Engine; Rep. gr. 26 .
– Unhook front and rear silencer ⇒ Engine; Rep. gr. 26 .
Note
The decoupling element of the front part of the exhaust system

should not be bent by more than 10° - risk of damage.


Note
A second mechanic is needed under the vehicle to remove the

shift mechanism.
– Unscrew nuts -1- and -2-.

Note
♦ Shift mechanism can also be replaced without selector lever

control cable, on the following vehicles:
♦ ⇒ “2.1.4 Summary of components - Shift mechanism up to
♦ ⇒ “2.10 Removing and installing the selector lever control ca‐
ble”, page 92 .
Note
♦ For vehicles Fabia II and Roomster as of production date

11.2011 and Rapid vehicles, the selector lever control cable
must not be removed from the shift mechanism and is replaced
together as a single part ⇒ Electronic catalogue of original
parts .
♦ Removing and installing shift mechanism together with selec‐
tor lever control cable
page 74 .

hicles

– Remove the shift mechanism with the selector lever control

cable to the top -arrow-, ensuring the selector lever control
cable does not get bent or kinked.
Install
Note
– Insert the shift mechanism and tighten the rear nuts -1- by
hand.
– Mount the strut for centre console -3- onto the shift mechanism
as illustrated in the fig.
– Tighten nuts -1- and -2- to tightening torque.


hicles
– Insert screws -arrows- into the shift housing.

– Fit plug connection -A- for the gearshift mechanism.

– Insert the selector lever control cable -1- in the cable support/
gearbox and carefully push onto the gearshift lever -3-. Do not
the gearbox. When installing the selector lever control cable,
respect a minimum distance of at least 5 mm from the ATF
cooler.
– Clamp the selector lever control cable on the gearbox side with
the fixing part to the heat shield of the exhaust system.
– Install exhaust system and align free of stress ⇒ Engine; Rep.
gr. 26 .
– Installing the selector lever handle and cover for the shift
mechanism:
11.2012”, page 70 .
– Check the function of the ignition key anti-removal lock
page 57 .
– Setting selector lever control cable
ble”, page 55 .
27 .
Note

Tightening torques
Summary of components - Shift ⇒ “2.1.4 Summary of com‐
mechanism (Fabia II and Room‐ ponents - Shift mechanism
ster) up to 10.2011 up to 10.2011 (Fabia II and
Roomster)”, page 47
mechanism (Fabia II and Room‐ ponents - Shift mechanism
ster) as of 11.2011 as of 11.2011 (Fabia II and
Summary of components - Gear‐ ⇒ “2.1.6 Summary of com‐
shift mechanism (Rapid) ponents - Gearshift mecha‐
nism (Rapid)”, page 51

2.9.2 Removing and installing slave cylinder

Octavia II, Superb II
Removing
Note

– Removing the selector lever handle and cover for the shift
mechanism:

11.2012”, page 70 .

– Disconnect plug connection -A- from the shift mechanism to

the vehicle wiring harness.
Note
♦ Ignore pos. -B-, -C- and -1-.

♦ As of production date 11.2009 the shift mechanism is
changed, the 4-pin plug connection -B- and the selector lever
lock solenoid - N110- -1- are already located in the shift mech‐
anism
⇒ “2.1.2 Summary of components - Gearshift mechanism -
Octavia II as of 11.2009”, page 44 .
– Raise vehicle.

Rep. gr. 26 .

– Separate exhaust system at the clamping sleeve -1-.

– Remove the bracket for the pre-exhaust pipe from the assem‐
bly carrier arrows ⇒ Engine; Rep. gr. 26 .
Note


– Clip off clips -arrows- and remove heat shield.

For Octavia II and Superb II vehicles up to 10.2011
Note

shift mechanism.
– Unscrew nuts -1- and -2-.

Note
♦ Shift mechanism can also be replaced without selector lever

control cable, on the following vehicles:
♦ ⇒ “2.1.1 Summary of components - Gearshift mechanism -
♦ On Superb II, Octavia II vehicles as of production date
11.2009, the selector lever control cable must not be removed
from the shift mechanism and is replaced together as a single
part ⇒ Electronic catalogue of original parts .
♦ ⇒ “2.10 Removing and installing the selector lever control ca‐
ble”, page 92 .
♦ Removing and installing shift mechanism together with selec‐
tor lever control cable
page 74 .
Install
following points:
Note

hand.
– Tighten nuts -1- and -2- to tightening torque.
The fitting together of the plug connection -A- must not be per‐
formed, if the plug connector housing is latched into the shift
mechanism. When fitting together (high resistance because of the
spring) the catch of the plug connector housing breaks off.
– Connect plug -A- and plug connector housing and then latch
into the shift mechanism.
Note
As of production date 11.2009 the shift mechanism is changed,

the 4-pin plug connection -B- and the selector lever lock solenoid
- N110- -1- are already located in the shift mechanism
tavia II as of 11.2009”, page 44 .

cooler.
– Clamp the selector lever control cable on the gearbox side with
the fixing part to the heat shield of the exhaust system.
gr. 26 .
mechanism:
11.2012”, page 70 .
page 57 .
ble”, page 55 .

27 .
Note

Tightening torques
shift mechanism -Octavia II up to ponents - Gearshift mecha‐
10.2009 nism -Octavia II up to
10.2009”, page 41
shift mechanism - Octavia II as of ponents - Gearshift mecha‐
11.2009 nism - Octavia II as of
11.2009”, page 44
shift mechanism -Superb II ponents - Gearshift mecha‐
nism -Superb II”, page 46
2.9.3 Remove and install shift mechanism Oc‐

tavia IlI
Removing
nism”, page 58 .

– Removing selector lever handle

11.2012”, page 70 .
Note


– Remove the centre console and air guide ⇒ Body Work; Rep.
gr. 68 .
– Disconnect plug connection for vehicle wiring harness to se‐
lector mechanism -1-.

Note
Ignore -position 2-.

gr. 23 .
Note
Ignore positions -2-,-4- and -arrows-.


– Remove the circlip -5- and release the selector lever control
cable -1- from the support -4-.
Caution
Risk of damage to the selector lever control cable.

♦ Do not press the selector lever control cable out of the
cable support towards the rear. The selector lever control
cable is only guided out of the cable support when remov‐
ing the gearshift mechanism.
– Raise vehicle ⇒ Maintenance ; Booklet Octavia III .
– Remove the rear tunnel bridge -1- and the front tunnel bridge
-2- from the body (if present).
– Detach the bracket -3- for the exhaust system from the as‐
sembly carrier.
– Slacken clamping sleeve -4-.
Note
♦ The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - risk of damage.
♦ The aid of a 2nd mechanic is required to remove the rear si‐
lencer.
– Remove the rear part of the exhaust system -5- as from the
clamping sleeve ⇒ Engine; Rep. gr. 26 .
– Slacken the trim panels for the underfloor on left -6- and right
-7- from the body.
– Unclip lambda probe cable at heat shield.
– Remove the heat shield below the shift mechanism towards

the rear, to do so slacken the clips -arrows-.
Note

shift mechanism.

– Unscrew the nuts -arrows- in the vehicle interior.

control cable downwards. Thus, guide the selector lever con‐
trol cable out of the gearshift mechanism.
Note
Install
Note
– Install the air guide and the centre console ⇒ Body Work; Rep.
gr. 68 .

– Install ashtray or storage area in front of the shift mechanism
⇒ Body Work; Rep. gr. 68 .
mechanism
11.2012”, page 70 .
27 .
Note


– Hang the selector lever control cable in the clip arrow at the
ATF radiator. When installing the selector lever control cable,
cooler.
page 57 .
ble”, page 55 .
23 .
the trim panels for the underfloor on the body ⇒ Body Work;
Rep. gr. 50 .
gr. 26 .
– Install the tunnel bridges below the exhaust system ⇒ Engine;
Rep. gr. 26 .
Tightening torques
shift mechanism (Octavia III, Yeti) ponents - Gearshift mecha‐
nism (Octavia III, Yeti)”,
page 53
2.9.4 Removing and installing shift mecha‐

nism (Yeti)
Removing
nism”, page 58 .
– Removing selector lever handle
11.2012”, page 70 .
Note



gr. 68 .
– Disconnect plug connection for vehicle wiring harness to se‐
lector mechanism -1-.
Note
Ignore -position 2-.
Caution

components.


– Undo the mounting bracket with the control unit for automatic
gearbox - J217- from the bearing and remove it upwards and
out.
gr. 27 .
Note
Ignore positions -2-,-4- and -arrows-.

– Remove the circlip -5- and release the selector lever control
cable -1- from the support -4-.
Caution
Risk of damage to the selector lever control cable.

♦ Do not press the selector lever control cable out of the
cable support towards the rear. The selector lever control
cable is only guided out of the cable support when remov‐
ing the gearshift mechanism.

– Remove rear tunnel bridge -1- and the front tunnel bridge -2-
from the body.
– Detach the bracket -3- for the exhaust system from the as‐
sembly carrier.
Caution
The decoupling element in the pre-exhaust pipe should not be

Note
The aid of a 2nd mechanic is required to remove the rear silencer.
-7- from the body.
– Remove the heat shield below the shift mechanism towards

the rear, to do so slacken the clips -arrows-.
Note

shift mechanism.

– Unscrew the nuts -arrows- in the vehicle interior.

control cable downwards. Thus, guide the selector lever con‐
trol cable out of the gearshift mechanism.
Install
following points:
Note
gr. 68 .
mechanism
11.2012”, page 70 .
27 .
Note


– Hang the selector lever control cable in the clip arrow at the
ATF radiator. When installing the selector lever control cable,
cooler.
page 57 .
ble”, page 55 .
Rep. gr. 50 .
gr. 26 .
Rep. gr. 26 .
Tightening torques
Component Nm
Control unit holder at 5
battery tray
Summary of compo‐ ⇒ “2.1.7 Summary of components -
nents - Gearshift mech‐ Gearshift mechanism (Octavia III, Ye‐
anism (Octavia III, Yeti) ti)”, page 53

lever control cable
Note
♦ Selector lever control cable can be replaced as a separate part

or only on the vehicles:
♦ ⇒ “2.1.1 Summary of components - Gearshift mechanism -
♦ ⇒ “2.1.4 Summary of components - Shift mechanism up to
Removing
– Remove engine cover engine ⇒ Engine; Rep. gr. 10
For vehicles Octavia II (up to production date 10.2009)
– Shift selector lever into position “S”.

For vehicles Fabia II and Roomster (up to production date

10.2011)
Note
Observe measures when disconnecting and connecting the bat‐

tery ⇒ Electrical System; Rep. gr. 27 .

– Disconnect plug from automatic gearbox control unit - J217- .
gr. 27 .


– Detach tunnel bridges below the exhaust system ⇒ Engine;
Rep. gr. 26 .


– Separate exhaust system at the clamping sleeve -1- ⇒ En‐

gine; Rep. gr. 26 .
Note


– Unscrew the nuts -arrows- for the lid of the shift mechanism.

Caution
♦ Under no circumstances touch the circuit board -B- of the

gearshift mechanism with the fingers, because static dis‐
charge can destroy the electronic components and the
circuit board.
♦ The circuit board can only be replaced together with the
gearshift mechanism!
– Detach catch plate -A- from the gearshift mechanism.
Note
The catch plate is clipped to the left and to the right with retaining
lugs.
– Pull out the locking clasp -1- for the selector lever control on
the gearshift mechanism downwards.
– Pull the plastic securing spring -2- slightly forwards and only
push the pin -3- as far as necessary upwards -arrow-.
Note
Make sure that the pin is not fully pressed out.
– Pull selector lever control cable -4- out of the gearshift mech‐
anism.
10.2011)
– Shift selector lever to position “Tiptronic”.
– Remove the pre-exhaust pipe with mounting bracket -1- ⇒



Rep. gr. 26 .


– Push away selector lever control cable -2- in

-direction of arrow- from the selector lever -3-.
– Pull out securing clasp -1-.
– Pull the selector lever control cable out of the protective cover.
Note
– Remove selector lever control cable.

Install
following points:
Note
♦ Inspect boot for damage; the boot must be replaced together

with the selector lever control cable.
♦ Check correct fitting of the boot and do not install the boot
twisted.
Caution
♦ Under no circumstances touch the circuit board -B- of the

charge can destroy the electronic components and the
circuit board.
– Insert the end of the selector lever control cable -4- into the
joint of the selector lever.
– Push the pin -3- downwards -arrow-.
– Check if the plastic securing spring -2- has locked the pin.
• Fitting position: Angled end of locking clasp points towards the
inside of the gearshift mechanism.

– Install catch plate -A-.
Note
The catch plate is clipped to the left and to the right with retaining
lugs.
– Screw in screws -arrow-.

– Screw the cover with affixed seal with new nuts to the shift
mechanism. Watch out for the correct arrangement of the seal.
– Tighten nuts for cover -arrows- to tightening torque

⇒ “2.1.1 Summary of components - Gearshift mechanism -
– Insert the boot of the selector lever control cable into the cover.
10.2011)
– Press the selector lever control cable -2- onto the selector lev‐
er -3-.
– Screw cover for shift mechanism -arrows- with new nuts and
tighten to the tightening torque
⇒ “2.1.4 Summary of components - Shift mechanism up to

– Press the gearshift lever -3- on the gearbox completely to‐

wards the rear to position “P” (in the figure: completely to the
right) until the parking lock locks into place. Both front wheels
are blocked (cannot be simultaneously turned in one direc‐
tion).
cooler.

control cable -1-.
– Tighten -2- to 13 Nm.
– Shift selector lever from “P” to “S” and shift back again.
lector lever control cable or repair gearshift mechanism.
gr. 26 .
Note


27 .
Tightening torques
Summary of components - Gearshift ⇒ “2.1.1 Summary of com‐
mechanism Octavia II up to 10.2009 ponents - Gearshift mech‐
anism -Octavia II up to
10.2009”, page 41
mechanism (Fabia II and Roomster) ponents - Shift mecha‐
up to 10.2011 nism up to 10.2011 (Fabia
II and Roomster)”,
page 47

switch - F189-
The Tiptronic switch is integrated firmly in the gearshift mecha‐
nism and cannot be replaced separately. To replace, the gearshift
mechanism must be replaced.

lock solenoid - N110-
⇒ “2.12.1 Removing and installing selector lever lock solenoid
N110 for Octavia II, Octavia III, Superb II, Rapid and Yeti vehi‐
cles”, page 100
N110 for Fabia II and Roomster vehicles up to 10.2011”,
page 101
N110 for Fabia II and Roomster vehicles as of 11.2011”,
page 104

lock solenoid - N110- for Octavia II, Oc‐

tavia III, Superb II, Rapid and Yeti vehi‐

cles
The selector lever lock solenoid is integrated firmly in the gearshift
mechanism and cannot be replaced separately. To replace, the

lock solenoid - N110- for Fabia II and
Roomster vehicles up to 10.2011
Removing
Note



nism”, page 58 .
– Pull out connector -A-.




– Press off locking tabs -arrows A-.

– Slightly pull the solenoid out of the attachment.
– Pull solenoid control cable out of the catch -arrow B-.
Install

– Insert selector lever lock solenoid - N110- -A- into the gearshift
mechanism.
– Insert solenoid control cable into the catch -arrow B-.
The locking tabs -A- must click into place audibly.
– Position cover for shift mechanism -arrows- and screw on.


– Install underbody cover on right and left -arrows-.
– Install tunnel bridge -arrows-.

– Mount the plug connection -A-.

– Install the centre console ⇒ Body Work; Rep. gr. 68 .
nism”, page 58 .
Note


27 .

lock solenoid - N110- for Fabia II and
Roomster vehicles as of 11.2011
The selector lever lock solenoid is integrated firmly in the gearshift
mechanism and cannot be replaced separately. To replace, the

gearshift mechanism
• Before repairing or checking the plug connections, try to de‐
termine the origin of the damage as accurately as possible

using the ⇒ Vehicle diagnostic tester in the functions “Targeted

fault finding”, “Vehicle self-diagnosis” and “Measuring meth‐
od”.
Before checking the plug connections, all control units in the ve‐
hicle should be checked for fault entries and if necessary the
faults must be rectified.
For Roomster and Rapid vehicles as of 11.2011, Octavia II, Su‐
perb II, Fabia II
A - 10-pin plug connection for connection lines from the gearshift
mechanism to the automatic gearbox control unit - J217-
B - 4-pin plug connection to selector lever lock solenoid - N110-
and selector lever switch blocked - F319- in P
page 57 .

A - 2-pin plug connection to selector lever lock solenoid - N110-
B - 10-pin plug connection for connection lines from the gearshift
mechanism to the automatic gearbox control unit - J217-

nism out of position “P”
Selector lever lock solenoid - N110- locks the selector lever in
position “P”. The selector lever can only be shifted out of “P” when
ignition on or a started engine, the brake pedal is actuated and
the button on the selector lever knob is pressed.
position “P”, i.e the vehicle cannot be moved because the parking
– Test fuses ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
– Check the battery voltage ⇒ Electrical System; Rep. gr. 27 .
If the selector lever cannot be moved out of the position “P” de‐
spite the troubleshooting, the emergency release of the solenoids
can be performed. If the selector lever is then shifted again into
the position “P”, it is blocked again in the position “P”.
Perform emergency release
nism”, page 58 .

Note
For Octavia II vehicles up to 05.2009

– Carefully insert a screwdriver from the top into the opening
(retaining eye) at the side of the cover -arrow-.
– Release the selector lever lock solenoid -A- using a screw‐

driver -1-.
– To do so press the lever -B- to the inside -arrow- using a

screwdriver and hold it in this position. This releases the sol‐
enoid from the selector lever.
For Octavia II vehicles as of 10.2009, Superb II, Octavia III, Fabia
II, Roomster, Rapid, Yeti vehicles

The magnet sets the locking of the selector lever in position “P”.
– Now, press the button on the selector lever, and release the
selector lever -B- out of position “P” in -direction of arrow 2-.
Note
♦ If the selector lever is then shifted again into the position “P”,
it is blocked again.
♦ The shift mechanism can only be replaced as a complete unit.
If individual parts of the shift mechanism are damaged, the
shift mechanism can be replaced completely ⇒ Electronic


⇒ “3.1 Removing the gearbox”, page 107
⇒ “3.3 Tightening torques ”, page 134
⇒ “3.4 Transporting an automatic gearbox”, page 145
⇒ “3.5 Attaching gearbox to assembly stand”, page 145

⇒ “3.1.1 Remove gearbox Superb II”, page 107
⇒ “3.1.2 Removing gearbox Octavia II”, page 111
⇒ “3.1.3 Removing gearbox Fabia II, Roomster, Rapid”,
page 117
⇒ “3.1.4 Removing gearbox Octavia III”, page 121
⇒ “3.1.5 Removing gearbox (Yeti)”, page 127
3.1.1 Remove gearbox Superb II

♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Support - T10346-
♦ Hook - MP9-200/10-
♦ Engine/gearbox jack - V.A.G 1383A-
♦ Hose clamp - MP7-602 (3094)-
♦ Wedge - T10161-
Note


gr. 27 .

– Disconnect plug connection -4- and expose electrical cable at
bracket -2-.
from the gearbox.

– Detach electrical cables -1- and -2- at starter and expose.
Note

– Clamp off the ATF-radiator hoses with hose clamps - MP7-602

– Seal the of the ATF radiator with a clean plug.
sible from the top.
– Remove the filling pieces from both upper edges of the wings.
– Tighten the holder - T10346- on the rear of the three location
holes for the battery tray.
– To do so, use a collar screw M6 or one of the fixing screws for
the battery tray.
– Position the supporting device - MP9-200 (10-222A)- behind

the pressurized gas strut -A- for the front flap.
– The feet of the supporting device must be placed as shown in
the illustration, behind the screws -arrow 1- and sideways up
to the screw -arrow 2- on the frame side rails for wheel arches
at the top.
– Connect the holder - T10346- with the supporting device .
– Hook the second spindle to the front left engine lifting eye.


and -2-.
gr. 50 .
– Remove the front wheelhouse liners ⇒ Body Work; Rep. gr.
66 .
– Disconnect plug connection -1- at oil level and oil temperature

sender - G266- .
– Unclip the mounting bracket -2- for the electrical cable to the
oil level and oil temperature sender - G266- at the assembly
bracket.
– Remove pendulum support -arrows A, B and C-.

– Unscrew bracket for electrical cables from the lower starter
fixing screw/gearbox.

– Remove the protective cap for right drive shaft from the engine
-arrows-.
– Disconnect the pre-exhaust pipe from the exhaust manifold ⇒
– Unscrew nut -arrow- on both vehicle sides and remove cou‐

pling rods from the anti-roll bar.
– Unscrew nuts -arrows- at left steering joint.

– Undo nuts from the holder of the front left vehicle level sender
- G78- (when present on vehicle).
– Unhook suspension arm from track control arm.
– Swivel the spring unit outwards- while doing so, press the drive
shaft out of the gearbox mounting by hitting on it with a plastic
hammer on the wedge - T10161- .
– Tie up drive shaft.
– Repeat the same procedure on the opposite side of the vehicle
as well.

– Remove the cap from assembly opening for the converter

nuts.
so turn the crankshaft each time 60°.
Note
engine!

50 mm.
– Mount engine/gearbox jack - 3282- onto engine/gearbox

mount - V.A.G 1383A- .
– Position adjusting plate - 3282/36- onto the gearbox mount -

3282- (adjusting plate fits in only one position).
plate.
plate.
– Position engine/gearbox jack - V.A.G 1383A- below vehicle,
– Secure the gearbox on the gearbox support - 3282- using
screw -1-.
– Support gearbox by raising the gearbox mount.
box. Installation position
⇒ “3.3 Tightening torques ”, page 134 .

rier downwards.
3.1.2 Removing gearbox Octavia II


♦ Surface - T30099/1-
♦ Alignment rail - MP3-457/2 (VW 457)-
♦ Support device for engine - MP3-470 (3300A)-
♦ Hook - MP9-200/10-
♦ Hose clamp - MP7-602 (3094)-
♦ Wedge - T10161-
Note


gr. 27 .
66 .
bracket -2-.
from the gearbox.

Note



– Seal the of the ATF radiator with a clean plug.
sible from the top.
Installation positions: ⇒ “3.3 Tightening torques ”, page 134
– Fit supporting device -T30099- .

– Tighten the holder - T10346- on the rear of the three location
holes for the battery tray.
– To do so, use a collar screw M6 or one of the fixing screws for
the battery tray.
– Position the supporting device - MP9-200 (10-222A)- behind
– The feet of the supporting device must be placed as shown in
the illustration, behind the screws -arrow 1- and sideways up
to the screw -arrow 2- on the frame side rails for wheel arches
at the top.
– Connect the holder - T10346- with the supporting device .
– Hook the second spindle to the front left engine lifting eye.

and -2-.
gr. 50 .
– Remove the bottom part of the front wheelhouse liner ⇒ Body
Work; Rep. gr. 66 .
– Disconnect plug connection -1- at oil level and oil temperature

sender - G266- .
– Unclip the mounting bracket -2- for the electrical cable to the
oil level and oil temperature sender - G266- at the assembly
bracket.


– Release vacuum hose -2-.
– Release screws -arrows- and remove vacuum pump for brake
servo unit.

-arrows-.



– Unhook suspension arm from track control arm.
as well.
– Remove the cap from assembly opening for the converter

nuts.
Note
engine!

50 mm.
Vehicles with aluminium assembly carrier

– Remove heat shield for the power-assisted steering control

unit -J500- from the assembly carrier -arrows-.
Note
If required the alignment rail - MP3-457/2 (VW 457)- has to be

adapted ⇒ page 116 .
Adapt alignment rail - MP3-457/2 (VW 457)-
– Fit 2 holes -arrows- ∅ 7 mm on the alignment rail - MP3-457/2

(VW 457)- .
♦ Dimension -c- = 11 mm
– Screw down alignment rail - MP3-457/2 (VW 457)- with bolts

M6 x 20 -arrows- onto the assembly carrier.
– Position the supporting device for engine - MP3-470 (3300A)-

onto the alignment rail - MP3-457/2 (VW 457)- .
– Carefully press the engine/gearbox forwards via the spindle of
the supporting device for engine - MP3-470 (3300A)-
Note
Observe all cables when displacing the engine/gearbox unit.


mount - V.A.G 1383A- .
plate.
plate.
– Position engine/gearbox jack - V.A.G 1383A- below vehicle,
screw -1-.
– Support gearbox by raising the gearbox mount.
box.
Installation positions: ⇒ “3.3 Tightening torques ”, page 134 .


rier downwards.
3.1.3 Removing gearbox Fabia II, Roomster,

Rapid
♦ Hook - MP9-200/10-
♦ Hose clamp - MP7-602 (3094)-
♦ Wedge - T10161-

Note


gr. 27 .
lever e.g. using an open-end wrench -1-.
from the gearbox.

– Detach cables -1- and -2- at starter and expose.
Note


gr. 50 .

– Close ATF-radiator with a clean plug.
sible from the top.

– Fit supporting device - MP9-200 (10-222A)- .


and -2-.
gr. 66 .

– Unscrew bracket for electrical cables from the gearbox.
– Unscrew bolts -1-.


– Repeat procedure on the opposite side of the vehicle.
with e.g. wire.
Note
wards.

– Remove the cap from the opening for the converter nuts.
Note
engine!

50 mm.

mount - V.A.G 1383 A- .

plate.
plate.
– Position engine/gearbox jack - V.A.G 1383 A- below vehicle,
screw -1-.
– Position gearbox by lifting the gearbox mount from the bottom.
box.

rier downwards.
3.1.4 Removing gearbox Octavia III

♦ Supporting device - T30099- with -10-222A/31-
♦ Supporting device - T40091/3-

♦ Hook - MP9-200/10-
♦ Adapter - MP9-200/18-
♦ Surface - T30119-
♦ Engine and gearbox jack - V.A.G 1383A-
♦ Hose clamp - MP7-602 (3094)-
♦ Bolt - VAS 3282/29-
♦ Wedge - T10161-
♦ Screw plug set for engine , e.g. -VAS 6122-
♦ Pliers for spring strap clamps
Note


gr. 27 .
bracket -2-.

Note



Caution
♦ When the engine is warm, the cooling system is under

overpressure.
♦ Before removing the coolant hoses, cover the cap of the
coolant expansion tank with a cloth and open it carefully.
– Seal the hoses of the ATF radiator with hose clamps -

MP7-602 (3094)- .
– Remove hoses from the ATF radiator.
– Seal support of ATF radiator and coolant hoses with suitable
stops from the screw plug set for engine , e. g. -VAS 6122- .

sible from the top.
– Mount the supporting device - T30099- with base as shown.


and -2-.
gr. 50 .
66 .


– Release screws -arrows- at holder for pre-exhaust pipe.




– Unhook the track control arm out of the steering joint.
as well.
– Remove the cap - where present - from assembly opening for

the converter nuts.
Caution
If not all 3 nuts are unscrewed from the torque converter, the
torque converter is pulled out when removing the gearbox from
the engine!

50 mm.
– Position gearbox mount - 3282- on the engine/gearbox jack -
V.A.G 1383A- .

– Install the gearbox mount - 3282- as follows:

• Move the engine/gearbox jack - V.A.G 1383A- with gearbox
mount - 3282- underneath the gearbox-1-.
• Set the engine/gearbox jack - V.A.G 1383A- with gearbox
mount - 3282- in such a way that the spindles -A- and -B- face
ahead in the driving direction.
• Insert the support -2- into the groove of the oil sump all the
way around as shown.
• Lock the bolts -3- into the countersink on the gearbox, front
right.
– Screw in the support with bolts - VAS 3282/29- into the rear
bore for pendulum support at the gearbox -1-.
– Support the gearbox by carefully raising the engine/gearbox

jack - V.A.G 1383A- .
– Remove the connecting screws for the engine/gearbox
-A-,-B- and then all the remaining connecting screws.
Installation positions of the engine/gearbox screws
Caution
When removing the gearbox, pay attention to the torque con‐

verter.
Prevent it from falling out.
– Push gearbox off engine, simultaneously press the torque

converter against the ATF pump -arrow-.
rier downwards.
Note
Change the gearbox position at the spindles of the gearbox mount

- 3282- when lowering.

– Prevent the torque converter from falling off, e.g. using a wire
-A-.
Note
The depiction of the torque converter and gearbox may vary.
3.1.5 Removing gearbox (Yeti)

♦ Supporting device - T30099- with -10-222A/31-
♦ Supporting device - T40091/3-
♦ Hook - MP9-200/10-
♦ Adapter - MP9-200/18-
♦ Surface - T30119-
♦ Engine and gearbox jack - V.A.G 1383A-
♦ Hose clamp - MP7-602 (3094)-
♦ Bolt - VAS 3282/29-
♦ Wedge - T10161-
♦ Screw plug set for engine , e.g. -VAS 6122-
♦ Pliers for spring strap clamps
Note



Caution

components.

gr. 27 .
bracket -2-.

Note


– Mark coolant hoses of ATF radiator in order to prevent inter‐
changing when installing.
Caution

overpressure.


MP7-602 (3094)- .
– Seal support of ATF radiator and coolant hoses with suitable
stops from the screw plug set for engine , e. g. -VAS 6122- .
sible from the top.
– Mount the supporting device - T30099- with base as shown.


and -2-.
gr. 50 .
66 .


– Release screws -arrows- at holder for pre-exhaust pipe.



– Unhook the track control arm out of the steering joint.

as well.
– Remove the cap - where present - from assembly opening for

the converter nuts.
Caution
If not all 3 nuts are unscrewed from the torque converter, the
torque converter is pulled out when removing the gearbox from
the engine!

50 mm.
– Position gearbox mount - 3282- on the engine/gearbox jack -
V.A.G 1383A- .
– Install the gearbox mount - 3282- as follows:

• Move the engine/gearbox jack - V.A.G 1383A- with gearbox
mount - 3282- underneath the gearbox-1-.
• Set the engine/gearbox jack - V.A.G 1383A- with gearbox
mount - 3282- in such a way that the spindles -A- and -B- face
ahead in the driving direction.
• Insert the support -2- into the groove of the oil sump all the
way around as shown.
• Lock the bolts -3- into the countersink on the gearbox, front
right.

– Screw in the support with bolts - VAS 3282/29- into the rear
bore for pendulum support at the gearbox -1-.
– Support the gearbox by carefully raising the engine/gearbox
jack - V.A.G 1383A- .
– Remove the connecting screws for the engine/gearbox
-A-,-B- and then all the remaining connecting screws.
Installation positions of the engine/gearbox screws
Caution
When removing the gearbox, pay attention to the torque con‐

verter.
Prevent it from falling out.
– Push gearbox off engine, simultaneously press the torque

converter against the ATF pump -arrow-.
rier downwards.
Note
Change the gearbox position at the spindles of the gearbox mount

- 3282- when lowering.
– Prevent the torque converter from falling off, e.g. using a wire
-A-.
Note
The depiction of the torque converter and gearbox may vary.

following:

Note
♦ Replace the self-locking nuts and screws when undertaking

assembly work.
Parts .
♦ Before installing the gearbox one should ensure that the tor‐
que converter is correctly installed in the gearbox
⇒ “1.4 Installing the torque converter”, page 18 .

Caution

– Inspect ATF level, if necessary top up with ATF

⇒ “4 ATF”, page 147 .
necessary
ble”, page 55 .
– Check coolant level in the cooling system ⇒ Engine; Rep. gr.
19 .

3.3 Tightening torques

⇒ “3.3.1 Tightening torques Octavia II”, page 134
⇒ “3.3.2 Tightening torques Superb II”, page 136
⇒ “3.3.3 Tightening torques Fabia II”, page 137
⇒ “3.3.4 Tightening torques Roomster”, page 139
⇒ “3.3.5 Tightening torques Rapid”, page 140
⇒ “3.3.6 Tightening torques Rapid Indie”, page 142
⇒ “3.3.7 Tightening torques Octavia llI”, page 143
⇒ “3.3.8 Tightening torques Yeti”, page 144
3.3.1 Tightening torques Octavia II

Gearbox to engine
Pos. Screw Piece Nm
1 M12 x 55 1 80
2 M12 x 55 1 80
31) M12 x 155 + M8 x 16 1 80
41) M12 x 165 + M8 x 16 1 80
5 M10 x 65 1 40
6 M10 x 55 1 40
7 M10 x 55 1 40
8 M12 x 100 1 80
A Dowel sleeves
1) Screw with threaded pin M8. This screw also fastens the starter.
Vehicles with 1.6 l/85 kW FSI engine

Gearbox to engine
Pos. Screw Piece Nm
1 M12 x 55 1 80
2 M12 x 55 1 80
3 M12 x 55 1 80
41) M12 x 165 + M8 x 16 1 80
5 M12 x 80 1 80
6 M10 x 50 1 40
7 M10 x 50 1 40
8 M12 x 80 1 80
A Dowel sleeves
Note
The second fixing screw for starter on gearbox (M12 x 55 + M8 x

10, tightening torque 80 Nm) is not shown in this illustration.

Vehicles with 2.0 l/110 kW FSI engine

Gearbox to engine
Pos. Screw Piece Nm
1 M12 x 55 1 80
2 M12 x 55 1 80
31) M12 x 155 + M8 x 16 1 80
41) M12 x 165 + M8 x 16 1 80
5 M10 x 65 1 40
6 M10 x 55 1 40
7 M10 x 55 1 40
8 M12 x 85 1 80
A Dowel sleeves
Vehicles with 1.8 l/112 kW TFSI engine

Gearbox to engine
Pos. Screw Piece Nm

1 M12 x 55 1 80
2 M12 x 55 1 80
31) M12 x 155 + M8 x 16 1 80
41) M12 x 155 + M8 x 16 1 80
5 M10 x 65 1 40
6 M10 x 55 1 40
7 M10 x 55 1 40
8 M12 x 70 1 80
A Dowel sleeves
Note


Gearbox console -A- to gearbox, 40 Nm + torque a further
screws 1) -1- 90° (1/4 turn)
Gearbox console -A- to gearbox 60 Nm + torque a further
mounting, screws 1) -2- 90° (1/4 turn)
Note
Install engine/gearbox mounting free of stress ⇒ Engine; Rep.

gr. 10 .


Torque converter to drive plate, 6 nuts 57 Nm
1) -arrow-
1) Replace nuts ⇒ Electronic Catalogue of Original Parts .

Component Nm
Screws/nuts M6 10
M8 20
M10 45
M12 65
3.3.2 Tightening torques Superb II

Vehicles with 1.8 l/112 kW TFSI engine
Gearbox to engine
Pos. Screw Piece Nm
1 M12 x 55 1 80
2 M12 x 55 1 80
31) M12 x 155 + M8 x 16 1 80
41) M12 x 155 + M8 x 16 1 80
5 M10 x 65 1 40
6 M10 x 55 1 40
7 M10 x 55 1 40
8 M12 x 70 1 80
A Dowel sleeves

screws 1) -1- 90° (1/4 turn)
Note

gr. 10 .


1) -arrow-

Component Nm
Screws/nuts M6 10
M8 20
M10 45
M12 65
3.3.3 Tightening torques Fabia II

Gearbox to engine
Pos. Screw Piece Nm
1 M12 x 55 1 80
2 M12 x 55 1 80
3 M12 x 55 1 80
41) M12 x 165 + M8 x 16 (up to 11.2010) 1 80
M12 x 155 + M8 x 16 (as of 12.2010)
5 M12 x 80 1 80
6 M10 x 35 1 40
7 M10 x 35 1 40
8 M12 x 80 1 80
A Dowel sleeves
Note



screws 1) -1- 90° (1/4 turn)
Note

gr. 10 .

1) -arrow-

Component Nm
Screws/nuts M6 10
M8 20
M10 45
M12 65

3.3.4 Tightening torques Roomster

Gearbox to engine
Pos. Screw Piece Nm
1 M12 x 55 1 80
2 M12 x 55 1 80
3 M12 x 55 1 80
41) M12 x 165 + M8 x 16 (up to 11.2010) 1 80
M12 x 155 + M8 x 16 (as of 12.2010)
5 M12 x 80 1 80
6 M10 x 35 1 40
7 M10 x 35 1 40
8 M12 x 80 1 80
A Dowel sleeves

Note


screws 1) -1- 90° (1/4 turn)
Note

gr. 10 .


1) -arrow-

Component Nm
Screws/nuts M6 10
M8 20
M10 45
M12 65
3.3.5 Tightening torques Rapid

Gearbox to engine
Pos. Screw Piece Nm
1 M12 x 55 1 80
2 M12 x 55 1 80
3 M12 x 55 1 80
41) M12 x 165 + M8 x 16 (up to 11.2010) 1 80
M12 x 155 + M8 x 16 (as of 12.2010)
5 M12 x 80 1 80
6 M10 x 35 1 40
7 M10 x 35 1 40
8 M12 x 80 1 80
A Dowel sleeves
Note



Gearbox to engine
Pos. Screw Piece Nm
s
1 M12 x 55 1 80
2 M12 x 55 1 80
31) M12 x 155 + M8 x 16 1 80
41) M12 x 170 + M8 x 16 1 80
5 M10 x 65 1 40
6 M10 x 55 1 40
7 M10 x 55 1 40
8 M12 x 70 1 80
9 M12 x 70 1 80
A Dowel sleeves

Gearbox console -A- to gearbox, 40 Nm + 90°
screws 1) -1-
Gearbox console -A- to gearbox 60 Nm + 90°
mounting, screws 1) -2-
Note

gr. 10 .

1) -arrow-

Component Nm
Screws/nuts M6 10
M8 20
M10 45
M12 65

3.3.6 Tightening torques Rapid Indie

Gearbox to engine
Pos. Screw Piece Nm
1 M12 x 55 1 80
2 M12 x 55 1 80
3 M12 x 55 1 80
41) M12 x 165 + M8 x 16 (up to 11.2010) 1 80
M12 x 155 + M8 x 16 (as of 12.2010)
5 M12 x 80 1 80
6 M10 x 35 1 40
7 M10 x 35 1 40
8 M12 x 80 1 80
A Dowel sleeves

Note


screws 1) -1-
Note

gr. 10 .


1) -arrow-

Component Nm
Screws/nuts M6 10
M8 20
M10 45
M12 65
3.3.7 Tightening torques Octavia llI

Gearbox to engine
Pos. Screw Piece Nm
s
1 M12 x 55 1 80
2 M12 x 55 1 80
31) M12 x 155 + M8 x 16 1 80
41) M12 x 170 + M8 x 16 1 80
5 M10 x 65 1 40
6 M10 x 55 1 40
7 M10 x 55 1 40
8 M12 x 70 1 80
9 M12 x 70 1 80
A Dowel sleeves

screws 1) -1-
Note

gr. 10 .


1) -arrow-

Component Nm
Screws/nuts M6 10
M8 20
M10 45
M12 65
3.3.8 Tightening torques Yeti

Gearbox to engine
Pos. Screw Piece Nm
s
1 M12 x 55 1 80
2 M12 x 55 1 80
31) M12 x 155 + M8 x 16 1 80
41) M12 x 170 + M8 x 16 1 80
5 M10 x 65 1 40
6 M10 x 55 1 40
7 M10 x 55 1 40
8 M12 x 70 1 80
9 M12 x 70 1 80
A Dowel sleeves

screws 1) -1-
Note

gr. 10 .


1) -arrow-

Component Nm
Screws/nuts M6 10
M8 20
M10 45
M12 65
3.4 Transporting an automatic gearbox

♦ Shackle - 10-222A/12-
Work procedure
For transporting the automatic gearbox, the shackle - 10-222A/
12- can be used.
– Secure torque converter against dropping out when transport‐
ing.
– Attach shackle - 10-222A/12- to gearbox housing.
3.5 Attaching gearbox to assembly stand

♦ Engine and gearbox mount - MP1-202- (as -VW540- , however
for assembly stand -MP9-101- )

– Attach gearbox to engine and gearbox mount - MP1-202-

-arrows-.
– The workshop crane can be used
⇒ “3.4 Transporting an automatic gearbox”, page 145 for in‐
serting.
WARNING
The centre of gravity of the gearbox is outside the turning cen‐

tre at the assembly stand. For turning the gearbox, a second
mechanic must hold the gearbox housing in order to avoid un‐
controlled movement.
Note
If the gearbox filled with oil on the assembly stand is turned with
the oil sump upwards, then the ventilation holes for the gearbox
housing must be sealed with plugs.


4 ATF
⇒ “4.1 Check the ATF level level and top up”, page 147
⇒ “4.2 Change ATF or top up after repair”, page 152
4.1 Check the ATF level level and top up

♦ ATF filling system - V.A.G 1924-
♦ Adapter for oil filling - VAS 6262- or -VAS 6262A-
♦ Quick coupling - VAS 6262/2-
♦ Protective gloves
Test conditions
• Gearbox must not be in the emergency running mode.
• Vehicle on level ground.
• With selector lever in “P” position, let the engine idle.
• Air conditioning and heating switched off.

• ⇒ Vehicle diagnostic tester connected, function “vehicle self-
diagnosis” and “vehicle system” “02 - gearbox electronics”
selected.
• The ATF temperature must not be higher than 30 °C for be‐
ginning the test, if necessary first the gearbox must be cooled
down.
Note
♦ The ATF temperature is read off at the ⇒ Vehicle diagnostic

tester.
♦ The ATF level changes with ATF temperature.
♦ Checking ATF level when ATF temperature is too low may re‐
sult in over-filling.
♦ Checking ATF level when ATF temperature is too high may
result in under-filling.
♦ Both over-filling as well as under-filling affect gearbox opera‐
tion.
matic gearbox 09G ⇒ Electronic Catalogue of Original Parts
♦ Other oils can lead to functional problems or to failure of the
gearbox.
♦ When topping up with ATF, shake the oil reservoir thoroughly
before opening.
4. ATF 147
Shorten the vent pipe of the adapter for oil filling - VAS 6262A-
– Shorten the vent pipe to the dimension -a-, so that it does not
touch the bottom of certain ATF bottles.
Dimension -a-: 210 mm
Note
The dimension -a- is measured on the shaft (starting with the

green area in the detail) of the adapter for oil filling - VAS 6262A- .
Caution
♦ The filling hose and the adapter - VAS 6262- or -

VAS 6262A- must be clean and the ATF must not be
mixed with other oils!
Inspection

Note
♦ The ATF level is checked at the ATF inspection plug.

♦ The ATF level is correct, if a small amount of fluid flows out at
the ATF inspection plug when the ATF temperature is between
35° and 45 °C (in hot countries 50 °C) (caused by the ïncrease
of the fluid level due to the heat).
– Fill ATF filling system - V.A.G 1924- with ATF for the automatic
gearbox 09G.
Caution
The ATF filling system must be clean and the ATF for automatic
gearbox 09G must not be mixed with other ATF oils!

– Run the vehicle on a four-column lift platform or over a work‐
gr. 50 .
– Position drip tray, e.g. -VAS 6208- under the gearbox.
WARNING
♦ When working close to the radiator, always keep an ade‐

quate distance from the radiator fan - risk of injury!
♦ The radiator fan can switch on automatically.
– Start engine and run in idle.

WARNING
– If an ATF temperature of 35 °C is achieved, unscrew the ATF

inspection plug -A-.
– Always replace gasket ring -arrows- for ATF inspection plug

First of all the ATF in the overflow tube -arrow 2- drains off.
If more ATF drips out of the ATF inspection opening (approx. 1
drop per second) via the overflow tube before the ATF has
reached 40°C, the ATF level is correct.
tighten to tightening torque
⇒ “1.2 Summary of components - oil pan, oil strainer, slide
valve body, internal wiring looms”, page 165 .
This completes the ATF level inspection.
Note

plug must be closed again.
If no ATF flows out at the ATF inspection opening up to 45 °C, the

ATF must be filled up
– End function “08 - read measured value block”.
– Tip “06 - End output”.
– Switch off ignition and disconnect the vehicle diagnostic tester.
Fill with ATF
4. ATF 149
Note
♦ Pay attention to all the notes and test conditions

⇒ page 147 .
♦ The ATF filler tube -arrow- is no longer available on gearboxes
For gearbox with filler tube (only vehicles Octavia II up to 05.2006)
– Lever off cap -arrow- securing the screw plug with a screw‐
driver.
Note
The filler tube is located at the front of the gearbox under the
starter.

– Always replace the cap, because the cap catch is destroyed
– Pull screw plug from the filler tube.
– Hook the hook of the ATF filling system - V.A.G 1924- into the
opening of the filler tube.
Note
Too much or too little ATF filling impairs the gearbox function.
– Continue to fill the ATF with -V.A.G 1924- until a temperature

of between 35 °C and 45 °C flows out of the inspection opening
via the overflow tube -arrow 2-.
– Allow all excess ATF to drip out only until it starts to drain off.
For gearbox without filler tube (vehicles up as of 06.2006)

– Screw in the adapter for ATF oil filling - VAS 6262/2- by hand
in the location of the gearbox inspection plug -arrow 1- and
connect adapter for oil filling - VAS 6262- or -VAS 6262A- .
– Shake the ATF reservoir before opening.
Note
Before screwing in the adapter for oil filling at the ATF reservoir,
check the length of the vent pipe and shorten if necessary
⇒ page 148 .
– Fill with 1 liter of ATF.

– Remove adapter for oil filling - VAS 6262- from adapter for ATF
oil filling - VAS 6262/2- .
– Observe whether ATF flows out of the opening of the adapter
for ATF oil filling - VAS 6262/2- .
If ATF flows out of the opening of the adapter for ATF oil filling -
VAS 6262/2- , the ATF level is correct.

– Allow all excess ATF to drip out until it starts to drain off.
If no ATF flows out of the opening of the adapter for ATF oil filling
- VAS 6262/2- but only drips, the ATF level is not O.K. and ATF
must be filled up.
– Unscrew adapter for ATF oil filling - VAS 6262/2- .
tighten to tightening torque
This completes the ATF level inspection.
Note

plug must be closed again, if necessary switch off the engine,
allow the gearbox to cool down and repeat the check.
– Insert the screw plug in the filler tube.

– Fit new safety cap -arrow- and lock in place.
Caution
Always replace the cap. The cap secures the screw plug ⇒

4. ATF 151
4.2 Change ATF or top up after repair

• Engine switched off.
♦ ATF filling system - V.A.G 1924-
♦ Adapter for oil filling - VAS 6262- or -VAS 6262A-
♦ Quick coupling - VAS 6262/2-
♦ Catch pan , e.g. -VAS 6208-
Note

shop pit, so that it will be kept horizontal.

gr. 50 .
Note
♦ Observe the disposal instructions.

♦ The engine must not be started without ATF and the vehicle
must not be towed!
WARNING
♦ When working close to the radiator, always keep an ade‐

quate distance from the radiator fan - risk of injury!
♦ The radiator fan can switch on automatically.
Drain ATF
WARNING


– Release the overflow tube -C- (5 mm Allen key) and drain re‐
maining ATF.
– Drain the ATF.
– Install overflow tube -C- with 5mm Allen key and tighten to
tightening torque
Fill with ATF
Note
♦ Pay attention to all the notes and test conditions

⇒ page 147 .
♦ The ATF filler tube -arrow- is no longer available on gearboxes

– Lever off cap -arrow- securing the screw plug with a screw‐
driver.
Note
The filler tube is located at the front of the gearbox under the
starter.
– Always replace the cap, because the cap catch is destroyed

– Pull off screw plug from the filler tube.
– Hook the hook of the ATF filling system - V.A.G 1924- into the
opening of the filler tube.
– Pour in 4 liters of ATF with ATF filling system - V.A.G 1924- .
For gearbox without filler tube (vehicles up as of 06.2006)
4. ATF 153
– Screw in the adapter for ATF oil filling - VAS 6262/2- by hand
in the location of the gearbox inspection plug -arrow 1- and
connect adapter for oil filling - VAS 6262- or -VAS 6262 A- .
– Shake the ATF reservoir before opening.
Note
Before screwing in the adapter for oil filling at the ATF reservoir,
check the length of the vent pipe and shorten if necessary
⇒ page 148 .
– Fill with 3 litres of ATF (when changing).

– Remove adapter for oil filling - VAS 6262- from adapter for ATF
oil filling - VAS 6262/2- .
– Unscrew adapter for ATF oil filling - VAS 6262/2- .
– Tighten ATF inspection plug by hand.

– Start engine.
– With the brake pedal actuated shift through all selector lever
positions “P, R, N, D, S” at idle speed, leaving the lever in each
position for about 10 seconds.
⇒ “4.1 Check the ATF level level and top up”, page 147 .

5 ATF coolant circuit

⇒ “5.1 ATF radiator - Summary of components”, page 155
⇒ “5.2 Removing and installing ATF radiator”, page 159
5.1 ATF radiator - Summary of components

⇒ “5.1.1 ATF radiator - Summary of components Octavia II”, page
155
⇒ “5.1.2 ATF radiator - Summary of components Octavia II for
gearboxes with identification characters KGV, KGU”, page 156
⇒ “5.1.3 ATF radiator - Summary of components Superb II for
gearboxes with identification characters KGV, KGU”, page 157
⇒ “5.1.4 ATF radiator - Summary of components Octavia III, Yeti”,
page 158
⇒ “5.1.5 ATF radiator - Fabia II, Rapid, Roomster”, page 159
5.1.1 ATF radiator - Summary of components Octavia II

1 - Gearbox housing
2 - O-ring
Parts
3 - ATF radiator
❑ Check fitting position
⇒ Fig. ““Fitting location
of ATF radiator”“ ,
page 156
stalling ATF radiator”,
page 159
4 - O-ring
Parts
5 - Washer
6 - Disc spring
❑ Fitting position: Must
must point upwards.
7 - Screw
❑ 36 Nm
5. ATF coolant circuit 155

Fitting location of ATF radiator

The peg -arrow B- must be positioned in the recess in the gearbox
housing.
5.1.2 ATF radiator - Summary of components Octavia II for gearboxes with iden‐
tification characters KGV, KGU
1 - ATF radiator
page 159
2 - Support
❑ for selector lever control
cable
3 - Screw
❑ for ATF radiator
❑ 12 Nm
4 - O-ring
Parts
5 - Screw
❑ for adapter plate
❑ 25 Nm
6 - Adapter plate
7 - O-ring
Parts
8 - Gearbox housing

5.1.3 ATF radiator - Summary of components Superb II for gearboxes with iden‐
tification characters KGV, KGU
1 - ATF radiator
page 159
2 - Support
❑ for selector lever control
cable
3 - Screw
❑ for ATF radiator
❑ 12 Nm
4 - O-ring
Parts
5 - Screw
❑ for adapter plate
❑ 25 Nm
6 - Adapter plate
7 - O-ring
Parts
8 - Gearbox housing

5.1.4 ATF radiator - Summary of components Octavia III, Yeti
1 - Gearbox housing
2 - O-ring
tronic Catalogue of
Original Parts
3 - ATF radiator
page 159
4 - Screw
❑ 20 Nm

5.1.5 ATF radiator - Fabia II, Rapid, Roomster
1 - Gearbox housing
2 - O-ring
Parts
3 - ATF radiator
❑ Check fitting position
⇒ Fig. ““Fitting location
of ATF radiator”“ ,
page 156
page 159
4 - O-ring
Parts
5 - Washer
6 - Disc spring
❑ Fitting position: Must
must point upwards.
7 - Screw
❑ 36 Nm
5.2 Removing and installing ATF radiator

⇒ “5.2.1 Removing and installing ATF radiator (Fabia, Rapid,
Roomster, Octavia II, Superb)”, page 159
⇒ “5.2.2 Remove and install ATF radiator (Octavia IlI)”,
page 161
⇒ “5.2.3 Removing and installing ATF radiator (Yeti) ”,
page 162
5.2.1 Removing and installing ATF radiator

(Fabia, Rapid, Roomster, Octavia II, Su‐
perb)
♦ Hose clamps - MP7-602 (3094)-
Removing

WARNING


gr. 27 .
– Mark hoses of ATF radiator in order to prevent interchanging
when installing.
Note



– Remove the ATF radiator -1- from the gearbox -arrow A-.
Install
following:
– Replace O-rings of ATF radiator ⇒ Electronic Catalogue of
Original Parts .
– The disc spring Pos. 6 must be installed in such a way that it
rests on the washer Pos. 5 and the curved side points upwards
⇒ “5.1 ATF radiator - Summary of components”, page 155 .
– When installing the ATF radiator -1- position the peg
-arrow B- in the recess in the gearbox housing.

– Connect hoses of ATF radiator according to the markings onto

the ATF radiator.
Note

– Check coolant level in the cooling system ⇒ Engine; Rep. gr.

19 .
– Inspecting ATF level and if necessary topping up
Tightening torques
Component Nm
ATF radiator to gearbox ⇒ “5.1 ATF radiator -
Summary of compo‐
nents”, page 155

5.2.2 Remove and install ATF radiator (Octa‐
via IlI)
♦ Hose clamp - MP7-602 (3094)-
Removing
Caution


gr. 27 .
when installing.
– Unlock the quick-release lock -2- and unhook the selector lev‐
er control cable -1-.
Caution

overpressure.


MP7-602 (3094)- .
– Unscrew screws-arrows- and remove ATF radiator.

Install
following:
• Always replace O-rings of ATF radiator ⇒ Electronic Cata‐
• Connect the coolant hoses to the ATF radiator using the mark‐
ings made during removal.
• Check coolant level in the cooling system ⇒ Engine; Rep. gr.
19 .
• Inspecting ATF level and if necessary topping up
⇒ page 147 .
gr. 27 .
– Install engine cover ⇒ engine; Rep. gr. 10 .
Tightening torques
Component Nm
ATF radiator to gearbox ⇒ “5.1 ATF radiator -
Summary of compo‐
nents”, page 155
5.2.3 Removing and installing ATF radiator

(Yeti)
♦ Hose clamp - MP7-602 (3094)-
Removing
Caution

components.


gr. 27 .
when installing.
– Unlock the quick-release lock -2- and unhook the selector lev‐
er control cable -1-.
Caution

overpressure.

MP7-602 (3094)- .

– Unscrew screws-arrows- and remove ATF radiator.

Install
following:
• Always replace O-rings of ATF radiator ⇒ Electronic Cata‐
• Connect the coolant hoses to the ATF radiator using the mark‐
ings made during removal.
• Check coolant level in the cooling system ⇒ Engine; Rep. gr.
19 .
• Inspecting ATF level and if necessary topping up
⇒ page 147 .
gr. 27 .
For the vehicles Yeti
– Install mounting bracket with automatic gearbox control unit -
J217- .

– Install engine cover ⇒ engine; Rep. gr. 10 .
Tightening torques
Component Nm
ATF radiator to gearbox ⇒ “5.1 ATF radiator - Sum‐
mary of components”,
page 155
Control unit holder at battery tray 5

38 – Gears, control
1 Removing and installing oil pan, oil
filter, slide valve body and internal
wiring looms
⇒ “1.1 General Instructions”, page 165
⇒ “1.2 Summary of components - oil pan, oil strainer, slide valve
body, internal wiring looms”, page 165
⇒ “1.3 Components at wiring loom of 8-pin plug”, page 168
⇒ “1.4 Removing and installing oil pan”, page 168
⇒ “1.5 Removing and installing the oil filter”, page 170
⇒ “1.6 Removing and installing the slide valve body”, page 171
⇒ “1.7 removing and installing wiring loom with 14-pin plug”, page
180
⇒ “1.8 Removing and installing wiring loom with 8-pin plug and
integrated gearbox oil temperature sender G93 ”, page 181
⇒ “1.9 Removing and installing the gearbox input r.p.m. sender
G182 ”, page 183
⇒ “1.10 Removing and installing the gearbox output r.p.m. sender
G195 ”, page 184
1.1 General Instructions
WARNING
been removed or without filling with ATF in the gearbox.
Note

♦ ⇒ “2 Information and repair instructions for the automatic gear‐
box 09G”, page 12 .
♦ Coat O-rings and gasket rings with ATF. Other types of lubri‐
cant will cause the gearbox hydraulic control system to mal‐
function.
♦ The slide valve body and the wiring looms with 8-pin and 14-
pin plug can also be removed with the installed gearbox.
1.2 Summary of components - oil pan, oil strainer, slide valve body, internal
wiring looms
1 - ATF level check screw

❑ Replace gasket ring
Pos. 2
❑ Inspecting ATF level
and if necessary topping
up
⇒ “4.1 Check the ATF
level level and top up”,
page 147
❑ 27 Nm
2 - Sealing ring
Parts
3 - Overflow tube
❑ screw with 5 mm Allen
key into the oil pan
❑ 2 Nm
4 - Oil pan
stalling oil pan”,
page 168
5 - Screw
the oil pan with the oil
pan gasket to the gear‐
box housing
❑ Tighten oil pan screws
crosswise in several
stages
❑ 7 Nm
6 - Gasket
7 - Magnet
❑ 2 magnets in the beads of the oil pan
❑ clean before installation
8 - Screw
❑ 3 pieces for attaching oil strainer to slide valve body
❑ 11 Nm
9 - Oil filter
❑ ⇒ “1.5 Removing and installing the oil filter”, page 170
10 - Screw
❑ for fastening power-steering gear to gearbox
❑ 12 pieces of different length
⇒ Fig. ““Screw lengths and fitting position at the slide valve body”“ , page 176
❑ pay attention to assignment ⇒ Electronic catalogue of original parts
❑ 8 Nm + 90°
❑ Replace after disassembly
12 - Screw
❑ 6 Nm
166 Rep. gr.38 - Gears, control


14 - Screw
❑ 7 Nm
17 - ATF bleeder
18 - ATF radiator
❑ ⇒ “5.2 Removing and installing ATF radiator”, page 159

20 - Sealing ring
21 - ATF drain plug
❑ 40 Nm
22 - Lever
❑ for inside selector lever shaft at the slide valve body
23 - Washer
24 - Nut
❑ Pay attention to fitting location of the nut
⇒ “1.6 Removing and installing the slide valve body”, page 171
❑ 10 Nm
25 - Large spring
26 - Small spring
27 - Shock absorber piston
❑ with O-ring at connector
G93 ”, page 181
❑ ⇒ “1.3 Components at wiring loom of 8-pin plug”, page 168
29 - Screw
❑ 6 Nm
❑ with O-ring at connector
31 - Screw
❑ 6 Nm
1.3 Components at wiring loom of 8-pin plug

1 for automatic gearbox -
G193-
❑ no longer available as of
12.2004
2 - Plug for gearbox input
r.p.m. sender - G182-
3 - Cables for gearbox input
2 for automatic gearbox -
G194-
❑ no longer available as of
12.2004
5 - Cables for gearbox output
6 - Plug for gearbox output
r.p.m. sender - G195-
7 - Holder for the gearbox oil
temperature sender - G93-
8 - Gearbox oil temperature
sender - G93-
❑ is integrated in the wir‐
ing loom -Pos. B-
A - 8-pin plug
stalling wiring loom with
8-pin plug and integra‐
ted gearbox oil temper‐
ature sender G93 ”,
page 181
C - Wiring harness bracket
D - Screw
❑ 7 Nm
E - Screw
❑ 7 Nm
1.4 Removing and installing oil pan

♦ Catch pan , e.g. -VAS 6208-
Note
⇒ “2 Information and repair instructions for the automatic gearbox

09G”, page 12 .

Removing
gr. 50 .
WARNING
– Unscrew ATF inspection plug and ATF drain plug-A-.

– Release the overflow tube -C- (5 mm Allen key) and drain re‐
maining ATF.
– Loosen the 8 screws -arrows- of the oil pan crosswise.
WARNING
There is still ATF in the oil pan because not all of it could be
drained via the drain opening.
– Remove oil pan together with the oil pan gasket.

Install
following points:
– Clean the two magnets Pos. 7 in the oil pan beads
valve body, internal wiring looms”, page 165 . Take care that
the full surface of the magnets rests against the oil pan.
Note
The magnets must be absolutely fitted on the provided points in

the oil pan.
– Clean gaskets and sealing surfaces and eliminate residues of

oil.
– Pay attention to correct fitting of oil pan gasket.
– When positioning the oil pan no cables must be trapped.
– Screw in the 8 screws of the oil pan crosswise.
– Replace gasket ring of ATF drain plug ⇒ Electronic Catalogue
of Original Parts .
– Install overflow tube -C- (with 5 mm Allen key).

– Top up with ATF and inspect ATF level ⇒ “4 ATF”, page 147 .
• Gasket ring -B- of ATF inspection plug must be replaced after
the ATF level inspection ⇒ Electronic Catalogue of Original
Parts .
Tightening torques
Component Nm
Overflow in oil pan ⇒ “1.2 Summary of components - oil pan, oil strainer, slide valve
ATF inspection plug to oil pan ⇒ “1.2 Summary of components - oil pan, oil strainer, slide valve
Oil pan to gearbox housing 1) ⇒ “1.2 Summary of components - oil pan, oil strainer, slide valve
1) Tighten crosswise in stages.
1.5 Removing and installing the oil filter
Note

09G”, page 12 .
Removing
– Removing the oil pan
⇒ “1.4 Removing and installing oil pan”, page 168 .
– Release screws -arrows- for oil strainer.
– Take the oil filter -A- out of the slide valve body.
Install
– Thinly coat gaskets on the intake collar of the oil filter (reverse
side) with ATF.
Note
If the gaskets on the reverse side of the oil filter for the slide valve
body are defective or no longer properly attached to the oil filter,
the oil filter must be replaced.
– Position oil filter on the slide valve body and screw in screws
-arrows- to tightening torque, and tighten

1.6 Removing and installing the slide valve

body
WARNING
been removed or without ATF filling.
Note
♦ The slide valve body as well as the wiring looms can be re‐
moved even if the gearbox is installed.
♦ Insert gasket rings with ATF. The use of other lubricants leads
to the malfunction of the gearbox hydraulic control system.
♦ Do not use fluffy cloths.

Removing
WARNING


– Removing oil filter
⇒ “1.5 Removing and installing the oil filter”, page 170 .
– Make a sketch by hand in the same way as for the illustration

with all the solenoid valves and their plug connections and
mark all the plugs with the corresponding colour. Also mark
the related cables with the corresponding colours.
Note
♦ This sketch is absolutely necessary, so that the plugs on the

solenoid valves are not inadvertently interchanged when re-
installing the slide valve body.
♦ Under certain circumstances an interchange of the plugs could
– With a small screwdriver, lever up the catches on the connec‐

tors at the solenoid valves -Pos. 1...8- and pull out the con‐
nectors.
Note
In case of damage of the plug connections, the entire wiring har‐

ness with 14-pin plug or the slide valve body with the solenoid
valves must be replaced.

– Unscrew the 3 screws -D- and -E-.

Carefully disconnect the following plug connections:
Note
Plug connection -1- and plug connection -4- are not available as
of 12.2004.
– Plug connection -1- for hydraulic pressure sender - G193- .

– Plug connection -2- for gearbox input r.p.m. sender - G182- .
– Plug connection -4- for hydraulic pressure sender 2 - G194- .
– Plug connection -6- for gearbox output r.p.m. sender - G195- .
– Carefully pull the gearbox oil temperature sender - G93- -8-
together with the bracket -7- out of the slide valve body.
Note
When re-installing, pay attention to the attachment of the bracket

on the gearbox oil temperature sender - G93- .
– Unhook wiring loom at bracket -C-.
Note
In case of damage of the plug connections (depending on the

defective plugs), the wiring loom with 8-pin plug or the gearbox
input r.p.m. sender - G182- or the gearbox output r.p.m. sender -
G195- must be replaced.
– Remove gearshift lever -A- on the gearshift shaft.
Note

switch - F125- .
♦ Pay attention to the slide valve in the slide valve body, in which
the gearshift lever is engaged, so that it is not damaged.
– Loosen the fixing screws -arrows- of the slide valve body

crosswise and carefully remove the slide valve body.
– Remove the bracket -1- and -2-.
3 - Designation of slide valve body, here e.g. “A2”

Note
♦ Observe when installing that the screws have different lengths

and must be replaced.
♦ Only the marked fixing screws -arrows- must be released.
♦ When releasing other screws the function of the slide valve
body can be impaired or the slide valve body splits.
♦ When removing the slide valve body, the shock absorber pis‐
ton -E- must be secured against dropping out or removed
together with both springs.
Install
Note
♦ The routing of the cables must be accurately observed, so that

when positioning the slide valve body they are not trapped or
damaged.

♦ Damaged or trapped cables must always be replaced.
– Route the wiring loom -C- (with 8-pin plug) according to the
illustration in the specified recess in the slide valve body.
• The wiring loom -C- must not rest against the planetary gear‐
box. The clearance -a- must be maintained, so that the wiring
loom is not chafed in the driving mode.
– Route the wiring looms -A-, -B- and -D- according to the illus‐
tration over the gearbox border.
– Make sure that the shock absorber piston -E- is installed in the
illustrated location in the gearbox.
Note
♦ If the shock absorber piston -E- was removed, is must be

cleaned together with both springs and installed according to
the illustration
valve body, internal wiring looms”, page 165 Pos. 27, Pos. 26
and Pos. 25.
♦ To do so insert both springs into each other, coat the outer wall
of the shock absorber piston and the opening in the gearbox
with ATF and insert all parts in the gearbox.
♦ Press the shock absorber piston in the gearbox and secure
against falling out, until the slide valve body is positioned.
– Position the slide valve body without force.
Screw lengths and fitting position at the slide valve body

• Wiring harnesses must not be trapped by the slide valve body,
trapped cables must always be replaced ⇒ Electronic Cata‐
– All fixing screws for slide valve body must be replaced ⇒
– Screw on by hand the bracket for the wiring loom -1- and -2-
with the corresponding screws.
– Tighten remaining screws for slide valve body -arrows- by
hand.
– Pay attention to the screw lengths:
Arrow - screw M6 × 21
Arrow A - screw M6 × 16
Arrow B - screw M6 × 28

Note
♦ If the cable -3- (for gearbox input rpm sender - G182- ) is too
ped by the slide valve body, then the slide valve body must be
removed again and the cable must be correctly routed.
♦ Trapped cables must be replaced ⇒ Electronic Catalogue of
Original Parts .
– Make sure that no cables are in fact trapped.

– After this, tighten the screws -arrows- for the slide valve body
from the outside to the inside to a final torque ⇒ page 180 .
– Hang the wiring loom in the bracket -B-.

– Position the gearshift lever -2- on the gearshift shaft -5-.
Note
Make sure that the pin of the gearshift lever -2- engages in the
slide valve -1- -arrow A-. If necessary the slide valve must be
moved accordingly out or into the slide valve body.
– Fit washer -4- and nut -3- onto the gearshift shaft.
Note
♦ The centering collar of the nut must point to the washer and
when screwing on catch in the washer.
♦ The wiring loom must be routed below the gearshift lever.
– Tighten nut to tightening torque

Note

switch - F125 - .
♦ Pay attention to the slide valve in which the gearshift lever on
the slide valve body is engaged so that it is not damaged.
– Connect plug connections -1...8- according to the sketches

made by hand on the solenoid valves during removal. Abso‐
lutely pay attention to the colours of the plug connections and
cables.
– Route the wiring harness -B- in the same way as the illustra‐
tion.

Caution
Under certain circumstances an interchange of the plugs could

– Mount plug -2-.

– Mount plug -6-.
Note
The connector lines must have the same colour as the respective
plugs.
– Position bracket -7- on the gearbox oil temperature sender -

G93- -8-.
– Insert gearbox oil temperature sender - G93- together with the
bracket in the slide valve body and tighten the screw (M6)
-E-.
– Fit plug connections -1- and -5- onto the pressure sender.
– Secure plug connections -2- and -6- with screws M5 -D- at

slide valve body.
Note
♦ If the cable -3- (for gearbox input rpm sender - G182- ) is too
ped by the slide valve body, then the slide valve body must be
removed again and the cable must be correctly routed.
♦ Trapped cables must be replaced.
– Hang the wiring harness -B- in the bracket -C- and route in the
same way according to the illustration.
– Install oil filter
Tightening torques
Component Nm
Slide valve body to gearbox housing (from out‐ ⇒ “1.2 Summary of components - oil pan, oil strainer, slide
side to the inside) valve body, internal wiring looms”, page 165
M6 screws, pay attention to different screw
lengths1)
Gearshift lever on gearshift shaft (nut) ⇒ “1.2 Summary of components - oil pan, oil strainer, slide
valve body, internal wiring looms”, page 165
Gearbox oil temperature sender - G93- ⇒ “1.2 Summary of components - oil pan, oil strainer, slide
(M6 screw with bracket to slide valve body) valve body, internal wiring looms”, page 165
2 x plug for the speed sender ⇒ “1.2 Summary of components - oil pan, oil strainer, slide
(M5 screw with bracket to slide valve body) valve body, internal wiring looms”, page 165
1) Replace bolts.
1.7 removing and installing wiring loom with

14-pin plug
Note

09G”, page 12 .
WARNING

Removing


– Remove the slide valve body
⇒ “1.6 Removing and installing the slide valve body”,
page 171 .
With gearbox installed
– Unplug the 14 pin plug connection -A- from gearbox plug.


ing.
through the wiring loom -D-.
Install
following points:
Parts .
box.
Tightening torque
Component Nm
Locking screw for 14-pin plug ⇒ “1.2 Summary of components - oil pan, oil strainer, slide valve
1.8 Removing and installing wiring loom

with 8-pin plug and integrated gearbox
oil temperature sender - G93-
⇒ “1.3 Components at wiring loom of 8-pin plug”, page 168 .
Note

09G”, page 12 .
WARNING

Removing
page 171 .
With gearbox installed
– Unplug the 8 pin plug connection -B- from gearbox plug.


ing.
through the wiring loom -C-.
Install
following points:
Parts .
box.
Tightening torque
Component Nm
Locking screw for 8-pin plug ⇒ “1.2 Summary of components - oil pan, oil strainer, slide valve

1.9 Removing and installing the gearbox in‐

put r.p.m. sender - G182-
Note

09G”, page 12 .
WARNING

Removing

page 171 .
– Pull gearbox input r.p.m. sender - G182- with cable -A- out of
the gearbox.
Install
following points:
– Carefully press gearbox input r.p.m. sender - G182- up to the
Tightening torque
Component Nm
Gearbox input r.p.m. sender - G182- to ⇒ “1.2 Summary of components - oil pan, oil strainer, slide valve
gearbox, M6 screw body, internal wiring looms”, page 165
1.10 Removing and installing the gearbox

output r.p.m. sender - G195-
Note

09G”, page 12 .
WARNING

Removing

page 171 .
– Pull gearbox output r.p.m. sender - G195- with cable -B- out
of the gearbox.
Install
following points:
– Moisten O-ring at sender with ATF.
– Carefully press gearbox output r.p.m. sende - G195- up to the
Tightening torque
Component Nm
Gearbox input r.p.m. sender - G195- to ⇒ “1.2 Summary of components - oil pan, oil strainer, slide valve
gearbox, M5 screw body, internal wiring looms”, page 165

2 Removing, installing and setting mul‐

ti-function switch - F125-
⇒ “2.1 Removing and installing the multi-function switch F125 ”,
page 185
⇒ “2.2 Setting multi-function switch F125 ”, page 187
2.1 Removing and installing the multi-func‐

tion switch - F125-
Removing
lever -6-, e.g using an open-end wrench, while ensuring that
the selector lever control cable does not get kinked.

Note
Do not release screw -2-.
– Unplug connector -5- at multi-function switch.

– Bend back the hooks of the circlip -2- using a screwdriver.
Note

– Remove nut -3- with washers -2- and -1-.

– Unscrew the 2 screws -B- and pull off the multi-function switch
-A- upwards over the gearshift shaft.
Install
following:
– Fit the multi-function switch - F125- onto the gearshift shaft.
– Tighten the fixing screws -B- for multi-function switch by hand.
– Fit washers -1-, -2- and nut -3- onto the gearshift shaft.
– Secure the nut by bending up the hooks to the circlip -2-.
Note

– Setting multi-function switch - F125-

⇒ “2.2 Setting multi-function switch F125 ”, page 187 .
– Install gearshift lever -1-.
Note
The gearbox must remain in the position “N”, if necessary shift

back into “N”.

– The plug -5- is placed onto the multi-function switch.

– Push selector lever control cable -1- onto the gearshift lever
-6-, while ensuring that the selector lever control cable does
not get kinked.
Note
Under some circumstances the gearshift lever must be shifted in

the correct position, in order to be able to push on the selector
– Inspect setting of selector lever control cable

ble”, page 55 .
Tightening torques
Component Nm
Multi-function switch - F125- to gearshift shaft 7
Gearbox shift lever to gearshift shaft 13

2.2 Setting multi-function switch - F125-

♦ Setting gauge - T10173-
lever -3-, e.g using an open-end wrench -2-, while ensuring
that the selector lever control cable does not get kinked.


– Loosen both screws -B-.
Note
Do not release the screws.
– Fit the setting gauge - T10173- onto the gearshift shaft.

– Turn the multi-function switch -A- until the peg of the plug
-arrow 1- engages in the groove of the setting gauge -
T10173- .
If the peg of the plug cannot engage into the groove of the setting
gauge, then the gearbox is no longer in the position “N”. In this
case, the gearbox must be shifted again with the setting gauge
into the position “N”:
To do so turn the setting gauge to the front or to the rear, until the
peg of the plug -arrow 1- can engage into the groove of the setting
gauge - T10173- (if necessary slightly turn the multi-function
switch -A-).
– Fix the setting gauge - T10173 - to the gearshift shaft using a
knurled screw -C-
– Tighten both screws -B- to tightening torque 6 Nm.
– Remove setting gauge from gearshift shaft.
Further installation occurs in reverse order.
– Inspect setting of selector lever control cable
ble”, page 55 .


⇒ “1.2 Replacing the right flange shaft seal ring”, page 190

ring
♦ Adapter - T10055/2-
Removing

Note

♦ Gasket rings can be replaced with the gearbox installed.
♦ The left drive shaft is completely removed.
♦ The right drive shaft remains on the vehicle and is only re‐
moved from the gearbox.

gr. 50 .
– Remove drive shaft, left ⇒ Chassis, axles, steering; Rep. gr.
40 .
-A-.
– Drill a hole in the outer metal of the gasket ring with a com‐
mercially available twist drill -B- (∅ 2 to 4 mm).
Note
♦ Grease drill -B- in such a way that the metal swarfs adhere.
♦ Only drill through the metal of the ring, otherwise the gearbox
may be damaged.


Note
the bearing behind the gasket ring is not damaged.
– Remove the gasket ring with the extractor - T10055- and

adapter - T10055/2- .
If the metal plate ring of the gasket ring is pulled out:

WARNING

Install
following:
– Coat the exterior area with ATF and half fill the space between
the sealing lips with sealing grease - G 052 128 A1- .
• Fitting position: The open side of the gasket ring faces towards
the gearbox.
– Position pressure plate - T10176- in the middle on the shaft

seal -A-.
– Install drive shaft, left ⇒ Chassis, axles, steering; Rep. gr. 40 .
Tightening torque
Flange shaft to gearbox ⇒ Chassis, axles, steering; Rep. gr. 40

♦ Adapter - T10055/2-

Removing
Note

09G”, page 12 .

gr. 50 .
– Remove drive shaft, right ⇒ Chassis, axles, steering; Rep. gr.
40 .
-A-.
Note

may be damaged.
♦ Grease drill -B- in such a way that the metal swarfs adhere.

Note
the bearing behind the gasket ring is not damaged.
– Remove the gasket ring with the extractor - T10055- and

adapter - T10055/2- .
If the metal plate ring of the gasket ring is pulled out:

WARNING
Install
following:
the gearbox.

– Position pressure plate - T10177- in the middle on the shaft

seal -A-.
– Install drive shaft, right ⇒ Chassis, axles, steering; Rep. gr.
40 .
Tightening torque
Flange shaft to gearbox ⇒ Chassis, axles, steering; Rep. gr. 40

2 Replacing the gasket ring for the

gearshift shaft
⇒ “2.1 Replacing the gasket ring for the gearshift shaft”,
page 193
2.1 Replacing the gasket ring for the gear‐

shift shaft
– Removing multi-function switch - F125-
⇒ “2.1 Removing and installing the multi-function switch F125
”, page 185 .
– Remove gasket ring with screwdriver, do not damage the
gearshift shaft.
the gearbox.
– Drive in the new gasket ring with pressure plate - T10174- up

to the stop, do not twist the gasket ring.
– Installing and setting multi-function switch - F125-
⇒ “2 Removing, installing and setting multi-function switch
F125 ”, page 185 .
2. Replacing the gasket ring for the gearshift shaft 193

Service
Workshop Manual
Fabia II 2011 ➤ , Octavia II 2004 ➤ ,
Octavia II 2010 ➤ , Rapid 2011 ➤ ,
Rapid NH 2014 ➤ , Roomster 2006 ➤ ,
Superb II 2008 ➤ , Superb II 2011 ➤ ,
Yeti 2010 ➤ , Yeti 2011 ➤

Gearbox 0AM-DSG
Edition 01.2015

Service
Repair Group
00 - Technical data
30 - Clutch
35 - Gears, shafts

Gearbox 0AM-DSG - Edition 01.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
2.2 Safety precautions during road tests in which testing and measuring equipment is used . . 2
2.3 Safety measures for working on the mechatronics for double clutch gearbox J743 . . . . . . 2
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Working with testing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7 Notes on tow starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Electric/electronic components and fitting locations of the automatic gearbox DSG - 0AM
........................................................................ 23
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.1 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2 Removing and installing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3 Adjust clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.1 Summary of components - double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Remove double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3 Install double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.4 Replacing the sealing ring for the outer drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.5 Replace gasket ring for inner drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1 Mechatronics for double clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.1 Summary of components - mechatronics for double clutch gearbox J743 . . . . . . . . . . . . 77
1.2 Remove mechatronics for double clutch gearbox J743 ; gearbox installed. . . . . . . . . . . . . 79
1.3 Bringing the mechatronics for double clutch gearbox J743 to the removal position by hand
........................................................................ 87
1.4 Install mechatronics for double clutch gearbox J743 ; gearbox installed . . . . . . . . . . . . . . 89
2 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.4 Check the function of the ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.6 Removing and installing handle for shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.7 Installing the lock button at the selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.8 Removing and installing shift mechanism with selector lever control cable . . . . . . . . . . . . 118
Contents i
2.9 Removing and installing selector lever control cable, vehicles up to 05.2009 (Octavia II,
Superb II, Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.10 Emergency release of gearshift mechanism out of position P . . . . . . . . . . . . . . . . . . . . . . 127
2.13 Removing and installing selector lever switch locked in P F319 . . . . . . . . . . . . . . . . . . . . 130
2.14 Removing and installing the selector lever sensor control unit J587 . . . . . . . . . . . . . . . . . . 130
2.15 Checking the plug connections at the shift mechanism (Octavia II, Superb II, Yeti) . . . . . . 131
3.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4 Transport the gearbox and secure to the assembly support . . . . . . . . . . . . . . . . . . . . . . . . 172
5 Change gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1 Pinions and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1 Replace gasket rings for rigid shafts and flange shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.1 Summary of components - gasket rings and output shafts . . . . . . . . . . . . . . . . . . . . . . . . 178
1.2 Replacing gasket ring for left rigid shaft (Octavia II, Superb II, Yeti) . . . . . . . . . . . . . . . . . . 179
1.3 Replacing gasket ring for right rigid shaft (Octavia II, Superb II, Yeti) . . . . . . . . . . . . . . . . 182
ii Contents
1 Identification
(SRL000769; Edition 01.2015)
⇒ “1.1 Identification of the gearbox”, page 1

The gearbox code letter -arrow- is located at the top and bottom
of the gearbox.
♦ KHP = gearbox identification character
♦ 15.01.08 = Production date 15th January 2008
♦ 14 = Factory code
♦ 09:49 = time
♦ 0042 = serial number
data stickers.
Note
If these vehicle data stickers are not present and another gearbox
is installed than the one intended or you have no other possibility
to identify the installed gearbox in case of doubt, then read off the
identification characters directly from the gearbox.
1. Identification 1
2 Safety instructions
⇒ “2.1 Safety precautions when working on vehicles with a start/
stop system”, page 2
⇒ “2.2 Safety precautions during road tests in which testing and
measuring equipment is used”, page 2
⇒ “2.3 Safety measures for working on the mechatronics for dou‐
ble clutch gearbox J743 ”, page 2
2.1 Safety precautions when working on ve‐

hicles with a start/stop system
WARNING

♦ Deactivate the start-stop system when working on the ve‐
hicle. Switch off ignition.
♦ If required switch on the ignition for a short period of time.
2.2 Safety precautions during road tests in

which testing and measuring equipment
is used
If test and measuring devices are required during test drives, ob‐
serve the following information:
WARNING
There is a risk of accident from unintended motion and insuf‐

ficient securing of testers and measuring instruments.
There is a risk of injury from the release of the passenger air‐
bag in the event of an accident.
• Operation of test and measuring instruments by the driver
while driving may result in deviating from the direction of
travel.
• There is an increased risk of injury or accident from un‐
secured testers and measuring instruments.
♦ Fasten test and measurement equipment with a strap on
the rear seat and secure their operation by another person
sitting on the rear seat.
2.3 Safety measures for working on the mechatronics for double clutch gearbox
- J743-
DANGER!
Do not remove the pressure tank. The pressure tank is under

pressure and should not be opened.

Caution
2. Safety instructions 3
3 Repair instructions
⇒ “3.1 General points”, page 4
⇒ “3.2 Explanation of the terms used in this workshop manual”,
page 7
⇒ “3.3 Contact corrosion”, page 9
⇒ “3.4 Gaskets and seals”, page 9
⇒ “3.5 Nuts and bolts”, page 9
⇒ “3.6 Working with testing devices”, page 10
⇒ “3.7 Notes on tow starting and towing”, page 11
3.1 General points

clutch gearbox.
The gearbox is built like a 7-speed manual gearbox.
Information on structure and function of the gearbox ⇒ Self-study
programme No. 75 ; automatic gearbox DSG - 0AM .

repair procedures.
the workshop manual - are summarised here.
Notes apply to this particular workshop manual.
Special tools
List of the special tools used in the workshop manual is detailed
in the individual repair descriptions.
Summary of components of gearbox for vehicles Octavia II, Su‐
perb II and Yeti
2- Screw cap
3- Gearshift lever
box - J743-
5- Mechatronics for double clutch gearbox - J743-
6- Double clutch
7- Up to production date “11.2008” rigid shaft, from production
date “11.2008” flange shaft ⇒ page 5
8- Oil drain plug

Gearbox with different output shafts

♦ -A- - Rigid shafts up to 11.2008
♦ -B- - Flange shafts as of 11.2008
Summary of components of gearbox for vehicles Fabia II, Room‐

ster, Rapid NH and Rapid India

2- Screw cap
3- Gearshift lever
box - J743-
5- Mechatronics for double clutch gearbox - J743-
6- Double clutch
7- Flange shaft
8- Oil drain plug
Gearbox
3. Repair instructions 5
The gearbox has an opening in the housing -arrow-.

Vehicles Octavia II, Superb II and Yeti
Note
ing.
♦ Cover the opening with a cloth before commencing installation
work.
For vehicles Fabia II, Roomster and Rapid NH
Note
♦ This opening is closed with a cap.

ing.
♦ If the covers are unscrewed from the gearbox or the gearbox

is without oil, do not let the engine run and do not tow the ve‐
hicle.
♦ Permanently ensure that no dirt can get into the opened gear‐
box.
and then release.
♦ When installing the gearbox, ensure the dowel sleeves are
correctly located between the engine and gearbox.
On some transmissions, a cover is present above the engaging

lever.
The cover protects against contamination.
Tightening torque securing bolts: 8 Nm
Mechatronics
♦ The new mechatronics for the gearbox is already precisely fil‐
led with oil at the factory, do not drain the oil.
♦ The removed mechatronics for the gearbox is sent back with
oil (close the ventilation opening with a suitable plug).
♦ During assembly work, remove the cover of the ventilation for
the mechatronics and close the opening with a suitable screw
plug. In case of oil leakage from the mechatronics , the me‐
chatronics must be replaced.
Gear oil

The “7-speed double clutch gearbox DSG - 0AM” has two sepa‐
rate, different oil fillings. One for the area with gearbox oil
-arrow A- and the other one for the area with hydraulic oil
-arrow B-.
The oil level cannot be checked. The correct gear oil level can
only be achieved by changing the gear oil, for example if the
gearbox leaks ⇒ “5 Change gearbox oil”, page 174 .
Caution
Be careful when handling oil. Dispose of drained oil appropri‐

ately.
♦ Shake oil bottle before opening.

♦ Do not mix any additives in the oil, also do not fill in other oil.
♦ Drained oil must not be reused.
Locking elements

If you touch objects out of metal, it can happen that this can lead
to an electrostatic discharge. This is due to the electrostatic
charge accumulated by the human body. This electrostatic
charge can lead to operational problems when touching the elec‐
trical components of the gearbox and the shift mechanism.
– Touch an earthed object, e. g. a metal pipe or a lift platform,
before working on the electrical components.
– Do not grab directly at the plug contacts.
Before repairing the gearbox try to determine the origin of the
damage as accurately as possible using “targeted fault finding”.
The “targeted fault finding” is performed with the ⇒ Vehicle diag‐

nostic tester.
Rules of cleanliness
before releasing.
♦ Only install clean parts: Remove spare parts from their wrap‐
♦ Always replace the paper gaskets. Completely remove old
gasket and thoroughly clean sealing surfaces.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Do not use fuzzy cloths!

workshop manual
These explanations are only related to the automatic gearbox
DSG - 0AM. They do not claim to be valid in all cases.
CAN databus
Data transfer. Before transmission, electrical signals are put into
certain forms (BUS). Further information on this can be found in
⇒ Self-study programme No. 24 ; Škoda OCTAVIA; CAN data‐
bus; Structure and Function .
DSG
Automatic gearbox DSG. Further information can be found in
⇒ Self-study programme No. 75 ; Automatic gearbox DSG -
0AM .
Self-diagnosis
The capability of the control unit to:
– Detect faults.
– React to faults.
– Store faults.
– Determine measured values and display them in the meas‐
ured value block.

The sender determines the speed at the clutch and sends it to the
mechatronics.
Gearbox
clutch gearbox. The engine torque is initiated in the gearbox via
the two-mass flywheel. The flywheel and the double clutch are
interconnected via a serration. The gearbox is built like a 7-speed
double clutch gearbox OAM. Due to the alternative hydraulic ac‐
tivation of the two dry clutches, it is operated like an automatic
gearbox, i.e. the gears are automatically or manually engaged via
the Tiptronic mode. A clutch pedal is not present.
Gear oil
The gearbox has separate oil fillings for mechatronics and manual
gearboxes. Oils are designed to be filled for life.
The selector lever lock solenoid is integrated into the shift mech‐
anism. Prevents (unintentional) tipping of the selector lever from
the positions P and N when the brake is not operated.
Emergency running mode
If individual or several components or sensors fail, the gearbox
control unit activates the corresponding backup functions or
emergency running programmes. This ensures a nondestructive
operation of the gearbox with the respective effect on the function
and quality of the shifting.
The emergency running mode is a status of the control unit,
which, if a fault of the control unit is detected, maintains driving
safety, protects the gearbox from damage, and ensures that ve‐
hicle running will be affected as little as possible.
Parking position
When the vehicle is parked, the selector lever mechanically locks
the parking gear thereby preventing the vehicle from moving off
unintentionally.
Shift mechanism
The selector lever position is no longer communicated mechani‐
cally, as for the other automatic gearboxes, via the selector lever
control cable and the multi-function switch (sensor for driving po‐

sition) to the gearbox. The selector lever positions or shifting are

transmitted via a separate control unit in the shift mechanism via
the CAN databus to the mechatronics. The shifting is then per‐
formed without control cable. Only in the selector lever position P
is the parking position engaged mechanically via the selector lev‐
er control cable.
gine power output.
♦ By directly selecting a gear via the Tiptronic, it is also possible
to use engine braking with a specific gear, e.g. for a slope
during trailer operation.
Tiptronic
Another one exists to the right of the normal selector lever gate.
In this selector lever gate, the selector lever can be tipped towards
the Plus sign (+) to change up the gears manually and vice versa
towards the Minus sign (-) to change down the gears manually.
3.3 Contact corrosion

The gearbox housing and the clutch housing are made out of
magnesium alloy.
Bolts and other components that come into direct contact with the
gearbox have a surface with varying finishes in relation to it.
The use of substitute components causes contact corrosion
(screws. nuts. washers ...). The gearbox housing and the clutch
housing are damaged.
Generally install parts which are indicated in the ⇒ Electronic
3.4 Gaskets and seals

♦ After removing all seals, inspect the contact faces on housings
and shafts for burrs and damage and remove all which are
found.
♦ Before a radial shaft seal is installed, coat the sealing lips and
the space in-between halfways with sealing grease - G 052
128 A1- .
♦ The open side of the sealing rings is assembled towards the
oil.
♦ Always replace O-rings, gasket rings and gaskets ⇒ Elec‐
♦ Before inserting the O-rings only coat with DSG oil to prevent
the rings being damaged during installation. A different lubri‐
cant can cause functional faults.
♦ After installing, check gear oil level
⇒ “5 Change gearbox oil”, page 174 .
3.5 Nuts and bolts

♦ Slacken and tighten screws or fixing nuts of covers and hous‐
ings diagonally across in stages.

screws.
agent with a wire brush. Insert bolts with locking agent - AMV
185 101 A1- .
♦ Clean all threaded holes into which bolts are screwed in with
locking agent, using a thread tap to remove locking agent res‐
idues. Otherwise there is a danger of bolts shearing when
subsequently being removed.
♦ Always replace the self-locking screws and nuts.
3.6 Working with testing devices

VAS/ODIS-
Work in the operating modes targeted functions and tar-
geted fault finding .
Adapt information regarding lining

The mechatronics detects the other control units in the vehicle via
the signals in the CAN bus. If the button adapt information
regarding lining is pressed, the mechatronics receives a
command to forget all systems with which it can communicate.
However, after switching on the ignition all active systems with
which it can communicate are detected.
No faults can be generated with this function. The function adapt
information regarding lining is always carried out after the
following operations:
♦ After installing the mechatronics.
♦ After the gearbox has been fitted.
♦ After installing the selector lever.
♦ After installing another control unit, for example the engine
control unit, the ABS control unit or the diagnostic interface for
data bus (Gateway).
♦ After working on the steering column gearshift.
Perform basic setting
The mechatronics memorises important settings in the function
COMPLETE BASIC SETTING . The important settings are also
memorised, e.g reset to preprogrammed points. For example, the
synchronisation points and the vertices for the engaging lever and
gear switches.
– Button COMPLETE BASIC SETTING only functions:
♦ after interrogating with “Targeted fault finding”,
♦ after rectifying the fault stored in the event memory,
♦ after installing the clutch,
♦ or after installing the Mechatronics.

3.7 Notes on tow starting and towing
Caution
When towing the vehicle, the selector lever must be in position

N and it must not be towed further than 50 km and faster than
50 km/h, otherwise the gearbox will be destroyed.
It is not possible to tow start an engine, e.g. if the battery is
weak or the starter does not operate.
4 Technical data
⇒ “4.1 Filling capacity”, page 12
⇒ “4.2 Allocation gearbox - engine”, page 13
⇒ “4.3 Calculation of gear ratios”, page 21

The 7-speed double clutch gearbox DSG - 0AM has two separate,
Gearbox capacity Area with gearbox oil

New filling 1.9 l
Top-up no top-up
Lubricant Gearbox oil for double clutch gearbox 0AM
part number ⇒ Electronic Catalogue of Original Parts
The gear oil filling is permanent for the 7-speed double clutch
gearbox 0AM (oils are designed to be filled for life). For this reason
the oil level is not checked and the inspection plug is not present
on this gearbox.
Capacity in the mechatronics for Area with hydraulic oil

double clutch gearbox - J743-
Filling 1 ltr.
Top-up no top-up
♦ The mechatronics is allocated according to the gearbox code letters ⇒ Electronic Catalogue of Original
Parts .
♦ The new mechatronics for the gearbox is already precisely filled with oil at the factory.

Caution
Only spare part gear oils should be used for the 7-speed double
clutch gearbox DSG - 0AM.
Other oils can lead to functional problems or to failure of the
gearbox.
4.2 Allocation gearbox - engine

(Octavia II)”, page 13
(Superb II)”, page 15
(Yeti)”, page 17
(Fabia II)”, page 18
(Rapid NH)”, page 20
(Rapid India)”, page 20
4.2.1 Identification characters, aggregate assignment, ratios (Octavia II)

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐ LKN LPK LSS
ters
throug 05.2009 05.2009 10.2009
h
Assignment Engine 1.8 ltr./118 kW TFSI 1.8 ltr./118 kW TFSI
1.8 ltr./112 kW TFSI

Gearbox Identification charac‐ MGL MLC MPJ
ters
throug 05.2010 10.2010 05.2011
h

Gearbox Identification charac‐ NAT NQB NTQ
ters
throug 10.2011 05.2012 10.2012
h
4. Technical data 13

Gearbox Identification charac‐ PMJ
ters
Manufactured from 11.2012
throug 04.2013
h

Gearbox Identification charac‐ KHN LKG LKM
ters
throug 11.2008 11.2008 05.2009
h
Assignment Engine 1.4 ltr./90 kW TSI


Gearbox Identification charac‐ LPJ LWZ MGK
ters
throug 05.2009 10.2009 05.2010
h

Gearbox Identification charac‐ MLB MPH NAS
ters
throug 10.2010 05.2011 05.2011
h

Gearbox Identification charac‐ NBA NQK NTZ
ters
throug 10.2011 05.2012 11.2012
h

Gearbox Identification charac‐ MGU MLJ MPQ
ters
throug 05.2010 10.2010 05.2011
h


ters

ters
throug 10.2011 05.2012 11.2012
h

Gearbox Identification charac‐ MGN MLE MPL
ters

throug 05.2010 10.2010 05.2011
h

Gearbox Identification charac‐ NKA NQE NTT
ters
throug 10.2011 05.2012 10.2012
h

Gearbox Identification charac‐ PML
ters
Manufactured from 11.2012
throug 04.2013
h
4.2.2 Identification characters, aggregate assignment, ratios (Superb II)

Gearbox Identification charac‐ KHP LKN LKN
ters
throug 10.2008 05.2009 05.2009
h

Gearbox Identification charac‐ LPK LSS MGL
ters
throug 05.2009 10.2009 05.2010
h

Gearbox Identification charac‐ MLC MPJ NAT
ters
throug 10.2010 05.2011 11.2011
h

Gearbox Identification charac‐ NQB NTQ PMJ
ters
throug 05.2012 10.2012 05.2013
h

Gearbox Identification charac‐ PKN PKQ PKP
ters
throug 10.2013 06.2013 10.2013
h
Assignment Engine 1.8 ltr./118 kW 1.6 ltr./77 kW TDI CR
TFSI

Gearbox Engine code PVV PVW
Manufactured fr 11.2013 11.2013
o 05.2014 05.2014
m
to
Assignment Engine 1.8 ltr./118 kW TFSI 1.6 ltr./77 kW TDI CR


Gearbox Identification QQU QGV QQV QGX
characters
Manufac‐ f 05.2014 11.2014 05.2014 11.2014
tured r 11.2014 11.2014
o
m
t
o
Assignment Engine 1.8 ltr./118 kW TFSI 1.6 ltr./77 kW TDI CR
4.2.3 Identification characters, aggregate assignment, ratios (Yeti)

ters
throug 05.2010 10.2010 05.2011
h

ters
throug 10.2011 05.2012 10.2012
h

Gearbox Identification charac‐ PMS PKW
ters
throug 05.2013 05.2013 10.2013
h
Assignment Engine 1.2 ltr./77 kW TFSI 1.4 ltr./90 kW TSI

Gearbox Engine code PWD
to 05.2014 05.2014
Assignment Engine 1.2 ltr./77 kW TFSI 1.4 ltr./90 kW TSI

Gearbox Identification characters QRB QHE
to 11.2014

Gearbox Identification characters QRB QHE
1.4 ltr./90 kW TSI

Gearbox Identification charac‐ PVW QQV QGX
ters
to 05.2014 11.2014
4.2.4 Identification characters, aggregate assignment, ratios (Fabia II)

ters

throug 05.2010 10.2010 05.2011
h

Gearbox Identification charac‐ NBD NQN NUC
ters
throug 10.2011 05.2012 10.2012
h

Gearbox Identification charac‐ PMV PKZ PWG
ters
throug 05.2012 10.2013 05.2014
h

Gearbox Identification charac‐ MLH MPP NAY
ters
throug 10.2010 05.2011 10.2011
h


Gearbox Identification charac‐ MLH MPP NAY
ters
throug 10.2010 05.2011 10.2011
h

Gearbox Identification charac‐ NQH NTW PMP
ters
throug 05.2012 10.2012 05.2013
h
Gearbox Identification charac‐ PKT PWA QQY

ters
to 11.2013 05.2014

Gearbox Identification charac‐ QRE QHH
ters
throug 11.2014
h
4.2.5 Identification characters, aggregate assignment, ratios (Roomster)

ters
throug 05.2010 10.2010 05.2011
h

Gearbox Identification charac‐ NBD NQN NUC
ters
throug 10.2011 05.2012 10.2012
h

Gearbox Identification charac‐ PMV PKZ PWG
ters
throug 05.2012 10.2013 05.2014
h

Gearbox Identification charac‐ QRE QHH
ters
throug 11.2014
h
4.2.6 Identification characters, aggregate assignment, ratios (Rapid NH)

Gearbox Identification charac‐ NUA PMT PKX
ters
throug 11.2012 05.2013 10.2013
h

Gearbox Engine code PWE QRC QHF
to 05.2014 11.2014

Gearbox Identification PKY PWF QRD QHD
characters
Manufac‐ from 08.2013 11.2013 05.2014 11.2014
tured to 10.2013 05.2014 11.2014
4.2.7 Identification characters, aggregate assignment, ratios (Rapid India)

Gearbox Identification charac‐ PWF QRD QHG
ters
throug 09.2014 01.2015
h


Gearbox Identification charac‐ PWF QRD QHG
ters
Assignment Engine 1.5 l/77 kW TDI CR
4.3 Calculation of gear ratios

Example:
5. gear Final drive
Drive gear ZG1 = 46 ZA1 = 24
Driven gear ZG2 = 33 ZA2 = 70
i = ZG2 : ZG1 1)
iG = Gear ratio = ZG2: ZG1 = 33 : 46 = 0,717
iA = Ratio of the final drive = ZA2 : ZA1 = 70 : 24 = 2,917
itotal = Total ratio = iG × iA = 0.717 × 2.917 = 2.091
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

The 7-speed double clutch gearbox DSG - 0AM has 2 drive shafts
and 3 output shafts.
A1 - 1. Drive shaft
A2 - 2. Drive shaft
B1 - 1. Output shaft
C - Front final drive
K1 - Clutch 1
K2 - Clutch 2
M - Engine
❑ with 1st, 3rd, 5th and 7th
gear
❑ with 2nd, 4th, 6th gear
and reverse gear R

6 Electrical components
⇒ “6.1 Electric/electronic components and fitting locations of the
automatic gearbox DSG - 0AM”, page 23
6.1 Electric/electronic components and fit‐

ting locations of the automatic gearbox
DSG - 0AM
⇒ “6.1.1 Electric/electronic components and fitting locations of the
automatic gearbox DSG - 0AM (Octavia II, Superb II and Yeti)”,
page 23
automatic gearbox DSG - 0AM (Fabia II and Roomster)”,
page 26
automatic gearbox DSG - 0AM (Rapid)”, page 29
6.1.1 Electric/electronic components and fitting locations of the automatic gear‐

box DSG - 0AM (Octavia II, Superb II and Yeti)

❑ Fitting location: under
the cover in the driver's
footwell
cator - Y6-
❑ Fitting location: Integra‐
sert
deactivated gearbox
control unit
System; Rep. gr. 90
scale illumination - L101-
the cover frame; fitting
location ⇒ page 25
L101- is checked by
self-diagnosis
❑ as of 11.2012 (CW 45),
the selector lever han‐
dle was changed
⇒ “2.1 Summary of components - Gearshift mechanism”, page 97
6. Electrical components 23
❑ Removing and installing ⇒ “2.5 Removing and Installing the cover for the shift mechanism”, page 109
❑ is a component and can only be removed and installed with the° mechatronics for double clutch gearbox
- J743- ⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77
5 - Mechatronics for double clutch gearbox - J743-
❑ Removing and installing ⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77
7 - Selector lever - E313- with Tiptronic switch - F189- , selector lever sensor control unit - J587- and selector
lever switch locked in P - F319-
❑ Tiptronic switch - F189- , selector lever sensor control unit - J587- and selector lever switch locked in P
- F319 - are integrated into the shift mechanism.
together with the gearshift mechanism
⇒ “2.8 Removing and installing shift mechanism with selector lever control cable”, page 118
8 - Brake light switch - F- and brake pedal switch - F47-
❑ removing and installing ⇒ Chassis; Rep. gr. 46
❑ Removing and Installing ⇒ Engine; Rep. gr. 20
Mechatronics for double clutch gearbox - J743-

Fitting location: The mechatronics for double clutch gearboxes -
J743- is screwed onto the front gearbox housing.
The control unit is firmly integrated in the mechatronics for double
clutch gearbox - J743- .
The senders and the actuators are located in the mechatronics
for double clutch gearbox - J743- . Further information can be
found in ⇒ Self-study programme No. 75 ; Automatic gearbox
DSG - 0AM .
box - J743-
⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77 .


Fitting location: The gearbox input speed sender - G182- is clip‐
The gearbox input r.p.m. sender - G182- can only be replaced
together with the mechatronics for double clutch gearbox - J743-

The selector lever lock solenoid - N110- fitting location -arrow- is
located in the gearshift mechanism
⇒ “2.1 Summary of components - Gearshift mechanism”,
page 97 .
The selector lever lock solenoid - N110- is installed firmly in the
gearshift mechanism and cannot be replaced individually. The
removal and installation procedure is only possible together with
the gearshift mechanism
⇒ “2.8 Removing and installing shift mechanism with selector lev‐
er control cable”, page 118 .
Lamp for selector lever scale illumination - L101-

Fitting location: The lamp for selector lever scale illumination -
L101- -1- is integrated in the bottom side of the cover frame -2-.
Selector lever - E313- with Tiptronic switch - F189- , selector lever

sensor control unit - J587- and selector lever switch locked in P -
F319-
Fitting location: Selector lever - E313- is firmly integrated in the
Tiptronic switch - F189- , Selector lever sensor control unit - J587-
and Selector lever switch blocked in P - F319- are firmly integra‐
ted into the PCB -arrow- of the shift mechanism (up to 05.2009).
A new shift mechanism is fitted as of 06.2009, then the cover for
the bottom shift mechanism can no longer be removed in this way.
These components cannot be replaced separately.
Brake light switch - F- and brake pedal switch - F47-

Fitting location: The brake light switch - F- and brake pedal switch
- F47- -3- is located on the master brake cylinder -4-.

G79- / accelerator pedal position sender 2 - G185- (integrated in
Fitting location: The accelerator pedal position sender - G79- /
accelerator pedal position sender 2 - G185- -arrow- are located
on the foot controls.

box DSG - 0AM (Fabia II and Roomster)

❑ Fitting location: Dash
panel in the area of the
driver's footwell
cator - Y6-
sert
deactivated gearbox
control unit
System; Rep. gr. 90

mechanism -arrow-
nosis
⇒ “2.5 Removing and In‐
shift mechanism”,
page 109
❑ as of 11.2012 (CW 45), the selector lever handle was changed
⇒ “2.1 Summary of components - Gearshift mechanism”, page 97
❑ Fitting location: Is integrated firmly in the gearshift mechanism and cannot be replaced separately
❑ Removal and installation is only possible together with the gearshift mechanism
7 - Selector lever - E313- with Tiptronic switch - F189- , selector lever sensor control unit - J587- and selector
lever switch locked in P - F319-
❑ Tiptronic switch - F189- , selector lever sensor control unit - J587- and selector lever switch locked in P
- F319- are integrated into the shift mechanism.


for double clutch gearbox - J743- . Further information can be
found in ⇒ Self-study programme No. 75 ; Automatic gearbox
DSG - 0AM .
box - J743-


- F47- -3- is located on the master brake cylinder.


Fitting location: Accelerator pedal position sender - G79- / accel‐
erator pedal position sender 2 - G185- -arrow- are located on the
foot controls.

box DSG - 0AM (Rapid)
❑ Fitting location: under
the cover in the driver's
footwell
cator - Y6-
sert
deactivated gearbox
control unit
System; Rep. gr. 90
mechanism
nosis
shift mechanism”,
page 109


8 - Shift mechanism
Selector lever - E313- with Tiptronic switch - F189- , selector lever sensor control unit - J587- , selector lever
switch locked in P - F319- and selector lever lock solenoid - N110-
❑ these components cannot be replaced separately, the removal and installation procedure is only possible

for double clutch gearbox - J743- . Further information on the
same gearbox type 0AM can be found in ⇒ Self-study programme
No. 75 und Nr. 94 ; Automatic gearbox DSG - 0AM .
box - J743-


Selector lever - E313- with Tiptronic switch - F189- , selector lever
sensor control unit - J587- , selector lever switch locked in P -
F319- and selector lever lock solenoid - N110-
Fitting location: Is integrated firmly in the gearshift mechanism
and cannot be replaced separately.
Removal and installation is only possible together with the gear‐
shift mechanism
er control cable”, page 118

- F47- -3- is located on the master brake cylinder -4-.

Fitting location: The accelerator pedal position sender - G79- /
accelerator pedal position sender 2 - G185- -arrow- are located
on the foot controls.
30 – Clutch
1 Clutch operation
⇒ “1.1 Assembly overview - clutch release mechanism”,
page 32
⇒ “1.2 Removing and installing clutch release mechanism”, page
34
⇒ “1.3 Adjust clutch release mechanism”, page 41
1.1 Assembly overview - clutch release

mechanism
⇒ “1.1.1 Summary of components - Clutch release mechanism,
version up to 05.2011”, page 32
⇒ “1.1.2 Summary of components - Clutch release mechanism,
version as of 06.2011”, page 33
1.1.1 Summary of components - Clutch release mechanism, version up to

05.2011
1 - Small engaging lever for K2

clutch
❑ is removed and installed
together with the top
and bottom part of the
guide bushing
❑ replace when replacing
the double clutch
2 - Adjusting washer for K2
clutch
the double clutch
⇒ “1.3.1 Adjust clutch
release mechanism,
gearbox up to 05.2011”,
page 41
3 - Small engaging bearing for
K2 clutch
the double clutch
4 - Large engaging lever for K1
clutch
❑ together with large en‐
gaging bearing
the double clutch
clutch
the double clutch
⇒ “1.3.1 Adjust clutch
release mechanism,

gearbox up to 05.2011”,
page 41
6 - Screw
❑ 8 Nm + 90°
7 - Clamp
❑ not present on some older gearboxes
❑ replace when replacing the double clutch
8 - Support for the engaging lever
1.1.2 Summary of components - Clutch release mechanism, version as of

06.2011

clutch

⇒ “1.3.2 Adjusting the
clutch release mecha‐
nism, gearbox as of
06.2011”, page 51
clutch
❑ together with large en‐
gaging bearing
the double clutch
3 - Hinge bearing
❑ for large engaging lever
Pos. 2 2
❑ is not replaced
K2 clutch
the double clutch
clutch
nism, gearbox as of
06.2011”, page 51
6 - Guide bushing-top part
❑ for small engaging lever
Pos. 7
❑ is removed and installed
together with the guide
bushing-bottom part
Pos. 7
7 - Small engaging lever for K2 clutch
❑ is removed and installed together with the top and bottom part of the guide bushing
1. Clutch operation 33
8 - Ball pin
❑ for small engaging lever Pos. 7
9 - Screw
❑ 8 Nm + 90°
10 - Guide bushing-bottom part
❑ for small engaging lever Pos. 7
❑ is removed and installed together with the guide bushing-top part Pos. 6
1.2 Removing and installing clutch release

mechanism
⇒ “1.2.1 Removing and installing clutch release mechanism, ver‐
sion up to 05.2011”, page 34
⇒ “1.2.2 Removing and installing clutch release mechanism, ver‐
sion as of 06.2011”, page 37

1.2.1 Removing and installing clutch release
mechanism, version up to 05.2011
Caution
If the double clutch has to be replaced, the following parts must

always be replaced too:
♦ The two engaging levers with the gear shift bearings
♦ Bearing of the engaging lever
♦ Shims for gear shift bearings
After replacing the double clutch and the corresponding parts,
the position of the gear shift bearings for clutches K1 and K2
will always require re-adjusting
⇒ “1.3.1 Adjust clutch release mechanism, gearbox up to
05.2011”, page 41
Note
♦ If all the listed parts are only removed and installed, no re-
adjustment is necessary.
♦ The circlip must be replaced under all circumstances.
• Double clutch gearbox removed

⇒ “2.2 Remove double clutch”, page 66
• The mechatronics for double clutch gearbox -J743- is installed
on the gearbox

Removing
– Remove the small engaging bearing with the adjusting wash‐
er.
– Remove the large engaging lever.
– Remove screws and remove the small engaging lever with

clamp.
Note
Only some older gearboxes have no clamp.
– Remove the support for the engaging lever.

Installing
The large adjusting washer for the clutch K1 is installed on the
large bearing, the small adjusting washer for the clutch K2 is in‐
stalled under the small bearing.
Caution
– Insert the plastic support of the engaging levers and check for
correct fit.
Note
Only some older gearboxes have no clamp. New gearboxes al‐

ways have a clamp.
– Use two screws to install the small engaging lever with clamp.
• The support of the engaging levers and the complete mecha‐
nism for the engaging bearings must be dry and free of oil or
grease.
• If necessary, clean these component parts with a clean cloth.
– Insert the large engaging lever.

This larger engaging lever is for clutch K1.
– Insert the small engaging bearing -A- for K2 with the measured
adjusting washer -B-.
Determine the thickness of the adjusting washer
The adjusting washer -B- belongs under the small engaging bear‐
ing -A-. Therefore, insert the adjusting washer first.

• The small engaging bearing fits in only one position due to the
4 grooves.
– While turning in -direction of arrow-, check if the small engag‐

ing bearing is correctly installed and the grooves are correctly
positioned.
– Fix adjusting washer for K1 -A- with 3 drops of adhesive - AMV

195 KD1 01- -arrows- on the bearing.
This prevents that the washer slips out of its position when the
clutch is inserted.
Specified torques
♦ Small engaging lever with clamp on gearbox
⇒ “1.1.1 Summary of components - Clutch release mecha‐
nism, version up to 05.2011”, page 32
1.2.2 Removing and installing clutch release

mechanism, version as of 06.2011
Caution
When replacing the double clutch, the following parts must al‐
ways be replaced too:
♦ the two engaging levers with engaging bearings
♦ Ball pin of the engaging lever for clutch K2
♦ Shims for engaging bearing
the position of the engaging bearings for clutches K1 and K2
⇒ “1.3.2 Adjusting the clutch release mechanism, gearbox as
of 06.2011”, page 51 .
Note
♦ If all the mentioned parts are only removed and reinstalled,

there is nothing to adjust.

• Mechatronics for double clutch gearbox -J743- installed
Removing
– Remove large engaging lever together with the shims and
bearing.
Note
Guide bushing top part cannot be removed or installed individu‐

ally. It is always removed and installed together with the guide
bushing bottom part and small engaging bearing.
– Remove screws and remove the small engaging lever.
If no parts are replaced, the ball pin -2- remains installed.
Note
The hinge bearing -1- cannot be removed.
Installing
The large adjusting washer for the clutch K1 is inserted with the
semispherical side downwards on the large bearing, the small
adjusting washer for the clutch K2 is inserted under the small
bearing.
Caution

– Insert ball pin -2-.

Installation instructions for the new engaging lever K2
The new engaging lever K2 is delivered with guide bushing upper

and lower part in the transport position. It must be brought to fitting
position before installation.
– Only guide bushing upper part by hand.

– Turn the guide bushing bottom part with your other hand in the
-direction of arrow- at the same time so that the sleeve can be
moved freely.
Since a large amount of force is needed to turn the guide bushing
bottom part, hold the two parts of the engaging lever firm.
In the installation position, the openings of the guide bushing bot‐

tom part lie vertically to the engaging lever and the sleeve can be
moved freely at the same time.
– Insert the small engaging lever with the top and bottom part of
the guide bushing and tighten the screws.
– Insert the second, larger engaging lever with the measured

adjusting washers for clutch K1 and K2.
The large adjusting washer for the clutch K1 is inserted with the
semispherical side downwards on the large bearing, the small
adjusting washer for the clutch K2 is inserted under the small
bearing.
The small engaging bearing and the adjusting washer fit in only
one position due to the 8 grooves.
– Insert the small engaging bearing.
– While turning the bearing, check if it is correctly installed and
the grooves are correctly positioned.
Specified torques
♦ Small engaging lever on gearbox
⇒ “1.1.2 Summary of components - Clutch release mecha‐
nism, version as of 06.2011”, page 33

1.3 Adjust clutch release mechanism

⇒ “1.3.1 Adjust clutch release mechanism, gearbox up to
05.2011”, page 41
⇒ “1.3.2 Adjusting the clutch release mechanism, gearbox as of
06.2011”, page 51
1.3.1 Adjust clutch release mechanism, gear‐

box up to 05.2011
♦ Gauge block - T10374-
♦ Straightedge - T40100-
♦ Adhesive - AMV 195 KD1 01-
Caution
♦ Bearing of the engaging lever
will always require re-adjusting.
Note

Conditions
• The flange of the clutch housing must be free of irregularities,
as the only way to ensure good contact with the straightedge.
Short description
gearbox DSG - 0AM, there are tolerances in the engaging system
of the gearbox and in the gearbox itself. Tolerances also exist
inside the double clutch. These tolerances must be considered
separately when adjusting.
In the following procedure, you will first see how to determine all
the necessary dimensions on the gearbox side in order to identify
the suitable adjusting washer. This has an impact on the clutch
tolerances determined earlier by the manufacturer. The toleran‐
ces on the gearbox side and the tolerances in the clutch deter‐
mine the thickness of the adjusting washer.
• The order of work steps must be observed!
Caution
Risk of damage to the clutch as well as to other components.

Bearing of the engaging lever and the entire engaging bearing
mechatronics must be dry and free of oil and grease.
Preparation
– Install the parts of the clutch up to the large engaging lever
⇒ “1.2.1 Removing and installing clutch release mechanism,
version up to 05.2011”, page 34 .
• Do not install the small engaging bearing and do not insert an
adjusting washer.
– Install the circlip of the outer drive shaft -arrow-.
Determine dimension -B-.

– Place the straightedge - T40100- upright on the flange of the

clutch housing.
Caution
The straightedge - T40100- must remain in this position during

the following measurements.
Do not turn or remove it.
– Perform null balance of the depth gauge .

– Note the result and name it B1.
Example: B1 = 2.91 mm
– Measure the dimension B once more at the opposite point.

• Do not measure on the joint of the ring. The ring could be
pressed off from the joint and thus the measuring result will be
inaccurate.
– Remove circlip again.
• This ring must not be re-used!
Example:
Dimension B = B1 + B2 2 = 2.91+3.02 = 2.96
Determine dimension -A1- of the large engaging bearing for clutch

K1.
• Do not insert an adjusting washer!
– Position the gauge block - T10374- on the large engaging

bearing.
The flat side faces upwards.

– Press on the gauge block - T10374- , and simultaneously ro‐
tate to ensure correct seating.
• The gear shift bearing rotates with the gauge block - T10374- .
– Attach the digital depth gauge upwards on the straightedge

and place the rod of the depth gauge on the outer driveshaft.
• The straightedge - T40100- is already positioned upright on
the flange of the clutch housing.
Caution

– Perform null balance of the digital depth gauge .
– Position the rod of the digital depth gauge on the gauge block
- T10374- , as shown in the figure, and measure the distance
from the shaft end.


accuracy resulting from the wobbling on the engaging bearing is
thus minimised.
– Calculate the mean value of both measurements.
– Note this value and name it A1.
Example:
Dimension A1 = 2.61+2.812 = 2.71
Result: Dimension A1 = 2.71 mm
Determining the installation depth of the gear shift bearing for
clutch K1
On the basis of measured dimension A1 and dimension B, the
actual value for the installation depth of the gear shift bearing for
clutch K1 is determined by the following calculation.
Dimension A1
- Dimension B

+ Height of the gauge block - T10374- (fixed value
51.81 mm)
= Actual value for the installation depth of the gear shift bear‐
ing K1
♦ 2.71 mm – 2.96 mm + 51.81 mm = 51.56 mm
♦ Value for the installation depth of gear shift bearing for clutch
K1 = 51.56 mm
Determining the clutch play of K1
The clutch play of clutch K1 is now determined as follows on the
basis of the actual value and the specified value for the installation
depth of the gear shift bearing.
Actual value for the installation depth of the gear shift bear‐
ing
- Specified value for the installation depth of the gear shift
bearing (50.08 mm, fixed value)
= Clutch play of clutch K1
♦ 51.56 mm – 50.08 mm = 1.48 mm
♦ Clutch play of clutch K1 = 1.48 mm
Determining the clutch tolerance of clutch K1
– Please read off the value of the clutch tolerance from the new
clutch.
♦ The clutch tolerance value you have read off for clutch K1 is
0.0 mm
Determining the thickness of the adjusting washer SK1
The thickness of adjusting washer SK1 is now determined as fol‐
lows on the basis of the determined clutch play and clutch toler‐
ance for clutch K1.
Clutch play of clutch K1
-/+ Clutch tolerance of clutch K1
= Determined thickness of adjusting washer SK1
♦ 1.48 mm + 0.0 mm = 1.48 mm
♦ Determined thickness of adjusting washer SK1 = 1.48 mm
washer
from to
0,31 0,90 0,8
0,91 1,10 1,0
1,11 1,30 1,2
1,31 1,50 1,4
1,51 1,70 1,6
1,71 1,90 1,8
1,91 2,10 2,0
2,11 2,30 2,2
2,31 2,50 2,4
2,51 2,70 2,6
2,71 3,30 2,8
Example:
♦ Selected thickness of the adjusting washer = 1.4 mm
– Measure all the adjusting washers and prepare the corre‐

sponding adjusting washer for installation.
Caution
Risk of damage to gearbox!

♦ Mark adjusting washer SK1 and prepare it as follows for
installation.
♦ Only this adjusting washer SK1 may be used for adjust‐
ment

Determine dimension -A2- of the small engaging bearing for

clutch K2.
– Only insert the small bearing.

grooves.
– While turning -arrows-, check if the small engaging bearing is

correctly installed and the grooves are correctly positioned.
– Position the gauge block - T10374- with the large opening up‐
wards on the small bearing.
– Lay the straightedge - T40100- at a right angle over the shaft
end onto the gearbox flange.
– Attach the digital depth gauge upwards on the straightedge -

T40100- and place the rod of the depth gauge onto the outer
driveshaft.
Caution

– Place the rod of the depth gauge on the gauge block -

T10374- , as shown in the figure.
– Measure the distance of A2 from the shaft end to the gauge
block - T10374- .

Position the digital depth gauge twice at opposite-facing points

thus minimised.
– Calculate the mean value of both measurements to the gauge
block - T10374- .
♦ Dimension A2 = 2.50 + 2.542 = 2.52
♦ Result: A2 = 2.52 mm
Determining the installation depth of the gear shift bearing for
clutch K2
actual value for the installation depth of the gear shift bearing for
Dimension A2

- Dimension B
+ Inside height of the gauge block - T10374- (fixed value
36.20 mm)
= Actual value for the installation depth of the gear shift bear‐
ing K2
♦ 2.52 mm – 2.96 mm + 36.20 mm = 35.76 mm
♦ Result: Actual value for the installation depth of the gear shift
bearing K2 - 35.76 mm
Determining the clutch play of K2
The clutch play of clutch K2 is now determined as follows on the
basis of the actual value and the specified value for the installation
depth of the gear shift bearing.
Actual value for the installation depth of the gear shift bear‐
ing
- Specified value for the installation depth of the gear shift
bearing (34.35 mm, fixed value)
= Clutch play of clutch K2
♦ 35.76 mm – 34.35 mm = 1.41 mm
♦ Result: Clutch play of clutch K2 = 1.41 mm
– Please read off the value of the clutch tolerance from the new
clutch.
0.4 mm
lows on the basis of the determined clutch play and clutch toler‐
ance for clutch K2.
Clutch play of clutch K2
♦ 1.41 mm minus +0.4 mm = 1.81 mm
Determined thickness of the Shim to be installed in millime‐
washer tres
from to
0,31 0,90 0,8
0,91 1,10 1,0
1,11 1,30 1,2
1,31 1,50 1,4
1,51 1,70 1,6
1,71 1,90 1,8
1,91 2,10 2,0
2,11 2,30 2,2
2,31 2,50 2,4
2,51 2,70 2,6
2,71 3,30 2,8
Example:

– Measure all the adjusting washers and prepare the corre‐

sponding adjusting washer for installation.
Caution

installation.
ment.
The adjusting washer for K2 is then also determined. Please in‐

stall this adjusting washer when installing the clutch at a later
stage. This washer belongs under the small engaging bearing.
The clutch can be installed
⇒ “2.3 Install double clutch”, page 69 .
1.3.2 Adjusting the clutch release mecha‐

nism, gearbox as of 06.2011

♦ Gauge block - T10466-
♦ Straightedge - T40100-
Caution
♦ Ball pin of the engaging lever for clutch K2
will always require re-adjusting.
Note

Short description
gearbox DSG - 0AM, there are tolerances in the engaging system
of the gearbox and in the gearbox itself. Tolerances also exist
inside the double clutch. These tolerances must be considered
separately when adjusting.
In the following procedure, you will first see how to determine all
the necessary dimensions on the gearbox side in order to identify
the suitable adjusting washer. The tolerances on the gearbox side
and the tolerances in the clutch determine the thickness of the

adjusting washer.
Conditions
• The flange of the clutch housing must be free of irregularities,
as the only way to ensure good contact with the straightedge.
• The order of work steps must be observed!
Caution
Risk of damage to the clutch as well as to other components.

Bearing of the engaging lever and the entire engaging bearing
mechatronics must be dry and free of oil and grease.

Removing and installing the ball pin
– Remove the ball pin with the pliers.
– Install a new ball pin.
Note
Press in the ball pin by hand, if necessary slightly drive in with a

plastic hammer (in order not to damage the ball pin).

– Install the old circlip of the outer drive shaft -arrow-.
Determine dimension -B-.
– Place the straightedge - T40100- upright on the flange of the

clutch housing.
Caution


Example: Dimension B1 = 2.62 mm
– Measure the dimension B once more at the opposite point.

• Do not measure on the joint of the ring. The ring could be
pressed off from the joint and thus the measuring result will be
inaccurate.
♦ Example: Dimension B2 = 2.58 mm

Example:
♦ Dimension B = B1+B2 2 = 2.62+2.582 = 2.60
This dimension B is required for the following calculations.
– Remove the circlip -arrow- again.

• The circlip may not be reused.
Determine dimension -A1- of the large engaging bearing for clutch

K1.

– Insert the large engaging lever.

– Position the gauge block - T10466- on the large engaging

bearing.
The flat side faces upwards.


Caution

from the shaft end.
– Perform a second measurement at the opposite point of the

gauge block - T10466- in the same way.
thus minimised.
– Calculate the mean value A1 of both measurements to the
gauge block - T10466- .
Example
♦ Dimension A1 = 4.93+4.912 = 4.92
♦ Result: A1 = 4.92 mm
Determining the height tolerance of the gear shift bearing for
clutch K1
actual value for the height tolerance of the gear shift bearing for
Dimension A1

- Dimension B
= Height tolerance of the gear shift bearing for clutch K1
Example
♦ 4.92 mm – 2.60 mm = 2.32 mm
♦ Height tolerance of gear shift bearing for clutch K1 = 2.32 mm

– Please read off the value of the clutch Tolerance -arrow- from
the new clutch.
A value between minus 0.40 and plus 0.40 mm is marked on the
new clutch.
0.0 mm
lows on the basis of the determined clutch tolerance for clutch K1.
Height tolerance of the gear shift bearing for clutch K1
♦ 2.32 mm + 0.0 mm = 2.32 mm
– Select the correct washer from the table and put it aside until
you are ready to install it.
Deter‐ Available adjusting Part number

mined washers thickness
thickness in mm
of the ad‐
justing
washer
mm
1,21...1,60 1,50 0AM 141 383
1,61...1,80 1,70 0AM 141 383 A
1,81...2,00 1,90 0AM 141 383 B
2,01...2,20 2,10 0AM 141 383 C
2,21...2,40 2,30 0AM 141 383 D
2,41...2,60 2,50 0AM 141 383 E
2,61...2,80 2,70 0AM 141 383 F
2,81...3,00 2,90 0AM 141 383 G
3,01...3,20 3,10 0AM 141 383 H
3,21...3,40 3,30 0AM 141 383 J
3,41...3,80 3,50 0AM 141 383 K
Example:
♦ Selected thickness of the adjusting washer = 2.30 mm (part
number 0AM 141 383 D)
Caution

installation.
ment
– Remove the gauge block - T10466- and remove the large en‐
gaging lever.
Determine dimension -A2- of the small engaging bearing for

clutch K2.
Guide bushing top part cannot be removed or installed individu‐
ally. It is always removed and installed together with the guide
bushing bottom part and small engaging bearing.
The new engaging lever K2 is delivered with guide bushing upper

and lower part in the transport position. It must be brought to fitting
position before installation.

– Only guide bushing upper part by hand.

– Turn the guide bushing bottom part with your other hand in the
-direction of arrow- at the same time so that the sleeve can be
moved freely.
Since a large amount of force is needed to turn the guide bushing
bottom part, hold the two parts of the engaging lever firm.
In the installation position, the openings of the guide bushing bot‐

tom part lie vertically to the engaging lever and the sleeve can be
moved freely at the same time.
– Insert the small engaging lever with the top and bottom part of
the guide bushing and tighten the screws.
– Insert the small engaging bearing.
grooves.
– While turning, check if the small engaging bearing is correctly
installed and the grooves are correctly positioned.
– Position the gauge block - T10466- on the small engaging

bearing.
• The flat side faces upwards.

Caution


from the shaft end.

thus minimised.
– Calculate the mean value of both measurements.
Example
Dimension A2 = 4.79 + 4.752 = 4.77
Result: A2 = 4.77 mm
Determining the height tolerance of the gear shift bearing for
clutch K2
On the basis of dimension A2 and dimension B, the tolerance of
the gear shift bearing for clutch K2 is determined by the following
calculation.
Dimension A2
- Dimension B
= Height tolerance of the gear shift bearing for clutch K2
♦ 4.77 mm – 2.60 mm = 2.17 mm
♦ Height tolerance of gear shift bearing for clutch K2 = 2.17 mm
– Please read off and note the value of the clutch tolerance from
the new clutch -arrow-.
Example: K2 “+ 0.4 mm” is given on the clutch.
Determining the thickness of the adjusting washer “SK2”
The thickness of adjusting washer “SK2” is now determined as
follows on the basis of the determined clutch play and clutch tol‐
erance for clutch “K2”.
Height tolerance of the gear shift bearing for clutch “K2”
-/+ Clutch tolerance of clutch “K2”
= Determined thickness of adjusting washer “SK2”
♦ 2.17 mm + 0.4 mm = 2.57 mm
♦ Determined thickness of adjusting washer “SK2” = 2.57 mm
Determined thickness of the Shim to be installed in millime‐
washer tres

from to
0,31 0,90 0,8
0,91 1,10 1,0
1,11 1,30 1,2
1,31 1,50 1,4
1,51 1,70 1,6
1,71 1,90 1,8
1,91 2,10 2,0
2,11 2,30 2,2
2,31 2,50 2,4
2,51 2,70 2,6
2,71 3,30 2,8
Example:
♦ Determined thickness of adjusting washer “SK2” = 2.57 mm
– From the delivered washers, determine the required adjusting

washer and put it aside until you are ready to install it.
Caution

installation.
ment.
– Install clutch ⇒ “2.3 Install double clutch”, page 69 .

2 Clutch
⇒ “2.1 Summary of components - double clutch”, page 63
⇒ “2.3 Install double clutch”, page 69
⇒ “2.4 Replacing the sealing ring for the outer drive shaft”,
page 74
⇒ “2.5 Replace gasket ring for inner drive shaft”, page 75
2.1 Summary of components - double clutch

⇒ “2.1.1 Summary of components - double clutch up to 05.2011”,
page 63
⇒ “2.1.2 Summary of components - double clutch as of 06.2011”,
page 65
2.1.1 Summary of components - double clutch up to 05.2011
1 - Circlip
❑ Replace after disas‐
sembly
2 - Hub
3 - Circlip
sembly
clutch
❑ with large engaging
bearing
installing clutch release
mechanism, version up
to 05.2011”, page 34
the double clutch gear‐
box
5 - Small engaging lever for K2
clutch
box
mechanism, version up
to 05.2011”, page 34
6 - Screw
sembly
❑ 8 Nm + 90°
7 - Support
❑ for engaging lever
❑ replace when replacing the double clutch gearbox
2. Clutch 63
8 - Clamp
❑ not present on older versions
9 - Sealing ring
❑ for inner drive shaft
❑ Renew ⇒ “2.5 Replace gasket ring for inner drive shaft”, page 75 .
10 - Sealing ring
❑ for outer drive shaft
❑ Renew ⇒ “2.4 Replacing the sealing ring for the outer drive shaft”, page 74 .
11 - Outer drive shaft
12 - Adjusting washer SK1
❑ Determine thickness ⇒ “1.3.1 Adjust clutch release mechanism, gearbox up to 05.2011”, page 41
❑ Determine thickness ⇒ “1.3.1 Adjust clutch release mechanism, gearbox up to 05.2011”, page 41
14 - Small engaging bearing for K2 clutch

⇒ “1.2.1 Removing and installing clutch release mechanism, version up to 05.2011”, page 34
15 - Double clutch
❑ removing ⇒ “2.2 Remove double clutch”, page 66
❑ installing ⇒ “2.3 Install double clutch”, page 69

2.1.2 Summary of components - double clutch as of 06.2011
1 - Hinge bearing
❑ for large engaging lever
for K1 clutch
❑ is not replaced
2 - Ball pin
for K1 clutch
mechanism, version as
of 06.2011”, page 37
box
nism, gearbox as of
06.2011”, page 51
nism, gearbox as of
06.2011”, page 51
K2 clutch
box
6 - Double clutch
❑ removing
❑ installing ⇒ “2.3 Install double clutch”, page 69
7 - Circlip
8 - Hub
9 - Circlip
10 - Large engaging lever for K1 clutch
❑ with engaging bearing
⇒ “1.2.2 Removing and installing clutch release mechanism, version as of 06.2011”, page 37
11 - Guide bushing-top part
❑ for small engaging lever for K2
❑ remove and install together with the small engaging lever Pos. 12 and guide bushing bottom part Pos.
14
2. Clutch 65
12 - Small engaging lever for K2 clutch

❑ is removed and installed together with the top and bottom part of the guide bushing Pos. 11 and 14
⇒ “1.2.2 Removing and installing clutch release mechanism, version as of 06.2011”, page 37
13 - Screw
❑ 8 Nm + 90°
14 - Guide bushing-bottom part
❑ for small engaging lever for K2
❑ remove and install together with the small engaging lever Pos. 12 and guide bushing top part Pos. 11
15 - Sealing ring
❑ for inner drive shaft
❑ Renew ⇒ “2.5 Replace gasket ring for inner drive shaft”, page 75 .
16 - Sealing ring
❑ for outer drive shaft
❑ Renew ⇒ “2.4 Replacing the sealing ring for the outer drive shaft”, page 74 .
2.2 Remove double clutch

♦ Hook - 3438-

Detach the clutch upwards when the gearbox is removed. The

mechatronics remains on the gearbox.
If a new clutch is installed, the positions of the engaging bearings
for clutches K1 and K2 must be determined and adjusted
⇒ “1.3 Adjust clutch release mechanism”, page 41 .
Then the clutch is pressed onto the drive shaft.
When installing a clutch, most mechanics press the clutch onto
the drive shaft up to the stop. This is not the optimum position of
the clutch!
After installation, the clutch is therefore pulled slightly upwards
against the circlip.
Caution
Risk of damage to the adjusting device of the clutch.

♦ The clutch is self-adjusting. Vibrations can have a nega‐
tive effect on the adjusting device. Therefore do not let the
clutch fall. Do not let the clutch fall into the gearbox when
installing it.

♦ A clutch that has been dropped on a hard surface, or which
is otherwise damaged, must no longer be installed.
♦ Similarly when the mechatronics is removed, the removal
of the drifts below the engaging levers can have a negative
effect on the adjusting device.
• Gearbox removed
⇒ “3 Removing and installing the gearbox”, page 132
• Gearbox attached to assembly stand
⇒ “4 Transport the gearbox and secure to the assembly sup‐
port”, page 172
• The mechatronics for double clutch gearbox - J743- is installed
on the gearbox
– Detach both ventilation caps -arrows- and close in an oil-tight

manner with suitable screw plugs.
Caution
The ventilation cap on the mechatronics is damaged when re‐

moved and must be replaced!
The oil filling in the area with the hydraulic oil for mechatronics
can not be checked. Before assembly work, the ventilation of
the mechatronics must be sealed oil-tight.
The oil escaping from the area with hydraulic oil for mecha‐
tronics cannot be refilled nor checked. In the event of an oil
loss, the mechatronics must be replaced!
2. Clutch 67
– Turn gearbox so that the clutch is facing up.
– Remove the circlip of the hub -arrow-.
– Use the hook - 3438- and a screwdriver to remove the hub.

It is possible that the clutch is resting on the circlip so that the
circlip fits very tightly. In this case it is possible to press the clutch
slightly downwards as described in the following work procedure.
In doing so, the circlip is released.
Caution
Do not knock on the clutch or the shaft with a hammer!
• Always replace circlip -arrow-.

Clutch circlip -arrow- cannot be removed

– Position the supporting bridge - T10323- parallel to the flange

– Equalise distances, e.g. using washers -B- with a total thick‐
ness of 15 mm.
– Attach the supporting bridge - T10323- with screws -A- and
secure with nuts.
Caution
Risk of damage to the clutch as well as to other components!

Press the clutch downwards with light force without pressing
it.
– Carefully press the clutch downwards via the spindle.

– Remove supporting bridge - T10323- .

• The circlip may not be reused.
Continue after removing the clutch circlip.
– Insert the extractor - T10373- in the clutch and remove the

clutch.
– Remove the clutch together with the extractor - T10373- .
2.3 Install double clutch

2. Clutch 69
♦ Adhesive - AMV 195 KD1 01-
Caution
♦ on gearboxes up to production date 05.2011: Bearing of
the engaging lever
♦ on gearboxes as of Production date 06.2011: Ball pin of
the engaging lever for clutch K2
⇒ “1.3 Adjust clutch release mechanism”, page 41 .
Note

Caution
Perform adjustment before installing the double clutch.

If not correctly adjusted, do not continue with further installa‐
tion.
Only one adjusting washer may be installed on all bearings.
The parts of the clutch must be installed free of grease and oil!
The clutch is self-adjusting. Vibrations can have a negative ef‐
fect on the adjusting device. Therefore do not let the clutch fall.
Do not let the clutch fall into the gearbox when installing it.
A clutch that has been dropped on a hard surface, or which is
otherwise damaged, must no longer be installed.
• The mechatronics for double clutch gearbox - J743- is installed

on the gearbox
• The clutch release mechanism is installed
⇒ “1.2 Removing and installing clutch release mechanism”,
page 34
– Screw out spindle of the extractor - T10373- .

– Position the extractor onto the clutch.

– Insert the clutch with extractor - T10373- into the gearbox and
then remove the extractor.
– Position the supporting bridge - T10323- parallel to the flange

– Equalise distances, e.g. using washers -B- with a total thick‐
ness of 15 mm.
– Secure the supporting bridge - T10323- with screws -A- and
nuts.
– Press the clutch downwards via the spindle as far as it will go.
During press-in procedure, place a hand onto the clutch. A slight
rattling can be felt. Rattling means that the clutch is pressed onto
its press seat. The stop should be felt in this way when the clutch
has reached its seat.
• The clutch is pressed in up to the stop if the circlip can be
inserted.
– Hold the circlip with the circlip pliers, as shown in the figure.
• Fitting position of the circlip: The narrower impact side of the
circlip facing upwards.
– Insert the new circlip -arrow-.
2. Clutch 71
– Turn the clutch against the extractor - T10373- by hand so that

the clutch finds its fitting position.
The clutch sits on the input shaft in the bottom part when it is
pressed up to the stop, but this is not the optimum position.
The clutch should only be pulled up until it touches the circlip.
– Only rotate the clutch by hand, and do not use any other tool.
The clutch then slides in place against the circlip.
– Place the hub in position.

The hub has a large tooth and therefore only fits in one position.
On the -engine side-, the large tooth has a marking -arrow-.
– Insert the circlip for the hub -arrow-.

• Install the hub with the marking on the large tooth in such a
way that it is flush with the marking on the drive plate
-arrow-.
• Fitting position: The joint of the ring must point to the hub on
the clutch.

– Turn the clutch by hand and, while turning it, pay attention to
the small engaging lever.
• During rotation, there should be no resistance or braking.

• During this process, the engaging lever must remain in its po‐
sition without moving. It must not move up or down -arrows-.
• If any of these events occur when rotating the clutch, the ad‐
justing washers are not seated correctly and the clutch must
be removed again ⇒ “2.2 Remove double clutch”, page 66 .
– Check the fitting position of the adjusting washers -arrows-.

♦ Have a close look at the adjusting washers -arrows-.
♦ The adjusting washers must be installed correctly and must
not be damaged.
♦ It is possible that there has been an error in the calculation. In
this case, check the measurement
– Remove the screw plugs and position both ventilation caps

-arrows- again.
with the ⇒ Vehicle diagnostic tester.
2. Clutch 73
2.4 Replacing the sealing ring for the outer

drive shaft
♦ Pipe section - MP3-450 (VW 415A)-
♦ Extractor tool - T20143-
2 shaft seals are located in the gearbox -arrows- on the clutch
side. Both seals can be replaced without disassembling the gear‐
box. If only the shaft seals are replaced, the double clutch must
not be adjusted.
In the event of a gearbox drive shaft “Leaks” error, the condition
of the engine crankshaft sealing flange on the gearbox side must
also be checked.
• Clutch release mechanism is removed
page 34

Caution
If there are leaks, you must check the double clutch. If the
double clutch is covered in oil, it will need to be replaced.
– Lever out shaft seal for outer drive shaft.

– Drive in new shaft seal so that it is flush with the clutch housing.
Use a plastic hammer for this purpose.
• The shoulder -arrow- on the pipe section - MP3-450- points
upwards.
Note
If the inner drive shaft is installed, position the pipe - T30055

(3296)- onto the pipe section - MP3-450- if necessary.
Caution
Touch the gasket ring until flush to ensure the oil bore under‐
neath is not blocked In this case, the bearing is not given a
sufficient supply of oil.
– Install the clutch release mechanism

page 34 .

– Install double clutch ⇒ “2.3 Install double clutch”, page 69 .
2.5 Replace gasket ring for inner drive shaft

♦ Gasket ring extractor - T10420-
2 shaft seals are located in the gearbox -arrows- on the clutch
side. Both seals can be replaced without disassembling the gear‐
box. If only the shaft seals are replaced, the double clutch must
not be adjusted.
In the event of a gearbox drive shaft “Leaks” error, the condition
of the engine crankshaft sealing flange on the gearbox side must
also be checked.
• Clutch release mechanism is removed
page 34
Caution
If there are leaks, you must check the double clutch. If the
double clutch is covered in oil, it will need to be replaced.
– Release the spindle of the gasket ring extractor - T10420- .
2. Clutch 75
– Screw in gasket ring extractor for shaft seals - T10420- without

spindle into the small inner shaft sealing ring.
While doing so, press onto the gasket ring extractor for shaft seals
- T10420- .
• Screw sealing ring extractor for shaft sealing ring - T10420- in
until the sealing ring begins to turn in its bearing.
– Next, screw the spindle back into the gasket ring extractor for
shaft seals . If necessary, hold the outer drive shaft while doing
so.
– Remove the shaft seal using the screws on the spindle.
– Drive in the new shaft sealing ring up to the stop of the thrust
piece - T10421- .
Depth of installation of the gasket ring: 17.5 ± 0.2 mm
– Install the clutch release mechanism
page 34 .
– Install double clutch ⇒ “2.3 Install double clutch”, page 69 .

1 Mechatronics for double clutch gear‐
box - J743-
⇒ “1.1 Summary of components - mechatronics for double clutch
gearbox J743 ”, page 77
⇒ “1.2 Remove mechatronics for double clutch gearbox J743 ;
gearbox installed.”, page 79
⇒ “1.3 Bringing the mechatronics for double clutch gearbox J743
to the removal position by hand”, page 87
⇒ “1.4 Install mechatronics for double clutch gearbox J743 ; gear‐
box installed”, page 89
1.1 Summary of components - mechatronics for double clutch gearbox - J743-
1 - Screw
gearbox - J743- at gear‐
box housing
sembly
❑ 10 Nm
2 - Screw
gearbox - J743- at gear‐
box housing
sembly
❑ 10 Nm
3 - Mechatronics for double
clutch gearbox - J743-
❑ The mechatronics is al‐
located according to the
gearbox code letters ⇒
Electronic Catalogue of
Original Parts .
❑ Bring the mechatronics
to removal position by
hand
⇒ “1.3 Bringing the me‐
chatronics for double
clutch gearbox J743 to
the removal position by
hand”, page 87
❑ Remove mechatronics
⇒ “1.2 Remove mecha‐
gearbox J743 ; gearbox installed.”, page 79
❑ Install mechatronics
⇒ “1.4 Install mechatronics for double clutch gearbox J743 ; gearbox installed”, page 89

On some transmissions, a cover is present above the engaging

lever.
The cover protects against contamination.
Tightening torque securing bolts: 8 Nm
View of the selector forks of the gearbox when the mechatronics
is removed
N - Neutral
R - Reverse gear
When the reverse gear is en‐
gaged, the extended tappet of
the mechatronics is hooked on
the gearbox housing.
Therefore, the mechatronics

must be put into the removal
position by hand
⇒ “1.3 Bringing the mechatron‐
ics for double clutch gearbox
J743 to the removal position by
hand”, page 87 .
1 - first gear
2 - second gear
3 - third gear
4 - fourth gear
5 - fifth gear
6 - sixth gear
7 - seventh gear

1.2 Remove mechatronics for double clutch

gearbox - J743- ; gearbox installed.
♦ Assembly lever - T10407-
♦ Catch pan - VAS 6208-
WARNING
Follow the safety measures when working on the mechatronics

for double clutch gearbox - J743-
⇒ “2.3 Safety measures for working on the mechatronics for
double clutch gearbox J743 ”, page 2 .
Note
♦ Observe general repair instructions and other instructions for

automatic gearbox DSG - 0AM

⇒ “3 Repair instructions”, page 4 .
♦ The new mechatronics for the gearbox is already precisely fil‐
led with oil at the factory, do not drain the oil.
♦ The removed mechatronics is sent back with oil (close the
ventilation opening with a suitable plug).
♦ Pay attention to the ventilation when handling the mechatron‐
ics .
♦ During assembly work, remove the air bleed valve and close
the opening with a suitable screw plug. In case of oil leakage
from the mechatronics , the mechatronics must be replaced ⇒
♦ The clutch is self-adjusting. Vibrations can have a negative
effect on the adjusting device. Even when the mechatronics is
removed, the sudden removal of the assembly lever - T10407-
below the engaging levers can have a negative effect on the
adjusting device.
♦ Ensure adequate clearance in front of the gearbox in order to
remove the mechatronics. Components, which are not directly
connected with the gearbox, must be removed on some vehi‐
cles. Any brackets on the screw plugs of the mechatronics
must be removed.
27 .
♦ Before removing the mechatronics , basic setting of the neutral
position of the gearbox must be performed ⇒ Vehicle diag‐
nostic tester
– Shift selector lever into position P.

– Connect vehicle diagnosis, measurement and information
system - VAS/ODIS- .
– Select Targeted functions .
Under “7-speed double clutch gearbox”, select bring gear ac-
tuator into neutral position .


gr. 23 .
gr. 27 .
Caution


– Release the connector catch of the mechatronics by pulling it
in -direction of arrow- and disconnect the plug.

the gearbox.
Caution
The ventilation cap on the mechatronics is damaged when re‐

moved and must be replaced!
The oil filling in the area with the hydraulic oil for mechatronics
can not be checked. Before assembly work, the ventilation of
the mechatronics must be sealed oil-tight.
The oil escaping from the area with hydraulic oil for mecha‐
tronics cannot be refilled nor checked. In the event of an oil
loss, the mechatronics must be replaced!
– Remove the cover from the ventilation and close the opening
with a suitable screw plug so that no oil can escape.
WARNING
When the engine is warm the cooling system is under pressure.

Slowly open the cap of the coolant expansion tank to first re‐
duce pressure before pulling off the coolant hoses.
– Raise vehicle.
gr. 50 .
– Remove the charge air hose from the bottom left charge air
cooler and the charge air pipe ⇒ Engine; Rep. gr. 21 .
– Shut off the opening of the charge air cooler so that no coolant
can penetrate.
Vehicles Octavia II, Superb II, Yeti, Rapid NH

– Disconnect plug -2- at the coolant temperature sender at ra‐

diator outlet - G83- .
– Place a catch pan for workshop crane - VAS 6208- under the
radiator.
– Remove the bottom coolant hose -1- from the radiator, to do
so raise the retaining clip ⇒ Engine; Rep. gr. 19 .
– Separate the plug connections -1- of the bottom radiator fan

at the fan shroud.
– Screw out screws -arrows- and remove fan shroud with radi‐
ator fans downwards.
Fabia II and Roomster vehicles with radiator fan control unit -

J293-
radiator fan control unit - J293- -4-.
• Do not disconnect the plugs -1- and -2-.
Continued for all Fabia II and Roomster vehicles


– Place a catch pan for workshop crane - VAS 6208- under the
radiator.
– Remove the bottom coolant hose from the radiator -arrow- and
drain the coolant ⇒ Engine; Rep. gr. 19 .
– Drain off oil.

Note
Suction off oil residues which do not escape from the gearbox
after removing the mechatronics with the diesel extractor, e. g. -
VAS 5226- .

– Where present, remove the cover above the engaging lever.

– Remove the electrical lines from the bottom holder at the front
of the mechatronics and tie up.
– Remove all the brackets from the gearbox.

– Carefully unlock the gearbox input r.p.m. sender - G182- with

a screwdriver and pull it out of the housing in the

Now both levers of the clutch control must be pressed off the me‐
chatronics with the assembly lever - T10407- . Otherwise the
levers for mechatronics strike the tappets and the mechatronics
cannot be removed.
– Insert the assembly lever - T10407- between the two clutch

engaging levers and the gearbox housing in the
The assembly lever - T10407- should rest with the complete sur‐
face of the reverse side against the gearbox housing and the
groove should form one level with the recess of the housing
-arrow-.
• Do not insert the assembly lever - T10407- up to the stop.

– Turn the assembly lever - T10407- to the left in

from the tappets.
• Do not remove the assembly lever - T10407- .
If necessary, press the assembly lever - T10407- against the

gearbox using a screwdriver, thereby both levers of the double
clutch gearbox are pressed off the mechatronics .
Caution
While doing so, the rubber grommets of the double clutch ad‐
justers should not be damaged.
– Unscrew long screws -B- (4 screws, M8 x 90) crosswise in

stages.

– Unscrew short screws -A- (3 screws, M8 x 35) crosswise in

stages.
Caution
Do not remove more than 7 screws!

There are 4 long and 3 short screws.
Do not loosen the screw plugs of the mechatronics .

Caution

clutch gearbox - J743- , after you have discharged yourself
contact with mass.
Caution
Place down the removed mechatronics so that no oil is able to

escape through the vent (seal ventilation opening with a suit‐
able plug).
After removing the mechatronics, leave the assembly lever -
T10407- inserted between the engaging levers of the double
clutch and gearbox housing. Removing the assembly lever can
produce negative effects on the automatic adjusting device of
the clutch.
If the double clutch gearbox mechatronics - J743- “is fixed in

place” and cannot be removed
It is possible that the mechatronics cannot be removed if the gear

actuator top left on the gearbox housing jams -arrow-.
Caution

creased force.
• The mechatronics must be repositioned at the gearbox hous‐

ing, fixed with a screw, and put into removal position by hand
⇒ “1.3 Bringing the mechatronics for double clutch gearbox
J743 to the removal position by hand”, page 87 .
Removed double clutch gearbox mechatronics - J743- is returned
with oil.

– Make sure that no oil flows out of the ventilation -arrow- (close
the ventilation opening with a suitable screw plug).
The new double clutch gearbox mechatronics - J743- is filled with
recycled oil.
Install mechatronics on installed gearbox
⇒ “1.4 Install mechatronics for double clutch gearbox J743 ; gear‐
box installed”, page 89 .
1.3 Bringing the mechatronics for double

clutch gearbox - J743- to the removal
position by hand
It is possible that the mechatronics cannot be removed. In this
case, the gear actuator -arrow- jams on the gearbox housing.
If the removal position could not be set with the vehicle diagnosis,
measurement and information system - VAS/ODIS- , the mecha‐
tronics must be brought to the removal position by hand.
The jammed gear actuator must now be pressed by hand into the
removal position. To do so, remove the cover on the gearshift
shaft.
Gearbox installed
• The mechatronics is located in the gearbox housing and is
secured with a screw.
Vehicles Octavia II, Superb II, Yeti and Rapid NH
gr. 27 (if they were not yet removed).
Vehicles Fabia II and Roomster
gine; Rep. gr. 24 .
– Expose the selector lever control cable -A- of the gearbox shift
lever with the removal tool for the inner lining of the door panel
-MP8-602/1- (if it has not yet been removed).


position.
– Carefully push the selector lever control cable to the rear, re‐
move it from the cable support and tie up.
Note
♦ The lock washer -arrow- of the selector lever must always be

replaced.
Gearbox removed
– Press the lever in -direction of arrow- by hand up to the stop

and shift the gearshift lever to position P.
The gearbox is installed or removed
– Remove gearshift lever.

– Remove cover.
Caution
The mechatronics will no longer clamp at the next work step.

This means, it will malfunction under certain circumstances. If
not yet performed, the mechatronics must be secured at the
gearbox with a screw against falling down.
– Push the shift lever to the side through the opening in the
By doing so, the jammed gear actuator is now pressed back and
the mechatronics can be removed.
– Clean the sealing surface on the gearbox and the cover.
– Grease the shaft seal in the cover with sealing grease - G 052
128 A1- .
Note
Replace the screw of the gearshift lever after removal.

– Install the cover and the gearshift lever again.

Fill gearbox with gear oil ⇒ “5 Change gearbox oil”, page 174 .
Specified torques
Component Nm
Screw for gearbox shift 15 Nm
lever to gearshift shaft
Screw for gearbox cov‐ 8 Nm
er to gearbox
1.4 Install mechatronics for double clutch

gearbox - J743- ; gearbox installed
♦ Assembly lever - T10407-
♦ Guide bolt - T10406-
♦ Catch pan for workshop cranes - VAS 6208-
♦ Diesel extractor , e. g. -VAS 5226-
Caution
In case of oil leakage from the mechatronics, the mechatronics

must be replaced ⇒ Electronic Catalogue of Original Parts .
The new mechatronics for double clutch gearbox - J743- is al‐
ready precisely filled with oil at the factory.
Therefore, it is only possible to fill the mechatronics with oil at
the factory.
Note
♦ The mechatronics for double clutch gearbox - J743- is as‐

signed to the gearbox identification characters ⇒ Electronic
♦ The removed mechatronics for double clutch gearbox - J743-
is sent back with oil (close the ventilation opening with a
suitable plug).
– If this is not yet the case, close the ventilation with a suitable
screw plug -arrow- so that no oil can flow out.

• Before installing the mechatronics, make sure that no oil is in

the gearbox.
• The assembly lever - T10407- is inserted between the engag‐
ing levers of the double clutch gearbox and the gearbox hous‐
ing.
– Suction off residual oil from the gearbox with diesel suction
device, e. g. -VAS 5226- .

The centre position is shown in the figure as position -N- (neutral).
No gear is engaged in this position, i.e neutral (neutral position)
is engaged.
– Then bring all the shift forks back to the centre position, posi‐
tion -N-.

N - Neutral
R - Reverse gear
1 - first gear
2 - second gear
3 - third gear
4 - fourth gear
5 - fifth gear
6 - sixth gear
7 - seventh gear
– Screw in guide bolts - T10406- by hand.
Adjust gear actuator:
Caution

J743- .
When removing the pins, do not press the senders.


for double clutch gearbox - J743- into the specified position.

– Clean the sealing surface on the gearbox housing on which
Oil residues on the sealing surface can lead to the wrong diag‐
nosis »leaking« at a later stage.

• The seal for mechatronics for double clutch gearbox - J743-

– Check the sender. The clip must not be damaged.
– Install mechatronics.
When handling and installing, make sure that the shift forks are
not unintentionally pressed out of their position. Also pay attention
to the engaging lever and the tappet of the mechatronics.

– Remove guide bolts - T10406- .

• Make sure that the tappets grip precisely into the engaging
lever bearing. Pull out the tappets by hand until they fit in these
bearings.
– Check the position of the tappets once again.

Incorrectly mounted tappets will damage the mechatronics.

The tappets can be put into their correct positions by means of a
hook made from welding wire.
gearbox - J743- crosswise to the specified tightening torque.
– Turn the assembly lever - T10407- slowly and carefully to the
right and remove it.
• Both clutch adjusters must correctly lock in the recesses of the
engaging levers of the double clutch.
• While doing so, the rubber grommets of the double clutch ad‐
justers should not be damaged.
• The rubber grommets must rest on the mechatronics.
• An incorrect assembly or damage to the rubber grommets
leads to oil leakage in the mechatronics.
– Position the gearbox input r.p.m. sender - G182- in the

-direction of arrow- on the gearbox housing.
– Check gearbox input r.p.m. sender - G182- . The clip must not
be damaged.
• The gearbox input r.p.m. sender - G182- must be positioned
completely and tightly with its tab on the gearbox housing.
• If the sender is loose, the clip of the mechatronics is broken
must be replaced.
ventilation cap.

– Install the cover against contamination above the engaging

lever.
Caution

– Grab with the hand (without gloves) at the mass, so that it dis‐
charges electrostatically.
– Mount the plug of the mechatronics and lock.

– Reattach all brackets and cables to the gearbox.
– Install fan shroud with fans ⇒ Engine; Rep. gr. 19 .
Vehicles Octavia II, Superb II, Yeti and Rapid NH
– Attach the bottom coolant hose -1- at the radiator ⇒ Engine;

Rep. gr. 19 .
– Fit on plug -2- and fill up with coolant ⇒ Engine; Rep. gr. 19 .
– Install charge air hose ⇒ Engine; Rep. gr. 21 .
– Pour in gear oil ⇒ “5 Change gearbox oil”, page 174 .
sary
ble”, page 105 .
gr. 27 .
23 .
– Connect battery ⇒ Electrical System; Rep. gr. 27 .

– Attach the bottom coolant hose at the radiator -arrow- and fill
up with coolant ⇒ Engine; Rep. gr. 19 .
– If removed, install the radiator fan control unit - J293- on the
left frame side rail.
– Pour in gear oil ⇒ “5 Change gearbox oil”, page 174 .
– Install the starter motor ⇒ Electrical System; Rep. gr. 27 .
gr. 27 .
sary
ble”, page 105 .

After the installation of the mechatronics , perform a basic set-
ting with the ⇒ Vehicle diagnostic tester.
Specified torques
Component Nm
Mechatronics for dou‐ ⇒ “1.1 Summary of components - me‐
ble clutch gearbox - chatronics for double clutch gearbox
J743- on gearbox J743 ”, page 77
Cover to prevent con‐ 8 Nm
tamination on gearbox

2 Shift mechanism
page 97
⇒ “2.2 Inspecting the gearshift mechanism”, page 104
⇒ “2.3 Inspecting and adjusting the selector lever control cable”,
page 105
page 108
⇒ “2.5 Removing and Installing the cover for the shift mechanism”,
page 109
⇒ “2.6 Removing and installing handle for shift mechanism”, page
112
⇒ “2.7 Installing the lock button at the selector lever handle”, page
116
er control cable”, page 118
⇒ “2.9 Removing and installing selector lever control cable, vehi‐
cles up to 05.2009 (Octavia II, Superb II, Yeti)”, page 123
⇒ “2.10 Emergency release of gearshift mechanism out of posi‐
tion P”, page 127
⇒ “2.11 Removing and installing the Tiptronic switch F189 ”, page
130
⇒ “2.12 Removing and installing selector lever lock solenoid N110
”, page 130
⇒ “2.13 Removing and installing selector lever switch locked in P
F319 ”, page 130
⇒ “2.14 Removing and installing the selector lever sensor control
unit J587 ”, page 130
⇒ “2.15 Checking the plug connections at the shift mechanism
(Octavia II, Superb II, Yeti)”, page 131
2.1 Summary of components - Gearshift

mechanism
⇒ “2.1.1 Summary of components - Gearshift mechanism up to
05.2009 - (Octavia II, Superb II, Yeti)”, page 97
⇒ “2.1.2 Summary of components - Gearshift mechanism as of
06.2009 - (Octavia II, Superb II, Yeti, Rapid NH)”, page 99
⇒ “2.1.3 Summary of components - Shift mechanism (Fabia II,
⇒ “2.1.4 Summary of components - Gearshift mechanism (Rapid
India)”, page 103
2.1.1 Summary of components - Gearshift mechanism up to 05.2009 - (Octavia

II, Superb II, Yeti)

❑ removing
shift mechanism”,
page 109
anism out of position P”,
page 127
the cover
sembly
ing claw - V.A.G 1275-
3 - Selector lever and shift
mechanism
solenoid - N110-
❑ Emergency release
page 127
stalling shift mechanism
with selector lever con‐
trol cable”, page 118
❑ after the installation adjust the selector lever control cable
⇒ “2.3 Inspecting and adjusting the selector lever control cable”, page 105
4 - Screw with spring
❑ 3 Nm
5 - Bolt
❑ removing
⇒ “2.9 Removing and installing selector lever control cable, vehicles up to 05.2009 (Octavia II, Superb
II, Yeti)”, page 123
❑ do not grease
6 - Lock washer
7 - Nut
❑ 4 pieces
❑ 9 Nm
8 - Shift housing
❑ with gasket

⇒ “2.9 Removing and installing selector lever control cable, vehicles up to 05.2009 (Octavia II, Superb
❑ testing and adjusting ⇒ “2.3 Inspecting and adjusting the selector lever control cable”, page 105
11 - Cable support
12 - Lock washer
❑ when installing, make sure that it locks correctly into place
13 - Nut
❑ 4 pieces
❑ 9 Nm
2.1.2 Summary of components - Gearshift mechanism as of 06.2009 - (Octavia

II, Superb II, Yeti, Rapid NH)


11.2012 (CW 45) (Octavia II,
Superb II, Yeti)
cover
shift mechanism”,
page 109
handle up to 11.2012
(CW 45)
stalling handle for shift
❑ As of 11.2012 (CW 45),
the selector handle was
changed, see Pos. 2
page 127
the cover
11.2012 (CW 45) (Octavia II,
Superb II, Yeti)
cover
shift mechanism”, page 109
❑ Removing and installing handle as of 11.2012 (CW 45)
⇒ “2.6 Removing and installing handle for shift mechanism”, page 112
⇒ “2.10 Emergency release of gearshift mechanism out of position P”, page 127
3 - Cover with handle (Rapid NH)
❑ Removing and installing cover
⇒ “2.5 Removing and Installing the cover for the shift mechanism”, page 109
❑ Removing and installing handle ⇒ “2.6 Removing and installing handle for shift mechanism”, page 112
5 - Selector lever and shift mechanism
❑ Emergency release ⇒ “2.10 Emergency release of gearshift mechanism out of position P”, page 127
6 - Screw
❑ 8 Nm
8 - Nut
❑ 4 pieces
❑ M6 - 8 Nm
❑ M8 - 25 Nm
9 - Gearshift lever
10 - Cable support
11 - Lock washer
❑ The selector lever control cable must not be removed from the shift mechanism Pos. 5 and it must be
replaced together as one component part.

-direction of arrow-. Do so by unscrewing 4 screws Pos. 6 from
the shift housing Pos. 7.
2.1.3 Summary of components - Shift mechanism (Fabia II, Roomster)

11.2012 (CW 45) (Fabia II,
Roomster)
cover
shift mechanism”,
page 109
handle
stalling handle for shift
❑ As of 11.2012 (CW 45),
the selector handle was
changed, see Pos. 2
from the centre console
page 127
the cover
11.2012 (CW 45) (Fabia II,
Roomster)
cover
shift mechanism”, page 109
❑ Removing and installing handle ⇒ “2.6 Removing and installing handle for shift mechanism”, page 112
❑ for the emergency release only the cover needs to be unclipped from the centre console

4 - Centre console
❑ remove it for the removal and installation procedure of the gearshift mechanism
5 - Noise insulation
❑ can only be removed after the removal of the centre console
6 - Gearshift mechanism with selector lever and selector lever control cable
❑ Emergency release ⇒ “2.10 Emergency release of gearshift mechanism out of position P”, page 127
7 - Screw
❑ 4 pieces
❑ 8 Nm

9 - Nut
❑ 4 pieces
❑ M6 - 8 Nm
❑ M8 - 25 Nm
11 - Cable support
12 - Circlip
❑ The selector lever control cable must not be removed from the gearshift mechanism Pos. 6 and it must
be replaced together with the gearshift mechanism.
-direction of arrow-. To do so, unscrew 4 screws Position 7 from
the shift housing Position 8.

2.1.4 Summary of components - Gearshift mechanism (Rapid India)

❑ Depending upon vehicle
equipment
shift mechanism”,
page 109
the cover
❑ Depending upon vehicle
equipment
shift mechanism”,
page 109
the cover
sembly
ing claw - V.A.G 1275-
4 - Shift mechanism
❑ Remove shift housing
⇒ Fig. ““Remove the shift mechanism together with the selector lever control cable from the shift hous‐
ing”“ , page 104
5 - Screw
❑ 8 Nm
7 - Nut
❑ 4 pieces
❑ 25 Nm
8 - Gearshift lever
9 - Cable support

10 - Screw
❑ 2 pieces
❑ 23 Nm
❑ The selector lever control cable must not be removed from the shift mechanism Pos. 4 and must be
replaced together as one component part.
exhaust system
12 - Support
13 - Nut
❑ 13 Nm
-direction of arrow-. To do so, unscrew the 4 screws Pos. 5.

♦ In selector lever positions S, D, R and Tiptronic position it must
not be possible to activate the starter.
N, the selector lever lock solenoid must not engage and block
position.
lector lever position N, the selector lever lock solenoid must
shifted from position N by activating the brake pedal.
Selector lever in position P, button on selector lever pressed and
ignition switched on
• Brake pedal is not operated.
The selector lever is locked when the button is pressed and can‐
not be shifted out of position P.
The selector lever lock solenoid blocks the selector lever.
• Brake pedal is operated.
lever from P through R, N, D, S; while doing so check whether the
selector lever position in the dash panel insert corresponds with
the actual selector lever position.

Selector lever in position N, button on selector lever pressed and

ignition switched on
• Brake pedal is not operated.
N. The selector lever lock solenoid blocks the selector lever.
• Brake pedal is operated.
Note
Shifting out of the position N to D by activating the brake pedal is

also possible without pressing the button on the selector lever.
From position N to R the button on the selector lever also must
be pressed.
Selector lever in position D, ignition switched on

The selector lever is locked and cannot be shifted from position
D to position S.
• Button pressed on selector lever.
The selector lever is released and can be shifted from position D
to position S.
Selector lever in position D, ignition and light switched on
• Guide selector lever in the Tiptronic gear.
The light for D on the lamp for selector lever scale illumination -
L101- must go out and the + and – symbols should light up.
When the selector lever is shifted to the Tiptronic gate, the se‐
lector lever position indicator - Y6- in the dash panel insert must
change from P R N D S to 7 6 5 4 3 2 1.
• Shift selector lever in the Tiptronic gear to + and –.
The display of the selector lever position 7 6 5 4 3 2 1 in the dash
panel insert must indicate (select) a higher or a lower gear when
shifting the selector lever to + or to –.
If the gearshift mechanism does not function as described:
ble”, page 105 .
– Check ignition key anti-removal lock
page 108 .
Selector lever position indicator
If all parts of the selector lever position display are lit, it indicates
that the gearbox is in emergency operation mode.

lever control cable
• The gearshift mechanism is checked
– Pull selector lever back approx. 5 mm out of position P with
the button pressed, and hold, but do not shift into position R.

• The selector lever must automatically jump back again to po‐

sition P.
If this is not the case, then the gearshift mechanism must be set
⇒ page 106 .
– Push selector lever to position N.
– Pull selector lever approx. 5 mm back out of position N with
the button pressed and hold, but do not shift into position D.
position “N”
⇒ page 106 .
– Pull selector lever forward approx. 5 mm out of position N with
the button pressed and hold, but do not shift into position R.
position “N”

⇒ page 106 .
Adjusting selector lever control cable
The selector lever control cable must always be set, if:
♦ the selector lever control cable was removed from the gear‐
box.
♦ Remove and install engine and (or) gearbox.
♦ Removed and installed parts of the unit mounting.
removed and installed.
a stress-free adjustment of the assembly bracket.
gr. 23 .

– Check if the lock washer -arrow- is correctly fitted and secured

towards the bottom.
Note
The lock washer -arrow- must be replaced after each removal ⇒

– Slide the selector lever from position P to position S.

– Check the protective cover at the front gearshift mechanism
on the selector lever control cable for damage. The selector
lever control cable must be replaced if damaged.
move smoothly when shifting gears. If this is not the case, re‐
place the selector lever control cable or repair the gearshift
mechanism:
♦ ⇒ “2.1 Summary of components - Gearshift mechanism”, page
97
Setting

– Shift selector lever in the vehicle to position P.
Note
If the clamping screw -arrow- is released, the selector lever of the

gearshift mechanism must remain in position P, otherwise the
setting is not correct.
– Set the gearbox gearshift lever to position P. To do so, pushed

the gearshift lever in -direction of arrow- towards the cable
support.

The figure shows the gearbox from the rear. -P- position is in the
direction towards the cable support -arrow-.
– Turn both front wheels in one direction, e.g. by rolling the ve‐
hicle forwards, until the parking lock in the gearbox engages
into the parking gear.
• Only if both front wheels cannot be simultaneously turned in
one direction, the parking lock is engaged.
– Slightly move the selector lever towards the front and rear,
without shifting into another selector lever position.
Note
The selector lever control cable is therefore released.
– Tighten screw -arrow- at selector lever cable without jolting to

tightening torque.
Note

Pay attention when tightening the screw -arrow- that the selector
lever control cable no longer shifts.

23 .
Specified torques
Component Nm
Screw for selector lev‐ 13
er control cable (Octa‐
via II, Superb II and
Yeti)
♦ up to 11.2008

er control cable (Octa‐
via II, Superb II and
Yeti)
♦ from 12.2008

er control cable (Fabia
II, Roomster and Rapid
NH)
2.4 Check the function of the ignition key re‐

moval lock
– Turn the ignition key slightly to the right (do not start the en‐
gine) in order to set the position “ignition on”.
• Shifting the selector lever out of the position P when the lock
sible without jerking.
• The ignition key should only be removable when the selector
lever is in P.

Note
Up to 10.2011, this condition is not valid for the vehicles Fabia ll

and Roomster, where there is no ignition key anti-removal lock
and the key can be withdrawn in any selector lever position. On
all vehicles as of 11.2011, the key cannot be withdrawn in any
selector lever position, except position P.

• Only withdraw the key from the ignition starter switch if the
selector lever is in position P.
• The selector lever cannot be shifted out of position P when the
button is pressed and the brake pedal is actuated.
ble”, page 105 .

♦ Check the vehicle with the vehicle diagnosis, measurement
and information system - VAS/ODIS- in the function “targeted
fault finding”.

the shift mechanism
♦ Unlocking tool - T30098- (Octavia II, Superb II, Yeti, Rapid NH)
♦ Disassembly wedge - 3409- (Fabia II, Roomster)
Note
As of 11.2012 (CW 45), the selector lever was changed:
Removing
– Push selector lever to position N.
– Open ashtray in the centre console (if required).
Vehicles Octavia II and Yeti
– Use the release tool - T30098- to unlock the cover at front right
-arrow-, then rear right and centre -arrow-, in stages.
Vehicles Superb II


Vehicles Rapid NH

– Release cover -3- from the centre console using the disas‐
sembly wedge - 3409- .
For Rapid vehicles

– Carefully press the release tool - T30098- in

-direction of arrow- and subsequently clip the cover out of the
centre console.

– Detach the plug connection -A- for lamp for selector lever scale
– Pull the cover upwards over the handle.
– Release plug connection -C- from the lamp for selector lever
scale illumination - L101- and disconnect.
Note
♦ Ignore pos. -A-, -B- and -1-.

anism
⇒ “2.1 Summary of components - Gearshift mechanism”, page
97 .
Installing
note the following:

Note
♦ When inserting the plug connection -C- ensure that the contact
pins of the lamp for selector lever scale illumination - L101-
are not bent and that the retaining lugs of the cover do not
break off.
anism
⇒ “2.1 Summary of components - Gearshift mechanism”, page
97 .
2.6 Removing and installing handle for shift

mechanism
⇒ “2.6.1 Removing and installing handle for shift mechanism up
to 11.2012 (CW 45)”, page 112
⇒ “2.6.2 Removing and installing handle for shift mechanism as
of 11.2012 (CW 45)”, page 114
2.6.1 Removing and installing handle for shift

mechanism up to 11.2012 (CW 45)
Removing
nism”, page 109 .
– Pull out the lock button above its pressure point and secure it
with a cable strap or a suitable wire.
This can prevent the button being inadvertently pressed into the
handle.

Vehicles Superb II
Vehicles Fabia II, Roomster and Rapid

– Pull the cover upwards over the handle.
– Release plug connection -C- from the lamp for selector lever
scale illumination - L101- and disconnect.
Note

anism
⇒ “2.1.2 Summary of components - Gearshift mechanism as
of 06.2009 - (Octavia II, Superb II, Yeti, Rapid NH)”,
page 99 .

– Open the warm-type clamp below the handle -arrow- and pull
Installing
♦ To install the selector lever handle, the lock button must be
removed as far as the stop and secured with cable ties or an
assembly aid, which is delivered with the new handle in the
factory.
♦ If the lock button is not secured, this can no longer be removed
from the selector lever handle with mechanical aids. Press out
the lock button if necessary by positioning a compressed air
pistol on the underside of the grip.
– Press the selector lever handle completely onto the selector
lever with a new warm-type clamp.
• The selector lever handle must be positioned with the lock
button in the direction of the driver.
• The handle must latch into the groove on the selector.
– Remove the cable strap or the assembly aid.
After removal, the lock button engages into the vertical groove on
the selector. Where necessary, press the lock button into the se‐
lector lever handle.
– Tighten warm-type clamp using hose binding claw .
Note
♦ When inserting the plug connection -C- ensure that the contact
pins of the lamp for selector lever scale illumination - L101-
are not bent and that the retaining lugs of the cover do not
break off.
anism
page 99 .
2.6.2 Removing and installing handle for shift

mechanism as of 11.2012 (CW 45)
Removing
nism”, page 109 .

– Open the warm-type clamp below the handle -arrow-.
– Detach the selector lever handle -1- together with the selector
lever collar from the selector lever towards the top -arrow A-
so that the lock button -2- is not pressed in.
Note
Ignore -arrow B-.

Installing

following points:
• The lock button -2- is located in direction of travel.
Caution
The shift mechanism can be damaged.

♦ The lock button at the selector lever handle can protrude
when installing. If the lock button is inadvertently pressed
in when removing the selector lever handle, it must be re‐
positioned
⇒ “2.7 Installing the lock button at the selector lever han‐
dle”, page 116 .
♦ If the selector lever handle is installed with the lock button
pressed in, then the selector lever handle as well as the
selector lever control cable can be destroyed.
– Press the selector lever handle -1- onto the selector lever in
-direction of arrow B- in such a way that the lock button -2- is
not touched.
• The selector lever handle must latch into the round slot of the
selector lever.

– Tighten warm-type clamp -arrow- using the hose binding claw .
Note
♦ The selector lever handle is correctly locked only if the warm-

type clamp is tensioned. Only then the lock button at the
handle may be pressed.
♦ The lock button may be slightly sluggish when pressing it for
the first time after installing the selector lever handle.
– Press lock button at selector lever handle.

– Install trim panel for selector lever position indicator - Y6-
nism”, page 109 .
2.7 Installing the lock button at the selector

lever handle
• The lock button -2- at the selector lever handle protrudes in its
installed position.
If the lock button -2- was inadvertently pressed in, it must then be
repositioned in order to fit the selector lever handle.

– Carefully guide the release tool - T40203- in

-direction of arrow- into the selector lever handle up to the stop
-1-.
Note
The selector lever handle in the illustration is shown without the

selector lever collar. The selector lever collar does not separate
from the handle.
• The recess at the release tool - T40203- points to the lock

button and the hook points to the left.
– Hold the selector lever handle -A- and turn the release tool -
T40203- by 180° in -direction of arrow 1-.
– Hold the selector lever handle and carefully pull out the release
tool - T40203- -arrow 2-.
• When pulling out the release tool - T40203- , the lock button
at the selector lever handle -A- is pressed in and locked.
• Do not touch and press in the lock button again before instal‐
ling the selector lever handle.


nism with selector lever control cable
The selector lever control cable was replaced as a separate com‐
ponent part up to production date 05.2009
page 97 .
As of production date 06.2009, this is no longer possible. The
selector lever control cable must not be removed (separated) from
the shift mechanism and must be replaced together as one com‐
ponent part ⇒ Electronic Catalogue of Original Parts .
Removing
– Remove handle for shift mechanism:
♦ up to production date 11.2012 (CW 45)
⇒ “2.6.1 Removing and installing handle for shift mechanism
up to 11.2012 (CW 45)”, page 112 .
♦ as of production date 11.2012 (CW 45)
as of 11.2012 (CW 45)”, page 114 .
gr. 68 .
– Pull out the plug connector housing of the plug connection
-A- towards the front.
– Disconnect plug connection -A- from the shift mechanism to
the vehicle wiring harness.
Note
♦ Ignore pos. -B-, -C- and -1-.

anism
page 99 .
Vehicles Fabia II, Roomster

– Remove the noise insulation from the gearshift mechanism.


anism.
gr. 23 .
– Expose the selector lever control cable -A- from the gearbox
shift lever with the removal tool for the inner lining of the door
panel -MP8-602/1- .
– Remove lock washer -arrow- of the selector lever control cable

and leave the selector lever control cable must be left in the
fitting position.
Note

Parts .
♦ Do not press the selector lever control cable out of the cable
support towards the rear. The selector lever control cable is
only guided out of the cable support when removing the gear‐
shift mechanism.
– Raise vehicle.

-7- from the body.
Caution

– Detach the bracket -3- for exhaust system from the assembly
carrier.
– Separate exhaust system at the clamping sleeve -4- ⇒ En‐
gine; Rep. gr. 26 .
Note
– Loosen the clips -arrows- and remove the heat shield to the
rear.

– Release the nuts -1- and -2-.
Note

shift mechanism.
– Lower the shift mechanism together with the selector lever

control cable downwards and simultaneously guide the selec‐
tor lever control cable out of the cable support.
The shift mechanism (only vehicles up to production date 05.2009
page 97 ) can also be replaced without selector lever control ca‐
ble. To do so the selector lever control cable must be separated
from the shift mechanism and the selector lever control cable
must be removed
⇒ “2.9 Removing and installing selector lever control cable, vehi‐
cles up to 05.2009 (Octavia II, Superb II, Yeti)”, page 123 .

– Remove shift mechanism -arrow-.

Installing

hand.
– Tighten nuts -1- and -2-.
The fitting together of the plug connection -A- must not be per‐
formed, if the plug connector housing is latched into the shift
mechanism. When fitting together (high resistance because of the
spring) the catch of the plug connector housing breaks off.
– Connect plug -A- and plug connector housing and then latch
into the shift mechanism.
Note

06.2009 - (Octavia II, Superb II, Yeti, Rapid NH)”, page 99 .
gr. 68 .
– Install the gearshift mechanism with selector lever control ca‐

ble and attach it to the shift housing with screws -arrows-.
– Mount the plug connection -A- and position the noise insula‐
tion on the gearshift mechanism.
– Install handle for shift mechanism.
♦ up to production date 11.2012 (CW 45)
up to 11.2012 (CW 45)”, page 112
♦ as of production date 11.2012 (CW 45)
as of 11.2012 (CW 45)”, page 114
nism”, page 109 .

gearshift lever and secure in the cable support with a new lock
washer -1-.
page 108 .
ble”, page 105 .
23 .
Rep. gr. 50 .
gr. 26 .
Rep. gr. 26 .
Specified torques
♦ ⇒ “2.1 Summary of components - Gearshift mechanism”, page
97

control cable, vehicles up to 05.2009
(Octavia II, Superb II, Yeti)
The selector lever control cable was replaced as a separate com‐
ponent part up to production date 05.2009
⇒ “2.1.1 Summary of components - Gearshift mechanism up to
05.2009 - (Octavia II, Superb II, Yeti)”, page 97 .
As of production date 06.2009, this is no longer possible. The
selector lever control cable must not be removed (separated) from
the shift mechanism and must be replaced together as one com‐
ponent part ⇒ Electronic Catalogue of Original Parts .
Removing
– Shift selector lever into position S.
gr. 23 .

– Expose the selector lever control cable -A- from the gearbox
shift lever with the removal tool for the inner lining of the door
panel -MP8-602/1- .

position.
Note

Parts .
– Raise vehicle.
– Detach the bracket -3- for exhaust system from the assembly
carrier.
Note
Caution

-7- from the body.

– Loosen the clips -arrows- and remove the heat shield to the
rear.
– Unscrew the nuts -1- and push the shift housing -2- as far as
possible onto the selector lever control cable towards the front.

Caution
– Pull the locking tab -3-, which secures the bolt -4-, carefully in
the -direction of arrow A-.
– Insert the screwdriver into the right opening of the shift mech‐
anism, as shown, and press on the bolt.
– Remove lock washer -5-.
– Remove selector lever control cable.
Installing
♦ Inspect boot of selector lever control cable for damage; the
boot can only be replaced together with the selector lever con‐
trol cable.
♦ Check correct fitting of the boot and do not install the boot
twisted.

Do not grease ball socket of the selector lever control cable and
ball head/selector lever.
Caution
♦ Under no circumstances touch the circuit board of the

charge can destroy the electrical components and the
circuit board.
– Insert the selector lever control cable with protective cover into
the shift housing. Do not damage the boot.
– Insert the end of the selector lever control cable -4- into the
joint of the selector lever.
– Press bolt -3- downwards in -direction of arrow- and check if
the locking tab -2- is locked.
– Insert the lock washer -1- for the selector lever control cable.
• Fitting position: angled end towards the gearshift mechanism.

– Screw the gear shift housing onto the shift mechanism

-arrows-.
washer -1-.
– Shift selector lever from S to P.
move smoothly when shifting gears.

ble”, page 105 .
23 .
Rep. gr. 50 .
gr. 26 .
Rep. gr. 26 .
Specified torques
♦ ⇒ “2.1.1 Summary of components - Gearshift mechanism up
to 05.2009 - (Octavia II, Superb II, Yeti)”, page 97

nism out of position P
Selector lever lock solenoid - N110- locks the selector lever in
position P.
The selector lever can only be shifted out of P when the ignition
is on or the engine is started, the brake pedal is actuated and the
button on the selector lever handle is pressed.
position P; i.e. the vehicle cannot be moved because the parking
– Test fuse ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
– Check the battery voltage ⇒ Electrical System; Rep. gr. 27 .

If the selector lever cannot be moved out of position P despite the

checks, emergency release of the solenoids must be performed.
If the selector lever is then shifted again into the position P, it is
locked again in position P.
2.10.1 Perform emergency release (Octavia II,

Superb II, Yeti)
– Use the release tool - T30098- to unlock the cover at front right
-arrow-, then rear right and centre -arrow-, in stages.
Vehicles Superb II

Note

Vehicles up to production date 05.2009

– Press from right to left -arrow- on the yellow plastic wedge.
– Now press the button on the selector lever knob and shift the
selector lever out of the position P.
Note

Vehicles as of production date 06.2009

– Now press the button on the selector lever handle and shift the
selector lever -B- in -direction of arrow 2- out of the position P.
Note

2.10.2 Performing emergency release (Fabia

II, Roomster, Rapid NH)
nism”, page 109 .
Note


– Now press the button on the selector lever handle and shift the
selector lever -B- in -direction of arrow 2- out of the position P.
Note


switch - F189-
The Tiptronic switch - F189- is integrated firmly in the gearshift
mechanism and cannot be replaced separately.
If the Tiptronic switch - F189- is defective, the gearshift mecha‐
nism must be replaced

lock solenoid - N110-
The selector lever lock solenoid - N110- is integrated firmly in the
gearshift mechanism and cannot be replaced separately.
If the selector lever lock solenoid - N110- is defective, the gear‐
shift mechanism must be replaced

switch locked in P - F319-
The selector lever switch locked in P - F319- is integrated firmly
in the gearshift mechanism and cannot be replaced separately.
If the selector lever switch locked in P - F319- is defective, the
gearshift mechanism must be replaced

lever sensor control unit - J587-
Selector lever sensor control unit - J587- is integrated firmly in the
gearshift mechanism and cannot be replaced separately.
If the selector lever sensor control unit - J587- is defective, the
gearshift mechanism must be replaced


shift mechanism (Octavia II, Superb II,
Yeti)
Before repairing or checking the plug connections, try to deter‐
mine the origin of the damage via the “targeted fault finding” using
the ⇒ Vehicle diagnostic tester.
Before checking the plug connections, all control units in the ve‐
hicle should be checked with the ⇒ Vehicle diagnostic tester, if
necessary the faults must be rectified.
– Check plug connections ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
A - 10-pin plug for connection lines from the gearshift mechanism
to the gearbox (with CAN databus line)
B - 4-pin plug to selector lever lock solenoid - N110- , selector
lever sensor control unit - J587- and selector lever switch locked
in P - F319-
C - 10-pin plug to lamp for selector lever scale illumination - L101-
in the cover for the shift mechanism

Note

06.2009 - (Octavia II, Superb II, Yeti, Rapid NH)”, page 99 .


⇒ “3.1 Removing the gearbox”, page 132
⇒ “3.3 Tightening torques”, page 169

⇒ “3.1.1 Removing the gearbox (Octavia II, Yeti)”, page 132
⇒ “3.1.2 Remove gearbox (Superb II)”, page 140
⇒ “3.1.3 Removing the gearbox (Fabia II, Roomster)”,
page 148
⇒ “3.1.4 Removing gearbox (Rapid NH)”, page 157
3.1.1 Removing the gearbox (Octavia II, Yeti)

♦ Wedge - T10161-

♦ Bolt - 3282/29-
♦ Tensioning strap - T10038-
♦ Socket insert - T10107 A-
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
♦ Spring strap clips , e.g. -VAS 6340-
♦ Socket insert , e.g. -T10035- or socket insert XZN 14 - T10061-
Observe instructions and safety instructions for automatic gear‐
box DSG - 0AM.
♦ ⇒ “2 Safety instructions”, page 2
♦ ⇒ “3 Repair instructions”, page 4
All cable straps which are detached or cut open when removing,
should be fitted on again in the same place when installing.

Gearbox with different output shafts.

A - Rigid shafts up to 11.2008
B - flange shafts as of 11.2008
• Do not take out ignition key.
gr. 23 .
gr. 27 .
– Use disassembly tool for inner door trim panel -MP8-602/1- to

release selector lever control cable -A- from the gearshift lev‐
er.

position.
• The lock washer -arrow- of the selector lever control cable
Parts .
• Do not press the selector lever control cable out of the cable
only guided out of the cable support once the gearbox was
removed.
– Remove the earth cable from the holding down bolt of the
gearbox console.
– Release all the upper connecting screws of the gearbox/en‐
gine.
To this end, use if necessary socket insert - T10035- or socket
insert - T10061- .

On some engines, one of the screws is located in the assembly

opening for the starter -arrow-.
– Unscrew engine/gearbox connecting screw -arrow-.
Caution



66 .
Vehicles Octavia II

– Position supporting device -T30099- with base - T30099/1- .

Vehicles Yeti

– Fit supporting device -T30099- .
Note
Use only one spindle of the supporting device on 1.2/77 kW en‐

gine.

– Slightly pre-tension the engine/gearbox unit via the spindles,
do not raise.
Vehicles with the rigid shafts (up to 11.2008)
– Loosen the front right wheel bolts.
– Raise vehicle.
– Remove right front wheel.
– Raise vehicle.
gr. 50 .
gr. 66 .
-arrows-.
– Remove pendulum support from gearbox, to do so, release

the bolts -arrows B and C-.
Vehicles with 1.2/77 kW engines

– Unhook the plug connections -1 … 3- from the bottom bracket

at the front of the gearbox and disconnect.
gine; Rep. gr. 26 .
– Separate exhaust system at the clamping sleeve and remove
bracket for the exhaust system from the assembly carrier ⇒
– Tie up pre-exhaust pipe.
– If present, disconnect the electrical plug connection -1- on the

oil level and oil temperature sender - G266- .
– Unclip the wiring loom from the holder -2-.
– If present, remove front left vehicle level sensor - G78- .
– Unscrew the nuts -arrows- from the steering joint to the left
track control arm.
– Unhook the steering joint from the track control arm.

– Remove the screw -arrow- and release the coupling rod from
the anti-roll bar on the left side.
– Unhook the steering joint from the track control arm and re‐
lease the coupling rods from the anti-roll bar on both sides of
the vehicle.
– Press off the left and right rigid drive shafts from the rigid shafts
of the gearbox, e.g. with wedge - T10161- or tyre iron ⇒ Chas‐
sis; Rep. gr. 40 .
– Tie up the drive shafts as far as possible. Avoid damaging the

Vehicles with flange shafts (as of 11.2008)
40 .

– To remove, insert 2 screws in the right flange and counterhold

the flange shaft using an assembly lever.

– Remove the right flange shaft with the pressure spring from
the gearbox with the socket insert - T10107 A- .
– Seal the gearbox with suitable screw plugs.
– Unscrew bottom connecting screws -arrow°A- and -arrow°B-

from engine/gearbox.
Do not undo screw -arrow- yet on the engine side in the vicinity
of the right rigid shaft or right flange shaft.
On diesel engines, this screw is underneath the shaft, on petrol
engines, above it.
– Slacken the screws -1- of the gearbox console by approx. one

turn and screw out the screws -2-.

– Then lower the engine and gearbox via the spindles of the
supporting device - MP9-200 (10-222 A)- as far as necessary
so that there is a gap of dimension -a- between the gearbox
console and the gearbox mount.
• Dimension -a- = 60 - 70 mm
– Screw out screws -arrows- and remove gearbox console.

The gearbox mount - 3282- is placed on the engine/gearbox jack
- V.A.G 1383 A- and is aligned using the adjusting plate - 3282/59-
to remove the gearbox.
– Align arms of the gearbox mount - 3282- to match the holes in

the adjusting plate - 3282/59- .
- 3282/59- .
– Position the engine/gearbox jack - V.A.G 1383 A- below the
vehicle with the gearbox mount - 3282- .
• The arrow symbol on the adjusting plate - 3282/59- points in
– Align the gearbox mount - 3282- parallel to the gearbox.
– Screw the bolt - 3282/29- into the gearbox.
shown.
• To do so, place the panel of the drift under the gearbox hous‐
ing and not under the mechatronics.
– Secure the gearbox with the tensioning strap - T10038- .
– Support the gearbox with engine/gearbox jack - V.A.G 1383
A- from underneath.

– Unscrew the last connecting screw -arrow- at engine and

gearbox.
– Separate the gearbox from the engine and carefully lower it.
– When lowering the gearbox, guide the selector lever control
cable out of the cable support.
Caution
Observe all lines and coolant hoses when lowering the gear‐
box.

– Reinstall the right flange shaft.
In some cases, they are installed at the front holder on the gear‐
box.
Note
If a new gearbox is installed, the holders must be modified to the

new gearbox. holder
Transport the gearbox and secure it to the assembly stand

⇒ “4 Transport the gearbox and secure to the assembly support”,
page 172 .
3.1.2 Remove gearbox (Superb II)

♦ Supporting device - MP9-200 (10-222 A)-
♦ Adapter - MP9 200/18 (10-222 A /18)-
♦ Mounting bracket - T10346-
♦ Wedge - T10161-
♦ Bolt - 3282/29-
box DSG - 0AM.


Gearbox with different output shafts:
gr. 23 .
gr. 27 .

release selector lever control cable -A- from the gearshift lev‐
er.

position.
Parts .
removed.
gearbox console.
gine.
insert - T10061- .


Caution




– Screw on the bracket - T10346- into the rear opening for fas‐
tening the battery tray.
To do so, use a collar screw M6 or one of the fixing screws for the
battery tray.
– Position the supporting device - MP9-200 (10-222 A)- behind
– The supports of the supporting device - MP9-200 (10-222 A)-
must be placed on the wheelhouse frame side rail, as shown
in the figure.
• The supports must be placed behind the screw -arrow 1- and
to the side and touching screw -arrow 2-.
– Connect the holder - T10346- with the supporting device -
MP9-200 (10-222 A)- .
– Hook the second spindle into the front left engine lifting eye.
– Slightly take up the weight of the engine/gearbox unit via the
spindle, do not raise.
– Loosen the front right wheel bolts.
– Raise vehicle.
– Remove right front wheel.
– Raise vehicle.
gr. 50 .
gr. 66 .
-arrows-.

– Remove pendulum support from gearbox, to do so, release

the bolts -arrows B and C-.

track control arm.

– Remove the screw -arrow- and release the coupling rod from
the anti-roll bar on the left side.
– Unhook the steering joint from the track control arm and re‐
lease the coupling rods from the anti-roll bar on both sides of
the vehicle.
sis; Rep. gr. 40 .

40 .




engines, above it.
– Slacken the screws -1- of the gearbox console by approx. one

turn and screw out the screws -2-.

– Then lower the engine and gearbox via the spindles of the
supporting device - MP9-200 (10-222 A)- as far as necessary
so that there is a gap of dimension -a- between the gearbox
console and the gearbox mount.
• Dimension -a- = 60 … 70 mm.
– Screw out screws -arrows- and remove gearbox console.


- 3282/59- .
shown.
A- from underneath.


gearbox.
Caution
box.

box.
Note

new gearbox. holder

page 172 .
3.1.3 Removing the gearbox (Fabia II, Room‐

ster)
♦ Supporting device - MP9-200 (10-222 A)-
♦ Adapter - MP9-200/3 (10-222A/3)-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Bolt - 3282/29-
box DSG - 0AM.


gr. 23 .
gr. 27 .


release selector lever linkage-A- from the gearshift lever.


position.
Parts .
removed.
gearbox console.
gine.
insert - T10061- .

Caution




– Position the supporting device - MP9-200 (10-222A)- as

shown.
Position the supporting device - MP9-200 (10-222A)- so that the
supports -A- are located next to screw -arrow 1- and the support
for the front flap -arrow 2-.
• If hose and cable connections are located in the area of the
– Slightly pre-tension the engine/gearbox unit via spindles (do
not raise).
– Loosen the wheel bolts and the drive shaft bolts on front left
and front right.
– Raise vehicle.
gr. 50 .
gr. 66 .

– Unscrew screws -arrow B- and -arrow C- and disconnect the
pendulum support from the gearbox.
– Unhook the plug connections -1-, -2- and -3- from the bottom
bracket at the front of the gearbox and disconnect.
gine; Rep. gr. 26 .
Fabia II vehicles with 1.4/132 kW engines
– Disconnect the two bottom plug connections -arrows- of the

lambda probe - G39- and lambda probe after catalytic con‐
verter - G130- .

– Disconnect the wiring loom of the generator, of the lambda

probe after catalytic converter - G130- and of the lambda
probe - G39- from the supports -arrows-.
– Release clamps -1- and -3- on the charge air pipe -4-.
– Unscrew screws -2- from bracket for coolant pipe and remove
bracket.
The charge air pipe is removed subsequently together with the
pre-exhaust pipe.
– Unscrew screws -5- and -7- from the bracket of the pre-ex‐
haust pipe.


– Unscrew the nuts -arrows- from the steering joint on the track
control arm on both sides.
– Unhook the steering joint from the two track control arms.
– Unscrew nut -1- from both sides of coupling rod -3-.

– On both sides, remove the coupling rod -3- from the anti-roll
bar -2- and press to the rear.
– Release and unscrew screws -arrows- for steering gear from

assembly carrier.
– Tie up the steering gear.
– Fix the assembly carrier before removing ⇒ Chassis; Rep. gr.
40 .
– Remove assembly carrier with console without a steering gear
⇒ Suspension; Rep. gr. 40 .
sis; Rep. gr. 40 .

40 .





engines, above it.
Vehicles with radiator fan control unit - J293-

at the console -A-.
at the gearbox.

• The engine/gearbox assembly must be lowered so that the
fixing screws of the console/gearbox are loosened and can be
unscrewed (following figure).

– Unscrew the fixing screws -arrows- for the console on the

gearbox.
– Remove the gearbox console.

- 3282/59- .
shown.
A- from underneath.

gearbox.
Caution
box.


box.
Note

new gearbox. holder

page 172 .
3.1.4 Removing gearbox (Rapid NH)

♦ Surface - T30099/1-

♦ Bolt - 3282/29-
box DSG - 0AM.


gr. 23 .
gr. 27 .

release selector lever linkage-A- from the gearshift lever.

position.
Parts .
removed.
gearbox console.
gine.
insert - T10061- .


Caution



66 .
– Position supporting device - T30099- with base - T30099/1- .

lock carrier.
– Position original spindle -A- on adapter - MP9-200/3 (10-222A/
3)- and hook it into the front engine lifting eye.
In order for the spindle -B- of the supporting device - MP9-200
Reduce length of support bracket spindle - MP9-200/10

(10-222A/10)- by 100 mm
I - Original spindle MP9-200/10 (10-222A/10)
– Position the shortened spindle -B- on the rear adapter -
MP9-200/3 (10-222A/3)- .

– Unclip the rubber grommet and hook the shackle - 10-222 A/

12- into the rear engine lifting eye.
Caution

-arrows-.
– Then hook the shackle - 10-222 A/12- into the shortened spin‐
dle ⇒ page 159 .
– Slightly pre-tension the engine/gearbox unit via spindles (do
not raise).
– Loosen the wheel bolts and the drive shaft bolts on front left
and front right.
– Raise vehicle.
gr. 50 .
gr. 66 .
-arrows-.
– Unscrew screws -arrow B- and -arrow C- and disconnect the

pendulum support from the gearbox.

– Unhook the plug connections -1-, -2- and -3- from the bottom
bracket at the front of the gearbox and disconnect.
gine; Rep. gr. 26 .

– Unscrew the nuts -arrows- from the steering joint on the track
control arm on both sides.
– Unhook the steering joint from the two track control arms.

– Unscrew nut -1- from both sides of coupling rod -3-.

– On both sides, remove the coupling rod -3- from the anti-roll
bar -2- and press to the rear.
– Release and unscrew screws -arrows- for steering gear from

assembly carrier.
– Tie up the steering gear.

– Fix the assembly carrier before removing ⇒ Chassis; Rep. gr.
40 .
– Remove assembly carrier with console without a steering gear
⇒ Suspension; Rep. gr. 40 .

sis; Rep. gr. 40 .

40 .




engines, above it.
Vehicles with radiator fan control unit - J293-


at the console -A-.
at the gearbox.

• The engine/gearbox assembly must be lowered so that the
fixing screws of the console/gearbox are loosened and can be
unscrewed (following figure).
– Unscrew the fixing screws -arrows- for the console on the

gearbox.
– Remove the gearbox console.


- 3282/59- .
shown.
A- from underneath.

gearbox.
Caution
box.

box.
Note

new gearbox. holder

page 172 .

Installation is carried out in reverse order of removal. When in‐
stalling, note the following:

♦ Replace the self-locking nuts and screws when undertaking

assembly work.
Parts .
♦ The lock washer of the selector lever control cable must al‐
ways be replaced ⇒ Electronic Catalogue of Original Parts .
♦ Replace the needle bearing -arrow- in the crankshaft ⇒ En‐
gine; Rep. gr. 13 .

• Replace O-Rings -1- and circlips -2- to rigid shafts when a new
gearbox is to be fitted.
– Carefully raise gearbox with the engine/gearbox jack - V.A.G

1383 A- and put in its installation position using the spindles
of the gearbox mount - 3282- .
• Carefully insert the selector lever control cable in the cable
support when raising the gearbox.
• Observe all lines and coolant hoses when raising the gearbox.
– Adjust the gearbox mount - 3282- via the spindles in such a
way that the engine and the gearbox are aligned.
– Position the gearbox carefully onto the engine until the gear‐
box flange touches the entire scope of the engine flange, turn
the crankshaft where necessary.
– Screw on gearbox to the engine
⇒ “3.3 Tightening torques”, page 169 .

– Insert the gearbox console -1- between the gearbox and the
supporting arm of the gearbox mount.
– Screw the gearbox console -1- with new screws to the gear‐
box.
– Lift up the gearbox via the spindles of the supporting device -
MP9-200 (10-222 A)- to the supporting arm of the gearbox
mount.
Caution
Before screwing in the screws -arrows- the gearbox console

must be absolutely parallel to the supporting arm of the gear‐
box mount, otherwise the thread is damaged.
– Screw new screws -arrows- by hand initially and then tighten

to the specified tightening torque
⇒ “3.3 Tightening torques”, page 169 .
– Install the console at the gearbox with the fixing screws -1-.
– Raise the engine/gearbox assembly via spindles, align it in the

installation position, and install with new screws for the gear‐
box mount.
– Remove the gearbox mount - 3282- from the gearbox.
– Mount the right flange shaft
⇒ “1.5 Replacing the right flange shaft seal ring”, page 188 .
– Install the left drive shaft and the right drive shaft ⇒ Chassis;
Rep. gr. 40 .
– Install the assembly carrier ⇒ Chassis; Rep. gr. 40 .
– Screw the steering gear to the assembly carrier ⇒ Chassis;
Rep. gr. 48 .
– Install the pendulum support with new screws

-arrows B, and C- ⇒ Chassis; Rep. gr. 40 .

– Screw the steering joints to the track control arms -arrows- ⇒

Vehicles with removed pre-exhaust pipe
– Install pre-exhaust pipe with catalytic converter ⇒ Engine;
Rep. gr. 26 .
– Install charge air pipe (if available) ⇒ Engine; Rep. gr. 21 .
– Install protective cap for right drive shaft on the engine (if
available). To do so tighten the screws -arrows-.
– Install the charge air hose at bottom left between the charge
air cooler and the charge air pipe ⇒ Engine; Rep. gr. 21 .
– Install the bracket for the pre-exhaust pipe to the assembly
carrier and install the exhaust system free of stress ⇒ Engine;
Rep. gr. 26 .

– The supporting device - MP9-200 (10-222 A)- , where neces‐
sary, remove supporting device - T30099- .
Vehicles Octavia II, Yeti and Rapid NH
– Install the plenum chamber cover ⇒ Body Work; Rep. gr. 66 .
washer -1-.
necessary
ble”, page 105 .
– Install the starter motor ⇒ Electrical System; Rep. gr. 27 .
gr. 27 .
23 .
– Install the front left wheelhouse liner ⇒ Body Work; Rep. gr.
66 .
– Install front wheel ⇒ Chassis; Rep. gr. 44 .
– If present, install the front left vehicle level sensor - G78- .
• Check the headlight beams setting ⇒ Electrical System; Rep.
gr. 94 .
with the ⇒ Vehicle diagnostic tester.
Specified torques
♦ Protective cap for drive shaft on engine - 35 Nm

3.3 Tightening torques

Fastening of gearbox to engines
1.6 l/77 kW TDI CR+; 1.8 l/118 kW TFSI on Octavia II vehicles
1.6 l/77 kW TDI CR+; 1.8 l/112;118 kW TFSI on Superb II vehicles
1.6 l/77 kW TDI CR+ on Yeti vehicles
1.6 l/66 kW TDI CR on Rapid NH vehicles
1.5 l/77 kW TDI CR on Rapid India vehicles
Pos. Screw Nm
1, 3 M12 x 55 80
21) M12 x 155 80
3 M12 x 55 80
4 M12 x 65 80
5 M10 x 55 40
6 M10 x 55 40
7 M10 x 55 40
82) M12 x 65 80
A Dowel sleeves
1) At the same time, fasten the starter.
2) Screwed in from the engine side.
Fastening of gearbox to engines
1.4 l/90 kW TSI on Yeti and Rapid NH vehicles

Pos. Screw Nm
1 M12 x 55 80
2 M12 x 55 80
31) M12 x 35 80
4 M12 x 65 80
5 M12 x 65 80
62) M10 x 55 40
72) M10 x 55 40
82) M12 x 65 80
A Dowel sleeves
1) Screw is located in the opening of the housing for the starter.
Attachment of gearbox to engine

1.2 l/77 kW TSI on Octavia II, Fabia II, Roomster and Yeti vehicles
Pos. Screw Nm
1 M12 x 65 80
2 M12 x 65 80
31) M12 x 50 80
4 M12 x 65 80
5 M12 x 65 80
62) 3) M10 x 25 40
72) 3) M10 x 25 40
82) M12 x 65 80
A Dowel sleeves
3) Cover plate for flywheel to gearbox.
Attachment of gearbox to engine
1.4 l/90 kW TSI on Octavia II vehicles
1.4 l/132 kW TSI on Fabia II vehicles

Pos. Screw Nm
1 M12 x 55 80
2 M12 x 55 80
31) M12 x 35 80
4 M12 x 65 80
5 M12 x 65 80
62) M10 x 50 40
72) M10 x 50 40
82) M12 x 65 80
A Dowel sleeves
Gearbox console to gearbox and gearbox mount to gearbox con‐
sole
♦ Screw -1- tightening torque 40 Nm + 90°

♦ Screw -2- tightening torque 60 Nm + 90°
Replace screws -1- and -2- ⇒ Electronic Catalogue of Original
Parts .

♦ Screw -arrow 2- (3 pieces) tightening torque 40 Nm + 90°

♦ Screws -arrow 1- (2 pieces) tightening torque 40 Nm + 90°
Always replace screws -1- and -2- ⇒ Electronic Catalogue of
Original Parts .

4 Transport the gearbox and secure to

the assembly support
♦ Ring bolt - 3368- (2 pieces)
♦ Shackle - 10-222 A/12-
♦ Lifting device - MP9-201 (2024 A)-
Transporting the gearbox
– Screw the ring bolt - 3368- into the threaded bore of the gear‐
box up to the stop and secure with nut M10.
– Insert hook of the workshop crane into the shackle - 10-222 A/
12- .

Secure the gearbox in the gearbox mount - T30109 (VW 353)-
Before the gearbox can be turned horizontally, both ventilation

caps -arrows- must be removed and the openings must be closed
with suitable screw plugs so that no oil can flow out. In case of oil
leakage from the mechatronics, the mechatronics must be re‐
The new mechatronics for the gearbox is already precisely filled
with oil at the factory. Therefore, it is only possible to fill the me‐
chatronics with oil at the factory.

Raise the gearbox on the assembly stand - MP9-101-

Attach gearbox to assembly stand - MP9-101-
– Screw the gearbox mount - T30109 (VW 353)- with screws

-arrows- onto the gearbox mount - T30108- .
4. Transport the gearbox and secure to the assembly support 173

5 Change gearbox oil

♦ Adapter -VAS 6262A-
♦ Adapter -VAS 6262/4-
♦ Adapter -VAS 6262/6-
♦ Catch pan for workshop cranes
The gear oil filling is permanent for the 7-speed double clutch
gearbox 0AM (oils are designed to be filled for life).
For this reason the oil level is not checked and the inspection plug
is not present on this gearbox.
• Observe the general repair instructions
Note


In case of leaks on the gearbox, the cause must be determined
and the fault rectified.
Then the oil must be completely drained and filled up with new
oil.
– Raise vehicle.
– Drain off oil.


The new oil is filled via the air release hole.
Note
If the gearbox is installed, the air filter or the battery with the bat‐
tery tray must be removed when filling up the oil, depending on
the model and engine.

gr. 23 .
gr. 27 .
– Detach the cap from the air release hole.
– Fit on adapter -VAS 6262A- and adapter -VAS 6262/4- .
Note

♦ An over-filling as well as an under-filling impairs the proper
♦ Shake oil reservoir before filling.
Before screwing the adapter - VAS 6262A- onto the oil dispenser,
measure the length of the vent pipe, dimension -a-, and if neces‐
sary cut the pipe length to match dimension -a-: Lengthen off 210
mm.
Note
The dimension -a- is measured on the shaft (starting with the

green area in the detail) of the adapter for oil filling - VAS 6262A- .

– Screw the oil bottle onto the adapter - VAS 6262 A- .
Note
If the oil dispenser thread does not match the adapter - VAS 6262
A- thread, the adapter must also -VAS 6262/6- be used.
– Fill with 1.7 liter of oil.

Note

♦ An over-filling as well as an under-filling impairs the proper
– Remove the adapter from the gearbox after filling up.

– Wipe the area around the air release hole clean using a cloth.
– Fit on the ventilation cap.
gr. 27 .
23 .

1 Pinions and shafts
At present no repairs are carried out on the pinions and shafts.
1. Pinions and shafts 177


1 Replace gasket rings for rigid shafts
and flange shafts
⇒ “1.1 Summary of components - gasket rings and output shafts”,
page 178
⇒ “1.2 Replacing gasket ring for left rigid shaft (Octavia II, Superb
⇒ “1.3 Replacing gasket ring for right rigid shaft (Octavia II, Su‐
perb II, Yeti)”, page 182
⇒ “1.5 Replacing the right flange shaft seal ring”, page 188
1.1 Summary of components - gasket rings and output shafts
1 - Sealing ring

❑ for the right rigid shaft
❑ Renew.
⇒ “1.3 Replacing gasket
ring for right rigid shaft
(Octavia II, Superb II,
Yeti)”, page 182 .
❑ Renew.
⇒ “1.5 Replacing the
right flange shaft seal
ring”, page 188 .
2 - Right rigid shaft up to
11.2008
⇒ “1.3 Replacing gasket
ring for right rigid shaft
(Octavia II, Superb II,
Yeti)”, page 182
❑ as of “11.2008” replaced
by flange shaft
⇒ page 179
⇒ “1.5 Replacing the
right flange shaft seal
ring”, page 188
3 - O-ring
sembly
❑ not present if the flange
shaft is installed
4 - Circlip
❑ insert into the round slot
of the rigid shaft
sembly
❑ not present if the flange shaft is installed

5 - Conical screw
❑ 30 Nm
6 - Sealing ring
❑ for the left rigid shaft
❑ Renew. ⇒ “1.2 Replacing gasket ring for left rigid shaft (Octavia II, Superb II, Yeti)”, page 179 .
❑ Renew. ⇒ “1.4 Replacing the left flange shaft gasket ring”, page 185 .
7 - Left rigid shaft up to 11.2008
⇒ “1.2 Replacing gasket ring for left rigid shaft (Octavia II, Superb II, Yeti)”, page 179
❑ as of “11.2008” replaced by flange shaft ⇒ page 179
❑ Removing and installing ⇒ “1.4 Replacing the left flange shaft gasket ring”, page 185
8 - O-ring
9 - Circlip
❑ insert into the round slot of the rigid shaft
10 - Conical screw
❑ 30 Nm
Different output shafts of gearbox 0AM

♦ -A- - Rigid shafts up to 11.2008
♦ -B- - Flange shafts as of 11.2008
1.2 Replacing gasket ring for left rigid shaft

♦ Inertia extractor - MP9-501 (VW 771)-
♦ Extractor - MP3-419/37 (VW 771/37)-
♦ Socket insert - T10107A- or socket insert 6 mm, commercially
available
1. Replace gasket rings for rigid shafts and flange shafts 179
♦ Thrust piece - T30028 (3305)-

♦ Catch pan
Removing
• Do not remove both drive shafts simultaneously from the gear‐
box. There is no other possibility to hold the opposite wheel in
order to remove or install the screws of the rigid shafts.
• Do not undo the two securing bolts in the left and right rigid
shafts at the same time, and do not remove both rigid shafts
from the gearbox at the same time. If the differential bevel
gears twist, it will be difficult to reinstall the rigid shafts.
Note
The assistance of a second mechanic is required for the next step.

– Actuate the brake pedal and slacken the drive shaft flange
-arrow- on the left by 90°.
Caution
After slackening the drive shaft flange -arrow- by more than

90°, the vehicle must no longer be lowered onto the floor.

– Raise vehicle.
gr. 50 .
– Remove coupling rod from anti-roll bar.
track control arm.


– Press off the left drive shaft from the rigid shaft of the gearbox
e.g with wedge - T10161- or tyre iron ⇒ Chassis; Rep. gr. 40 .

– Release the screw in the rigid shaft with the socket insert -
T10107A- or a commercially available 6°mm socket insert.
– Pull out rigid shaft.
– Remove gasket ring for flange shaft with inertia extractor -

MP9-501 (VW 771)- and extractor - MP3-419/37 (VW
771/37)- .
Installing
sealing grease - G 052 128- .
– Drive in new gasket ring with thrust piece - T30028 (3305)- up

to the stop.
• When driving in the gasket ring, ensure that the new gasket
ring is not tilted.
– Replace the O-ring -1- at the rigid shaft.

– Replace the circlip -2- at the rigid shaft.
– Insert rigid shaft.
– Tighten the new conical screw on the rigid shaft to the speci‐
fied tightening torque.
– Install left drive shaft ⇒ Chassis; Rep. gr. 40 .
– Change gearbox oil ⇒ “5 Change gearbox oil”, page 174 .
Note
– Install left front wheel ⇒ Chassis; Rep. gr. 44 .

If the front left vehicle level sensor - G78- was removed, then the
headlight beam setting must be checked ⇒ Electrical System;
Rep. gr. 94 .
Tightening torque
Component Nm
Rigid shaft on gearbox (conical screw) ⇒ “1.1 Summary of components - gasket rings and output shafts”,
page 178
1.3 Replacing gasket ring for right rigid shaft



available
♦ Thrust piece - T30028 (3305)-
♦ Catch pan
Removing
• Do not remove both drive shafts simultaneously from the gear‐
box. There is no other possibility to hold the opposite wheel in
order to remove or install the screws of the rigid shafts.
• Do not undo the two securing bolts in the left and right rigid
shafts at the same time, and do not remove both rigid shafts
gears twist, it will be difficult to reinstall the rigid shafts.
gr. 50 .
-arrows-.
– Unscrew the nuts -arrows- from the steering joint to the right
track control arm.
– Unhook the steering joint from the right track control arm.
Note
♦ It is not necessary to slacken the screw connection of the drive

shaft on the wheel side.
♦ The drive shaft must not be removed, it is sufficient to tie it up.
Caution
The drive shaft must not hang down, because overstretching

will cause damage to the inner joint.
– Press off the drive shaft from the rigid shaft of the gearbox e.g.
using a tyre iron.

– Release the screw -arrow- in the rigid shaft with the socket
insert - T10107A- or a commercially available 6°mm socket
insert.
– Pull out rigid shaft.
– Remove the gasket ring of the rigid shaft e.g with extractor tool
- T20143- or tyre iron.
Installing
Caution
Do not press in gasket ring with pressure plate - T30028

(3305)- up to the stop!
The shaft seal reaches its inner stop in the gearbox before the
thrust piece - T30028 (3305)- .
The pressure plate - T30028 (3305)- can therefore not be type-
punched up to the stop of the tool.
– Drive in the new gasket ring up to the gasket ring stop with
feeling, while doing so , do not tilt the gasket ring.

– Replace the O-ring -1- at the rigid shaft.

– Replace the circlip -2- at the rigid shaft.
– Insert rigid shaft.
– Tighten the new conical screw on the rigid shaft to the speci‐
fied tightening torque.
– Press the right drive shaft onto the rigid shaft of the gearbox
until the circlip locks in place ⇒ Chassis; Rep. gr. 40 .
– Screw the steering joint to the track control arm -arrows- ⇒

– Install protective cap for right drive shaft on the engine

Note
Specified torques
Component Nm
Rigid shaft on gearbox (conical screw) ⇒ “1.1 Summary of components - gasket rings and output shafts”,
page 178
Protective cap for drive shaft on engine 35 Nm

ring
♦ Inertia extractor - MP9-501 (VW 771)-
♦ Extractor - MP3-419/37 (VW 771/37)-
available
♦ Thrust piece - T30028 (3305)-

♦ Catch pan
Removing
• Do not undo the two securing bolts in the left and right flange
shafts at the same time, and do not remove both flange shafts
gears twist, it will be difficult to reinstall the flange shafts.
– Raise vehicle.
gr. 50 .

gr. 40 .
– Unscrew nut -1- from the anti-roll bar -2- and disconnect cou‐
pling rod -3-.
– Pull the anti-roll bar -2- upwards slightly.
– Remove left drive shaft from flange shaft ⇒ Chassis; Rep. gr.
40 .
Caution



– Unscrew screw for flange shaft with socket insert - T10107A-

– Remove gasket ring for flange shaft with inertia extractor -

MP9-501 (VW 771)- and extractor - MP3-419/37 (VW
771/37)- .
Installing
– Drive in the new gasket ring with thrust piece - T30028 (3305)-
up to the stop, do not twist the new gasket ring.
– Tighten new conical screw to the specified tightening torque.
– Attach the left drive shaft to the flange shaft ⇒ Chassis; Rep.
gr. 40 .
Note
– Install left front wheel ⇒ Chassis; Rep. gr. 44 .

– If the front left vehicle level sensor - G78- was removed, check
headlight beam setting ⇒ Electrical System; Rep. gr. 94 .

Tightening torque
Component Nm
Flange shaft on gearbox (conical screw) ⇒ “1.1 Summary of components - gasket rings and output shafts”,
page 178

available
♦ Extractor tool - T20143-
♦ Thrust piece - T30028 (3305)-
♦ Catch pan
Removing
• Do not undo the two securing bolts in the left and right flange
shafts at the same time, and do not remove both flange shafts
gears twist, it will be difficult to reinstall the flange shafts.
gr. 50 .

-arrows-.
– Remove right drive shaft from flange shaft ⇒ Chassis; Rep.
gr. 40 .
Caution


– Unscrew screw for flange shaft with socket insert - T10107A-

– Remove the gasket ring of the flange shaft e.g with extractor
tool - T20143- or tyre iron.
Installing
Caution
When driving in the gasket ring with the thrust piece - T30028
(3305)- , ensure that the gasket ring for the flange shaft rea‐
ches its stop in the gearbox before the thrust piece - T30028
(3305)- reaches its stop.
Therefore, the thrust piece - T30028 (3305)- must never be
driven fully into the gearbox housing!
– Carefully drive the new gasket ring into the gearbox up to the
stop, during this procedure do not twist the gasket ring.
– Tighten new conical screw to the specified tightening torque.
– Fit the right drive shaft to the flange shaft ⇒ Chassis; Rep. gr.
40 .
– Install protective cap for right drive shaft on the engine

Note
Specified torques
Component Nm
Flange shaft on gearbox (conical screw) ⇒ “1.1 Summary of components - gasket rings and output shafts”,
page 178
Protective cap for drive shaft on engine 35

Skoda-Fabia-Skoda-Rapid 2007-2009-2011 en Manual de Taller Caja de Transmision B929d3ee5a

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Service

Service Department. Technical Information

39 - Final drive, differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1.1 Identification of the gearbox

The gearbox identification characters also appear on the vehicle

1.2 Identification characters, aggregate assignment, ratios

1. Technical Data for the Gearbox 1

Automatic gearbox 6-speed gearbox 09G

Automatic gearbox 6-speed gearbox 09G

2 Rep. Gr.00 - Technical data

2 Information and repair instructions for

2.1 Information for the automatic gearbox

2.2 Repair instructions

2. Information and repair instructions for the automatic gearbox 09G 3

4 Rep. Gr.00 - Technical data

O-rings, gasket rings, gaskets

2.3 Explanation of the terms used in this

2. Information and repair instructions for the automatic gearbox 09G 5

6 Rep. Gr.00 - Technical data

tribute it via the oil galleries to the gearshift elements (clutches

2. Information and repair instructions for the automatic gearbox 09G 7

♦ Repair instructions ⇒ page 3 .

1.1 Torque converter identification

Torque converter identification

1.2 Draining the torque converter

1.3 Removing and installing gasket ring for

8 Rep. Gr.32 - Torque converter

Removing gasket ring for torque converter

Install gasket ring for torque converter

1.4 Checking the torque converter

The torque converter is welded and must be replaced completely

1.5 Installing the torque converter

– Measure the dimension -a- between the screw-on flange of the

If the converter is installed wrongly the driver of the torque

When subsequently installing the gearbox, the following point

10 Rep. Gr.32 - Torque converter

1.1 Electric/Electronic components and fitting locations

1 - Automatic gearbox control

1. Electric/Electronic components and fitting locations 11

8 - Cover for shift mechanism

12 Rep. Gr.37 - Control, housing

Selector lever lock solenoid -N110-

Slide valve body

Wiring loom with 14-pin plug

1. Electric/Electronic components and fitting locations 13

Multi-function switch -F125-

Fitting location: The multi-function switch is located at the top of

Switch for Tiptronic -F189-

14 Rep. Gr.37 - Control, housing

Gearbox output r.p.m. sender -G195-

Gearbox input r.p.m. sender -G182-

Selector lever position indicator -Y6-

The selector lever position indicator -Y6- can only be replaced

1. Electric/Electronic components and fitting locations 15

Kick-down switch -F8-

Brake light switch -F-

The switch may only be installed once to ensure that it has an

1.2 Removing and installing automatic gear‐

Observe measures when disconnecting and connecting the

– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐

16 Rep. Gr.37 - Control, housing

– Press off locking tabs -arrows- from control unit holder.

Observe measures when disconnecting and connecting the