Skoda Fabia 2000 Workshop Manual Gearbox

Service 5
Workshop Manual
FABIA 2000 ³
Gearbox 02T
Edition 08.99
Gearbox code EYY FDN EYX FDM EYW FDL EJZ FNJ FVS
FVT FVU FCU FCV FVV FRA FPU FSP GDN
GDH GDL GDG GDM GDJ GDR GEY GDP GKX
GSH GSB GRP GRZ GRQ GRY GSC GRS GSA
Service Department. Technical Information Printed in Czech Republic

S00.5316.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5316.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ³ Gearbox 02T
List of Supplements to Workshop Manual

FABIA 2000 ³
Gearbox 02T
Edition 08.99
Supple-
Edition Subject Article Number
ment
08.99 Basic Edition S00.5316.00.20
1 12.99 Supplement to Basic Edition S00.5316.01.20
2 11.00 Supplement to manual gearboxes with the code EJZ, FDL, FDM, S00.5316.02.20
FDN and FNJ
3 12.01 Supplement to manual gearboxes with the code FVS, FVT, FVU, S00.5316.03.20
FCU, FCV, FVV, FRA and FPU
4 09.02 Supplement to manual gearboxes with the code FSP, GDN, GDH, S00.5316.04.20
GDL, GDG, GDM, GDJ, GDR and GEY
5 01.03 Supplement to gearboxes with code GDP and GKX S00.5316.05.20
6 04.03 Supplement to manual gearboxes with the code GSH, GSB, GRP, S00.5316.06.20
GRZ, GRQ, GRY, GSC, GRS and GSA
Edition 04.03 List of Supplements

S00.5316.06.20
List of Supplements Edition 04.03

S00.5316.06.20
Table of Contents
00 – Technical Data
Identification of the gearbox ......................................................................... 00-1 page 1
- Identification characters, aggregate assignment, ratios, capacities ........................... 00-1 page 2
Overview of Transmission System ................................................................. 00-2 page 1
- Designation of components and transmission ratio .............................................. 00-2 page 1
General Repair Information .......................................................................... 00-3 page 1
30 – Clutch
Clutch control ........................................................................................... 30-1 page 1
- Summary of components - Foot controls .......................................................... 30-1 page 1
- Summary of components - Hydraulics ............................................................. 30-1 page 2
Repair of the clutch control .......................................................................... 30-2 page 1
Repairing the clutch ................................................................................... 30-3 page 1
34 – Control/Housing
Shift mechanism ........................................................................................ 34-1 page 1
- Fitting location of shift mechanism .................................................................. 34-1 page 1
I - Gearshift knob and cover - Summary of components .................................... 34-2 page 1
- Separating collar from gearshift lever .............................................................. 34-2 page 2
II - Assembly Overview – Shift Lever and Shift Housing ...................................... 34-3 page 1
III - Control cables - Summary of components ................................................. 34-4 page 1
Removing and Installing Shift Mechanism ...................................................... 34-5 page 1
- Removing ............................................................................................... 34-5 page 1
- Installing ................................................................................................ 34-5 page 2
Setting shift mechanism .............................................................................. 34-6 page 1
- Operation ............................................................................................... 34-6 page 3
Removing and installing the gearbox ............................................................. 34-7 page 1
- Removing ............................................................................................... 34-7 page 1
- Installing ................................................................................................ 34-7 page 5
Inspecting gear oil ..................................................................................... 34-8 page 1
Disassembling and assembling the gearbox .................................................... 34-9 page 1
- I - Disassembling and assembling gearbox housing cover and 5th gear ..................... 34-9 page 2
- II - Disassembling and assembling clutch housing ............................................... 34-9 page 3
- III - Disassembling and assembling the drive shaft, output shaft, differential and gearshift
forks ..................................................................................................... 34-9 page 4
- Mounting sequence ................................................................................... 34-9 page 5
Repairing the gearbox housing and clutch housing ........................................... 34-10 page 1
Disassembling and assembling the gearshift mechanism on the gearbox side ........ 34-11 page 1
Disassembling and assembling the gearshift forks ............................................ 34-12 page 1
35 – Wheels, shafts
Disassembling and assembling the drive shaft ................................................. 35-1 page 1
Disassembling and assembling the drive shaft ................................................. 35-2 page 1
39 – Final drive/Differential
Edition 04.03 Table of Contents I

S00.5316.06.20
Replacing the flange shaft gasket rings (gearbox fitted) .................................... 39-1 page 1
- Removing ............................................................................................... 39-1 page 1
- Installing ................................................................................................ 39-1 page 1
- Tightening torques .................................................................................... 39-1 page 2
Disassembling and assembling the differential ................................................. 39-2 page 1
Adjusting the differential gear ...................................................................... 39-3 page 1
Table of Contents Edition 04.03

II S00.5316.06.20
FABIA 2000 ³ Gearbox 02T 00
00 – Technical Data
00-1 Identification of the gear-

box
Assignment ⇒ 00-1 page 2
Location on the gearbox
Identification characters and manufacturing date -arrow
1-.
Identification of materials for the gearbox housing -arrow
2-.
S34-0665
Identification characters and manufacturing date of

the gearbox
Exam- EYW 17 08 9
ple:
I I I I
Identifi- Day Month Manufac-
cation turing
charac- year
ters (1999)
Additional data depend on the manufacturing.
Note
The gearbox identification characters also appear on the
vehicle 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 geabox lettering to determine
whether it is an aluminium or a magnesium gearbox.
Edition 04.03 Identification of the gearbox 00-1 page 1

S00.5316.06.20
00 FABIA 2000 ³ Gearbox 02T
Identification characters, aggregate assignment, ratios, capacities
Manual gearbox 5 speed 02T

Identification characters EYY FDN FVU GDJ GRS
Manufac- from
11.99 10.00 02.02 06.02 05.03
tured
until 10.00 02.02 06.02 05.03
Assign- Engine 1.9 l/47 kW SDI
ment:
Ratio: Final drive 64:19 = 3,368 65:18 = 3,611
Z2:Z1 1. Gear 38:11 = 3,455
2nd gear 43:22 = 1,955
3rd gear 41:32 = 1,281
4th gear 38:41 = 0,927
5. Gear 37:50 = 0,740
Reverse gear 35:24 x 24:11 = 3.182
Speedometer1) electronic
Capacity 1.9 l
Specification Gearbox oil G 005 000 SAE 75W90 (synthetic oil)
Gear oil change interval Filled for life
Clutch control hydraulic
Clutch plate ∅ 190 mm2)
Drive shaft flange ∅ 90 mm

Identification characters FCX FRA GDR GSA
Manufac- from
10.99 02.02 06.02 05.03
tured
until 02.02 06.02 05.03
Assign- Engine 1.9 l/47 kW SDI
ment:
Z2:Z1 1. Gear 38:11 = 3,455
2nd gear 43:22 = 1,955
3rd gear 41:32 = 1,281
4th gear 38:41 = 0,927
5. Gear 37:50 = 0,740
Reverse gear 35:24 x 24:11 = 3.182
Capacity 1.9 l
Identification of the gearbox Edition 04.03

00-1 page 2 S00.5316.06.20


Identification characters EYX FDM FVT GDH GRP
Manufac- from
10.99 10.00 09.01 06.02 05.03
tured
until 10.00 09.01 06.02 05.03
Assign- Engine 1.4 l/55 kW
ment:
Ratio: Final drive 66:17 = 3,882
Z2:Z1 1. Gear 38:11 = 3,455
2. Gear 44:21 = 2,095
3rd gear 43:31 = 1,387
4th gear 40:39 = 1,026
5. Gear 39:48 = 0,813
Reverse gear 35:24 x 24:11 = 3.182
Capacity 1.9 l

Identification characters FCU GDL GRZ
Manufac- from
03.01 06.02 05.03
tured
until 06.02 05.03
ment:
Z2:Z1 1. Gear 38:11 = 3,455
2. Gear 44:21 = 2,095
3rd gear 43:31 = 1,387
4th gear 40:39 = 1,026
5. Gear 39:48 = 0,813
Reverse gear 35:24 x 24:11 = 3.182
Capacity 1.9 l

S00.5316.06.20


Identification characters EYW FDL FVS GDG GRQ
Manufac- from
08.99 10.00 09.01 06.02 05.03
tured
until 10.00 09.01 06.02 05.03
ment:
Z2:Z1 1. Gear 38:11 = 3,455
2. Gear 44:21 = 2,095
3rd gear 43:30 = 1,433
4th gear 41:38 = 1,079
5. Gear 41:46 = 0,891
Reverse gear 35:24 x 24:11 = 3.182
Capacity 1.9 l

Identification characters FCV GDM GRY
Manufac- from
01.01 06.02 05.03
tured
until 06.02 05.03
ment:
Z2:Z1 1. Gear 38:11 = 3,455
2. Gear 44:21 = 2,095
3rd gear 43:30 = 1,433
4th gear 41:38 = 1,079
5. Gear 41:46 = 0,891
Reverse gear 35:24 x 24:11 = 3.182

00-1 page 4 S00.5316.06.20

Capacity 1.9 l

Identification characters EJZ FNJ FVV
Manufac- from
07.00 09.00 09.01
tured
until 09.00 09.01 06.02
ment:
Z2:Z1 1. Gear 31:09 = 3,444 38:11 = 3,455
2nd gear 34:16 = 2,125 44:21 = 2,095
3rd gear 32:22 = 1,455
4th gear 32:29 = 1,103
5. Gear 32:36 = 0,889
Reverse gear 35:24 x 24:11 = 3.182
Capacity 1.9 l

Identification characters FPU GEY GKX GSC
Manufac- from
04.02 08.02 11.02 05.03
tured
until 08.02 11.02 05.03
ment:
Z2:Z1 1. Gear 38:11 = 3,455
2nd gear 44:21 = 2,095
3rd gear 32:22 = 1,455 43:30 = 1,433
4th gear 32:29 = 1,103

S00.5316.06.20

5. Gear 32:36 = 0,889
Reverse gear 35:24 x 24:11 = 3.182
Capacity 1.9 l

Identification characters FSP GDN GSH GDP GSB
Manufac- from
01.01 06.02 05.03 03.03 05.03
tured
until 06.02 05.03 05.03
Assign- Engine 1.2 l/40 kW 1.2 l/47 kW
ment:
Z2:Z1 1. Gear 38:11 = 3,455
2nd gear 43:22 = 1,955
3rd gear 41:32 = 1,281 43:31 = 1,387
4th gear 38:41 = 0,927 40:39 = 1,026
5. Gear 37:50 = 0,740 40:47 = 0,851
Reverse gear 35:24 x 24:11 = 3.182
Capacity 1.9 l
1) Only on vehicles without ABS.

2) This serves as information. Assign the clutch disc and the pressure plate following the spare parts catalogue.

00-1 page 6 S00.5316.06.20
00-2 Overview of Transmission System

Designation of components and transmission ratio
Note
The arrows point in the direction of travel.
1- Engine
2- Clutch
3- Gearbox
4- Drive shaft
5- Output shaft/input shaft
6- Differential
I- 1. Gear
II - 2. Gear
III - 3. Gear
IV - 4. Gear
V- 5. Gear
R- Reverse
A- Final drive
T- Speedometer drive
Edition 08.99 Overview of Transmission System 00-2 page 1

S00.5316.00.20
Overview of Transmission System Edition 08.99

00-2 page 2 S00.5316.00.20
00-3 General Repair Informa-

tion
To carry out gearbox repairs successfully and correctly,
scrupulous care and cleanliness, as well as the proper
tools, are essential requirements. Obviously, the general
rules for basic safety have to be applied.
Below is a summary of the general instructions to be ap-
plied to individual repair operations (also given elsewhere
at various parts of the workshop manual). They are to be
applied to this workshop manual.
Gearbox
Gearboxes are constructed of aluminium and of magne-
sium ⇒ Chap. 00-1.
♦ Gearbox housing, transmission case cover and final
drive cover are all made of the same materials.
♦ Bolts and other attachments that come into direct con-
tact with the gearbox can have varying finishes de-
pending on whether the gearbox is of aluminium or
magnesium.
♦ On magnesium gearboxes, the bolts must always be
replaced at the following attachment locations: Trans-
mission case cover to gearbox housing and final drive
cover to gearbox housing.
♦ The use of substitute components causes contact cor-
rosion. This will result in damage to the gearbox.
♦ Bolts and other attachments should have a classifica-
tion in the ET. Catalogue.
♦ When installing, ensure the dowel sleeves are correct-
ly located between engine and gearbox.
♦ If replacing the gearbox, pour in gear oil up to lower
edge of filler hole.
♦ Capacity and Specifications ⇒ Chap. 00-1
Gaskets, seals
♦ Clean contact surfaces thoroughly and apply sealant
AMV 188 020.
♦ Apply sealant evenly, and not too thickly.
♦ Replace O-rings.
♦ Replace radial shaft seals.
Before installing:
Lightly oil the outer diameter and pack the space between
the seal lips -arrow- with grease.
After installing:
Check gear oil level, if necessary pour in up to lower edge
of filler hole, specification ⇒ Chap. 00-1.
Locking elements
Edition 12.01 General Repair Information 00-3 page 1

S00.5316.03.20
♦ Replace circlips.
♦ Do not over-tension the circlips.
♦ Circlips must be positioned in the base of the groove.
♦ Replace roll pins. Fitting position: slot longitudinally to
power flow -arrow-.
Bolts, nuts
♦ Unscrew and tighten cover and housing attachment
bolts and nuts crosswise.
♦ Particularly sensitive components such as clutch
pressure plates must not be tilted - loosen and tighten
crosswise, by stages.
♦ Tightening torques are indicated for non-lubricated
bolts and nuts.
♦ Always replace self-locking bolts and nuts.
♦ Take care with all bolt attachments, that locating sur-
faces, nuts and bolts are waxed immediately after as-
sembly if necessary.
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 bear-
ings of the same make.
♦ When assembling, heat inner rings to around 100°C.
♦ Do not exchange outer and innner rings for bearings
of the same size - bearings go in pairs.
♦ Position needle bearing with the lettered side (thicker
end) towards the drift pin.
Shim washers
♦ Gauge the shims at several points with a micrometric
screw. Different tolerances make it possible to meas-
ure the required shim thickness precisely.
♦ Inspect for burrs and damage.
♦ Install only shims that are in perfect condition.
Synchronizer rings
♦ These are not interchangeable. If re-using, allocate
synchronizer rings to the same gear.
♦ Inspect for wear, and replace if necessary.
♦ Insert with some gearbox fluid.
Gears
♦ Clean and heat on a heating plate to about 100°C be-
fore pressing on.
♦ Temperature can be checked with a temperature
measuring instrument (e.g. -V.A.G 1558-).
General Repair Information Edition 12.01

00-3 page 2 S00.5316.03.20
30 – Clutch
30-1 Clutch control
Summary of components - Foot controls

Special tools, test and measuring equipment and
auxiliary items required
♦ Polycarbamide grease -G 052 142 A2-
Note
♦ Summary of components - Hydraulics ⇒ 30-1 page 2.
♦ Disconnect earth strap of the battery.
♦ Before disconnecting the battery determine the code of radio sets fitted with anti-theft coding.
♦ If the battery earth strap is disconnected and connected, carry out additional operations ⇒ Electrical System;
Rep. Gr. 27.
♦ Grease all bearing and contact surfaces with polycarbamide grease -G 052 142 A2-.
♦ Prior to working on the foot controls remove the storage area on the driver's side ⇒ Body Work; Rep. Gr. 70.
1 - Support/Front wall
T for master cylinder and
bracket
2 - Gasket
T always replace
3 - Bracket
4 - Screw
5 - Gas/brake foot controls
6 - 25 Nm
T always replace
7 - Clutch pedal switch
T Always push the clutch pedal
down when removing or in-
stalling the switch.
T before removing the clutch
pedal ⇒ item 11 turn the
switch 90° to the right and
draw out through the assem-
bly opening
8 - Over-centre helper spring
T removing and installing
⇒ Rep. Gr. 30; Gearbox
02R
9 - Spacer bush
10 - Bushing
11 - Clutch pedal
02R
12 - Support
02R
Edition 01.03 Clutch control 30-1 page 1

S00.5316.05.20
13 - 25 Nm
T always replace
14 - Master cylinder
T removing and installing ⇒ Rep. Gr. 30; Gearbox 02R
15 - Spring strap clip
16 - Tubing
17 - Bearing
T insert in bracket
T always replace
18 - Screw
T Pedal stop on bracket
19 - Pedal stop
T screw onto bracket with screw ⇒ item 18 in 30-1 page 2
20 - 25 Nm
T always replace
Summary of components - Hydraulics

1 - Brake fluid reservoir
2 - Tubing
3 - Master cylinder
02R
4 - Locking clip
T remove for tube-hose line
⇒ item 9 pull out from mas-
ter cylinder up to stop
5 - Support
T only replace if the master cyl-
inder has been removed
⇒ item 3
02R
6 - Clutch pedal
02R
7 - 25 Nm
T always replace
8 - O-ring
T moisten with brake fluid be-
fore installing
9 - Tube and hose line
T assign following spare parts
catalogue
10 - Bracket
T at front left frame side rails
T clip on for tube and hose line
⇒ item 9
11 - Bracket
T holds the tube and hose line ⇒ item 9 on the gearbox
Clutch control Edition 01.03

30-1 page 2 S00.5316.05.20
12 - 20 Nm
13 - Locking clip
T remove for tube-hose line ⇒ item 9 in 30-1 page 2 pull out from master cylinder up to stop
14 - Dust cap
15 - Vent valve
T Bleed clutch system ⇒ Rep. Gr. 30; Gearbox 02R
16 - Slave cylinder
T removing and installing ⇒ Rep. Gr. 30; Gearbox 02R
T after installing bleed the clutch system ⇒ Rep. Gr. 30 ; Gearbox 02R
17 - Gearbox
Edition 01.03 Clutch control 30-1 page 3

S00.5316.05.20
Clutch control Edition 01.03

30-1 page 4 S00.5316.05.20
30-2 Repair of the clutch control

Special tools, test and measuring equipment and aids required
♦ Grease MoS2
1 - Clutch release bearing

T Do not wash the bearing only
wipe it clean
T replace noisy bearing
⇒ Fig. 3 in 30-2 page 2
T remove and install ⇒ Fig. 1
in 30-2 page 2 together with
the clutch release lever
⇒ item 3 and guide bushing
⇒ item 5
2 - 9 Nm
3 - Clutch release lever
the clutch release bearing
⇒ item 1 and guide bushing
⇒ item 5
4 - Retaining spring
T attach to clutch release lever
5 - Guide bushing for clutch re-
lease bearing
⇒ Fig. 2 in 30-2 page 2
the clutch release lever
⇒ item 3 and clutch release
bearing ⇒ item 1
6 - Gasket ring for drive shaft
T replacing ⇒ Chap. 34-10
7 - Ball stud, 20 Nm
T Grease with MoS2-grease
8- Gearbox
9- 20 Nm
10 - Holder
11 - Slave cylinder
T removing and installing ⇒ Chap. 30-1
T Grease tappet end with MoS2-grease
Edition 12.99 Repair of the clutch control 30-2 page 1

S00.5316.01.20
Fig. 1: remove and install the clutch release lever

together with the clutch release bearing and
guide bushing
– Release screws -arrows-.

– Separate the clutch release lever together with the
clutch release bearing and guide bushing from the
drive shaft and ball stud.
The installation occurs in reverse order.
Fig. 2: Removing and installing the guide bushing
– Rotate the guide bushing -3- opposite the clutch re-

lease bearing -2- 90° in the direction of the arrow until
the catch pegs of the guide bushing fit into the slots -4-
of the clutch release bearing.
– In this position remove the guide bushing from the
clutch release bearing.
The installation occurs in reverse order.
Fig. 3: Removing and installing the clutch release

bearing
– Press the catch pegs -arrows- together and remove

the clutch release bearing -A- from the clutch release
lever.
– To install press the clutch release lever into the clutch
release bearing -A- until the catch pegs -arrows- lock
into position.
Repair of the clutch control Edition 12.99

30-2 page 2 S00.5316.01.20
30-3 Repairing the clutch

♦ Counterholder -MP 1-223-
♦ Centering mandrel -MP 3-475-
♦ Centering mandrel -T10086-
♦ Grease -G 000 100-
(Gearbox removed)
Note
♦ Replace the clutch discs and pressure plates if the riveting is damaged or loose.
♦ Make the clutch disc and pressure plate coincide in accordance with the Spare Part Catalogue and engine identi-
fication characters.
1 - Flywheel
T make sure the centering pins
are tight
T The locating face for the
clutch lining must be free
from grooves, oil and grease
⇒ Rep. Gr. 13 des jeweili-
gen; removing and installing
flywheel
2 - Clutch disc
T Diameter ⇒ Chap. 00-1
T Fitting position: the spring
cage pointing towards the
pressure plate
T centering for vehicles with
1.9 ltr/47 kW engine and 2.0
ltr./85 kW engine ⇒ Fig. 1 in
30-3 page 2
T centering for vehicles with
1.4 l ltr engine ⇒ Fig. 2 in
30-3 page 2
T slightly grease the splines
Note
♦ Clean the drive shaft serra-
tion 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.
3 - Pressure plate
T removing and installing vehicles with 1.9 ltr/47 kW engine and 2.0 ltr./85 kW engine ⇒ Fig. 1 in 30-3 page 2
T removing and installing for vehicles with 1.4 ltr. engine ⇒ Fig. 2 in 30-3 page 2
T Check the extremities of the membrane springs ⇒ Fig. 3 in 30-3 page 2
Edition 11.00 Repairing the clutch 30-3 page 1

S00.5316.02.20
Note
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.
4 - 20 Nm
T assign following Spare Parts Catalogue
T release or tighten gradually and crosswise
Fig. 1: Centering clutch disc and removing and in-

stalling pressure plate for vehicles with 1.9
ltr./47 kW engine and 2.0 ltr./85 kW engine
– Release and tighten screws gradually and crosswise.

– When removing use counterholder -MP 1-223-.
Note
♦ The thrust surface of the pressure plate and the clutch
disc lining must fully rest against the flywheel before
the screws are inserted.
♦ Tighten the screws crosswise and uniformly so as not
to damage the centering holes on the pressure plate
and the centering pins of the flywheel.
Fig. 2: Centering the clutch disc and removing and

installing the pressure plate for vehicles
with 1.4 l ltr engine
– Release and tighten screws gradually and crosswise.

– When removing use counterholder -MP 1-223-.
Note
♦ The thrust surface of the pressure plate and the clutch
disc lining must fully rest against the flywheel before
the screws are inserted.
♦ Tighten the screws crosswise and uniformly so as not
to damage the centering holes on the pressure plate
and the centering pins of the flywheel.
Fig. 3: Check the extremities of the membrane

springs
• Wear is allowed up to half the membrane spring thick-

ness.
Repairing the clutch Edition 11.00

30-3 page 2 S00.5316.02.20
34 – Control/Housing
34-1 Shift mechanism
Fitting location of shift mechanism

A - Shift cable
B - Selector cable
C - Heat shield
T take off before removing the
shift mechanism R
Pfeil A - Shift movement B
Pfeil B - Selector movement
1 - Gearshift lever
A
2 - Reversing lever
A
2 A
B B
S34-0594
Edition 01.03 Shift mechanism 34-1 page 1

S00.5316.05.20
Note
♦ Disconnect earth strap at battery before carrying out work in the engine compartment.
♦ Before disconnecting the battery determine the code of radio sets fitted with anti-theft coding.
♦ 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 ⇒ Chap. 34-5.
♦ Do not kink the control cables.
I - Gearshift knob and cover -

Summary of components
⇒ Chap. 34-2
II - Shift lever and shift housing -
Summary of components
⇒ Chap. 34-3
III - Control cables - Summary of
components ⇒ Chap. 34-4
Removing and installing shift
mechanism ⇒ Chap. 34-5
Setting shift mechanism
⇒ Chap. 34-6
Shift mechanism Edition 01.03

34-1 page 2 S00.5316.05.20
34-2 I - Gearshift knob and cover - Summary of components

1 - Gearshift knob I
T with collar
T It is not possible to separate
the gearshift knob from the
collar
T always replace together
⇒ 34-2 page 2
1
2 - Collar clamp
T for securing the gearshift
knob to the gearshift lever
3 - Surround of centre console
S34-0485
Edition 11.00 I - Gearshift knob and cover - Summary of components 34-2 page 1
S00.5316.02.20
Separating collar from gearshift lever

– Lever the collar out of the surround of centre console
-arrows-.
– Pull the collar upwards over the gearshift knob.
– Open clamp -arrow- and pull off gearshift knob togeth-

er with the collar.
Installing
– Turn collar inside out.
– Install gearshift knob, join together collar and collar
clamp -arrow-.
When positioning the gearshift knob on the gearshift lever
the gearshift knob must lock into the round slot of the
gearshift lever.
I - Gearshift knob and cover - Summary of components Edition 11.00

34-2 page 2 S00.5316.02.20
34-3 II - Assembly Overview – Shift Lever and Shift Housing
Note
Grease bearing points and contact surfaces with poly resin grease -G 052 242 A2-.
1 - Circlip
⇒ Fig. 1 in 34-3 page 2
2 - Bush
3 - Compression spring
4 - Bush
5 - 5 Nm
6 - Cover
7 - Bearing shell
8 - Insulation
9 - Shift lever guide
10 - Insulating washer
11 - Gasket
T between shift housing and
body
T self-adhesive
T stick onto shift housing
12 - Shift lever
13 - Insulation
14 - Shift housing
15 - Bearing bush
16 - 25 Nm
17 - Bearing pin
18 - Guide bush
19 - Compression spring
T installing ⇒ Fig. 2 in 34-3
page 2
20 - Selector lever
21 - 5 Nm
22 - Floor plate
T bend up tabs for removing
T replace
23 - Selector cable
T at selector angle plate
T fitting location⇒ Chap. 34-1
24 - Shift cable
T press onto shift lever guide
T fitting location⇒ Chap. 34-1
25 - Circlip
26 - 25 Nm
27 - Bearing bush
T fits only in one position
28 - Circlip
Edition 08.99 II - Assembly Overview – Shift Lever and Shift Housing 34-3 page 1
S00.5316.00.20
Fig. 1: Removing and installing circlip
– To remove and install the circlip -A-, pull shift lever in

direction of arrow -A- and at the same time use a
screwdriver to press down bush in direction of arrow
-B- as far as the stop.
Note
♦ Do not twist bush when pressing down.
♦ Mounting slot in shift lever for circlip must be visible.
♦ Release spring carefully
Fig. 2: Installation of compression spring
– Insert the compression spring so that the leg -A- is po-

sitioned above the stud -arrow-.
– After this, pull the web -B- down far enough so that it
moves underneath the stud -arrow-.
II - Assembly Overview – Shift Lever and Shift Housing Edition 08.99

34-3 page 2 S00.5316.00.20
34-4 III - Control cables - Summary of components
Note
Grease bearing and friction surfaces with polycarbamide grease -G 052 242 A2-.
1 - Shift cable lll

T pressed onto shift lever
guide
T Fitting location ⇒ Chap. 34-1
2 - Selector cable
T at selector angle plate
3 - Circlip
4 - Circlip
T do not damage cables when
removing
5 - Shift housing
6 - Support
7 - Grommet
T mounting of support to gear-
box
8 - Spacer
9 - 20 Nm
T 3 pieces
T for support
10 - Cable lock
T for selector cable
11 - Cable lock
T for shift cable
12 - Circlip
13 - Bearing bush 7
14 - Relay lever
T Fitting position ⇒ Fig. 1 in
34-4 page 2
15 - Sliding shoe
16 - Shift lever
T with balancing weight
T insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft in the same position
T after installing set shift mechanism ⇒ Chap. 34-6
T Fitting position ⇒ Fig. 1 in 34-4 page 2
17 - 20 Nm
Edition 11.00 III - Control cables - Summary of components 34-4 page 1

S00.5316.02.20
Fig. 1: Fitting location of gearbox shift lever/relay

lever
1 - Gearbox shift lever with balancing weight
2 - Relay lever is inserted over the sliding shoe into the
sliding rail of the gearbox shift lever -arrow-
III - Control cables - Summary of components Edition 11.00

34-4 page 2 S00.5316.02.20
34-5 Removing and Installing

Shift Mechanism
Removing
– Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
– Disconnect the earth strap from the battery with the ig-
nition off.
– Remove battery and battery tray ⇒ Electrical System;
Rep. Gr. 27.
– Use an open-end wrench to lever off selector cable
-A- and shift cable -B- at gearbox.
1 - Open-end wrench size 13, commercially available
2 - Pliers, commercially available
– Disconnect the Bowden cable support from gearbox

-arrows-.
– Lever the collar out of the surround of centre console

-arrows-.
– Pull the collar upwards over the gearshift knob.
Edition 11.00 Removing and Installing Shift Mechanism 34-5 page 1

S00.5316.02.20
– Open clamp -arrow- and pull off gearshift knob togeth-

er with the collar.
– Removing surround for the centre console ⇒ Body
Work; Rep. Gr. 70.
– Release the front fixing nuts -arrows- for the gearbox

housing.
N34-1085
– Detach bracket -1- below the exhaust system.

– Unclip the lambda probe line from clip -2-.
– Remove protective cover -3-.
– Separate exhaust system at the double clamp -4-.
– Unbolt bracket -5- for rear exhaust pipe.
– Unhook the front exhaust pipe from the assembly car-
rier.
– Remove heat shield -6-.
– Unscrew the shift housing from the body.
– Swivel shift housing down and remove with control ca-
bles.
Installing
The installation occurs in reverse order. Pay attention to
the following:
Removing and Installing Shift Mechanism Edition 11.00

34-5 page 2 S00.5316.02.20
– Before installing the cable locks apply a small amount
of polycarbamide grease in the ball sockets -A- and
-B-.
Note
The seals -arrows- outside the ball socket must be free of
grease.
– Press the shift cable onto the gearshift lever and the
selector cable onto the relay lever -arrows-.
Setting shift mechanism ⇒ Chap. 34-6.
Tightening torques
Components Tightening torque

Shift housing to body 25 Nm
Bracket to body 25 Nm
Cable support to gearbox 20 Nm
Edition 11.00 Removing and Installing Shift Mechanism 34-5 page 3

S00.5316.02.20
Removing and Installing Shift Mechanism Edition 11.00

34-5 page 4 S00.5316.02.20
34-6 Setting shift mechanism

♦ Rig pin -T10027-
Note
♦ The following are required for correct setting of the
shift mechanism:
♦ Operating and transmission elements of the shift
mechanism are in perfect condition.
♦ Shift mechanism operates freely. 2
♦ Gearbox, clutch and clutch control must be in perfect
condition.
• Gearbox in Neutral.
– Pull forward the locking mechanism at shift cable and
at selector cable as far as the stop -arrow 1-, then lock
by turning to the left -arrow 2-.
Lock the shift shaft as follows:
– Press the shift shaft down in direction of -arrow 1-.

– At the same time, turn angle lever -A- in -direction of
arrow 2-.
Edition 12.01 Setting shift mechanism 34-6 page 1

S00.5316.03.20
– Lever the collar upwards and out of centre console

surround -arrows-.
– Guide shift lever in Neutral to the left into the 1st/2nd
gear gate.
– Insert rig pin -T10027- through hole -A- into hole -B-.
– Now turn the locking mechanism at the shift cable and

at the selector cable to the right as far as the stop -di-
rection of the arrow-.
The spring pushes the locking mechanism into the initial
position.
Setting shift mechanism Edition 12.01

34-6 page 2 S00.5316.03.20
– Now turn the angle lever -A- back to the initial position
-in direction of arrow-.
– Pull rig pin -T10027- out of hole -A- and -B-.

– Fit collar into the surround for centre console.
Operation
• Shift lever must be in Neutral in the 3rd/4th gear gate.
– Depress clutch.
– Shift through all gears several times. Pay particular at-
tention to proper operation of the reverse gear lock.
If the gearshift lever catches when repeatedly engaging a
gear, check the play (stroke) of the shift shaft as follows:
– 1. Engage 1st gear.

– Push shift lever fully to the left and release again.
– At the same time, observe the shift shaft at the gear-
box (2nd mechanic).
– When the gearshift lever is moved, the shift shaft must
make a stroke of about 1 mm -direction of arrow-.
– If this is not the case, set shift mechanism ⇒ Chap.
34-6.
Edition 12.01 Setting shift mechanism 34-6 page 3

S00.5316.03.20
Setting shift mechanism Edition 12.01

34-6 page 4 S00.5316.03.20
34-7 Removing and installing

the gearbox
Removing
♦ Gearbox mount -3282-
♦ Adjusting plate -3282/31-
♦ Engine/gearbox jack (e.g. -V.A.G 1383 A -)
♦ Transport device -MP 3-478-
♦ Supporting device -MP 9-200-
♦ Grease -G 000 100-
– Remove the engine trim panel.

– Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
– Disconnect the earth strap from the battery with the ig-
nition off.
– Remove battery and battery tray ⇒ Electrical System;
Rep. Gr. 27.
– Remove Bowden cable support -arrows-.
– Disconnect the hose line -A- from the gearbox holder.
– Remove slave cylinder -B- and lay aside, secure with
wire. Do not open line system.
Note
Do not depress the clutch pedal.
– Remove selector cable -A- with relay lever. To do so

remove the circlip -arrow 1- from the relay lever.
– Remove the shift cable -B- with the gearshift lever. To
do so unscrew nut -arrow 2-.
– Unplug connector -arrow- from speedometer sender

-G22- (only on vehicles without ABS).
– Remove engine/gearbox connecting screw at the top.
– Remove fixing screw for starter at the top.
– Remove front left wheel and raise vehicle.
– Remove soundproofing panel.
Edition 01.03 Removing and installing the gearbox 34-7 page 1

S00.5316.05.20
– Release double clamp -1- and separate the exhaust

system.
– Unclip the lambda probe line from clip -2-.
– Remove the earth strap from the engine/gearbox con-

necting screw at the bottom front -1-.
– Disconnect plug -2- from the reversing light switch
-F4-.
– Unscrew bracket -3- from the gearbox -arrow- and lay
aside together with the lines.
– Remove the front left wheelhouse liner ⇒ Body Work;
Rep. Gr. 66.
– Remove the starter ⇒ Electrical System; Rep. Gr.
27.
– Disconnect the drive shafts from the flange shafts,
turn steering wheel to the left.
– Mark installation position of bolts -1- for left steering

joint, otherwise the steering geometry must be
checked.
– Release screws -1-.
– Unbolt anti-toll bar-coupling rod -2- -arrow-.
– 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.
Removing and installing the gearbox Edition 01.03

34-7 page 2 S00.5316.05.20
– Unbolt the pendulum support -arrows-.
– Unscrew the engine/gearbox connecting screw above
the right flange shaft.
– Install supporting device -MP 9-200-.
Note
When installing the lifting hooks of the supporting device,
pay attention to hose and cable connections in the area
of the lifting eyes of the engine to avoid damaging them.
– Take up the weight of the engine/gearbox unit at the

spindles.
– Unscrew the fixing screws -arrows- from the gearbox
mount.

S00.5316.05.20
– Detach gearbox mounting bracket -A- from the gear-

box.
Remove the fixing screws -arrows- for the gearbox
mounting bracket as follows:
– Lower engine/gearbox unit sufficiently at the two spin-

dles 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.
– Insert engine/gearbox mount -3282- into engine/gear-

box jack e.g. -V.A.G 1383 A -.
Complete engine/gearbox jack with gearbox mount
-3282-, adjusting 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).
– Align arms of the gearbox mount to match the holes in
the adjusting plate.
– Screw in the mounting elements -A- as shown on ad-
justing plate.
– Position engine/gearbox jack below vehicle, ⇒ Fig.

S34-0340 arrow symbol -B- on 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 fixing screws for the engine/gear-
box.
– Press gearbox off the engine and swivel towards the
assembly carrier.
– Ask a second mechanic to push the engine forwards.
– Carefully lower the gearbox.
– Change the gearbox position at the spindles of the
gearbox mount -3282- when lowering.

34-7 page 4 S00.5316.05.20
– Screw down gearbox suspension device -MP 3-478-
onto clutch housing.
– Adjust supporting arm at slide with locking pin -arrow-.

Number of visible holes = 5.
– Raise gearbox with workshop crane and gearbox sus-

pension device -MP 3-478-.
– Place down gearbox, e.g. in a transport container.
MP 3-478
Installing
– Before installing, unscrew plug for gearbox oil inspec-
tion and pour in gear oil.
Capacity and specification ⇒ Chap. 00-1.
The installation of the gearbox occurs in reverse order. S34-0344
Pay attention to the stress-free assembly bracket in the
vehicle ⇒ Rep. Gr. 10; of the relevant engine.
– After installing, check gear oil ⇒ Chap. 34-8.
Note
♦ Clean splines of drive shaft and apply a thin film of
grease -G 000 100-.
♦ If the gearbox is replaced, ensure the intermediate
plate between the engine and gearbox is correctly in-
stalled.
♦ Check whether the dowel sleeves for centering the
gearbox are present in the cylinder block; insert if nec-
essary.
♦ Installing starter and cables ⇒ Electrical System;
Rep. Gr. 27.
♦ Setting shift mechanism ⇒ Chap. 34-6.
♦ If the battery earth strap is disconnected and connect-
ed, carry out additional operations ⇒ Electrical Sys-
tem; Rep. Gr. 27.
Tightening torques
Gearbox ³ 09.00 to 1.4/55 kW and 1.4/74 kW engine

S00.5316.05.20
Position Screw Qty Nm

1 M12 x 65 1 80
21) M12 x 140 2 80
3 M12 x 65 1 80
42) M10 x 55 2 40
5 M12 x 80 1 80
1) Screw with threaded pin M8
2) only for 1.4 ltr/55 kW engine screws M10 x 35 (cover plate for fly-
wheel)
A: Dowel sleeves for centering

Gearbox 10.00 ³ to 1.4/55 kW and 1.4/74 kW engine
Position Screw Qty Nm

1 M12 x 65 1 80
21) M12 x 140 2 80
3 M12 x 65 1 80
4 M10 x 55 2 40
5 M12 x 80 1 80

1
Gearbox to 1.9/47 kW and 2.0/85 kW engine 1
Position Screw Qty Nm 2
1 M12 x 55 2 80
21) M12 x 140 2 80 2
3 M10 x 50 3 40
4 M12 x 65 1 80
A
3
Component Torque A 4 3 S34-0442
Gearbox mounting bracket to
40 Nm + 90°
gearbox 1) M10
Gearbox mounting bracket to
40 Nm + 90°
gearbox mount 1) M10
Cable support to gearbox 20 Nm
Gearbox shift lever to gearbox 20 Nm
Slave cylinder to gearbox 20 Nm
Steering joint to front track con-
20 Nm + 90°
trol arm 1) M8
Coupling rod to anti-roll bar 40 Nm
Wheel bolts to wheel hub 120 Nm
Nut for attaching double clamp
40 Nm
of exhaust system
1) always replace these bolts

34-7 page 6 S00.5316.05.20
Fixing the pendulum support ⇒ Rep. Gr. 34; Gearbox

02R.
Drive shaft to flange shaft ⇒ Rep. Gr. 40; Running Gear.

S00.5316.05.20

34-7 page 8 S00.5316.05.20
34-8 Inspecting gear oil

♦ Socket wrench insert -T30023-
Gear oil specification ⇒ Chap. 00-1
– 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.
– Tighten plug -arrow-, 24 Nm.

When re-filling, pay attention to the following points:
– Unscrew 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 ro-
tate for about 2 minutes.
– Switch off engine, unscrew plug -arrow- and again top
up gear oil to lower edge of filler hole.
– Tighten plug -arrow-, 24 Nm.
Edition 12.99 Inspecting gear oil 34-8 page 1

S00.5316.01.20
Inspecting gear oil Edition 12.99

34-8 page 2 S00.5316.01.20
34-9 Disassembling and assembling the gearbox

Mounting sequence ⇒ 34-9 page 5
I - Disassembling and assem-

bling gearbox housing cover
and 5th gear ⇒ 34-9 page 2
II - Disassembling and assem-
bling clutch housing ⇒ 34-9
page 3
III - Disassembling and assem-
bling the drive shaft, output
shaft, differential and gear-
shift forks ⇒ 34-9 page 4
Edition 12.01 Disassembling and assembling the gearbox 34-9 page 1

S00.5316.03.20
I - Disassembling and assembling gearbox housing cover and 5th gear

1 - Gearbox housing
2 - 5th gear pinion
T fitting position ⇒ 34-9
page 9
3 - Circlip
T replacing
T Determine thickness
⇒ 34-9 page 10
4 - Gasket
5 - Cover for gearbox housing
Note
If the gearbox housing cover is
installed with the gearbox
mounted, inspect the gear oil
level and if necessary top up
with gear oil ⇒ Chap. 34-8.
6- 9 Nm
7- Circlip
T replacing
⇒ 34-9 page 10
8- Synchronizer body with slid-
ing sleeve and stop ring for
5th gear
T disassembling and assem-
bling ⇒ Chap. 35-1
9- 5th gear synchronizer ring
10 - 5th gear sliding gear
11 - Needle bearing
T for 5th gear
T replace together with Pos. 12
T 27x32x24.8 mm
12 - Bushing
T for 5th gear needle bearing
T pressing off with bearing support for grooved ball bearing ⇒ Chap. 35-1
T pressing on ⇒ Chap. 35-1
T 21.8x27x25.8
13 - 5th gear shift fork
T disassembling and assembling ⇒ Chap. 34-12
14 - Bolt
T for 5th gear shift fork
Disassembling and assembling the gearbox Edition 12.01

34-9 page 2 S00.5316.03.20
II - Disassembling and assembling clutch housing
Special tools, test equipment and appliances required
♦ Sealant -AMV 188 200-
1 - Conical screw, 25 Nm
2 - Flange shaft with pressure
spring
⇒ 34-9 page 5
T complete ⇒ Chap. 39-2
3 - turn 8 Nm and 90°
T always replace
4 - Clutch housing
T repairing ⇒ Chap. 34-10
5 - Gearbox housing
6 - Clutch release lever
T with guide bushing and
clutch release bearing
⇒ 34-9 page 5
T always replace

S00.5316.03.20
III - Disassembling and assembling the drive shaft, output shaft, differential and
gearshift forks
1 - Differential
2 - Gearbox housing
T repairing ⇒ Chap. 34-10
3 - Oil drain plug, 25 Nm
4 - Flange shaft with pressure
spring
⇒ 34-9 page 5
T complete ⇒ Chap. 39-2
T self-locking
T always replace
T to secure the bearing support
with grooved ball bearings
for the drive and output shaft
⇒ item 16
7 - 23 Nm
T for shift mechanism
⇒ item 15
8 - O-ring
T always replace
9 - Bearing pins
T always replace
11 - Gearshift shaft with cover
T always replace
13 - Switch for reversing lights -F4-, 25 Nm
14 - Gasket
T replacing
15 - Shift mechanism
T Gearshift forks
T disassembling and assembling ⇒ Chap. 34-12
16 - Drive shaft and output shaft with bearing support for grooved ball bearings
T always replace after disassembling the bearing support
T Pressing the bearing support off and on ⇒ Chap. 35-1
T Disassembling and assembling the drive shaft ⇒ Chap. 35-1
T Disassembling and assembling the output shaft ⇒ Chap. 35-2
17 - Reverse wheel shaft
T wtih reverse gear support
18 - Screw
T if supporting reverse gears where the material is:
Magnesium M 6 - turn 8 Nm and 90°
aluminium M 8 - turn 25 Nm and 45°
T
T always replace

34-9 page 4 S00.5316.03.20
19 - Reverse gear
T always replace
Mounting sequence
Removing and installing cover for gearbox housing,
clutch housing, gearshift shaft with cover, drive
shaft, output shaft, differential and gearshift mecha-
nism

♦ Pressure plate -MP 3-406-
♦ Thrust piece -MP 3-408-
♦ Assembly stand -MP 9-101-
♦ Gearbox mount -T30012-
♦ Guide bolt -T10079-
♦ Support -T10083-
♦ Pressure plate -T10085-
Removing
– Secure gearbox to the assembly stand -arrows-.
– Position catch pan beneath.
– Drain gear oil.
– Removing the clutch release lever together with the
clutch release bearing and guide bushing ⇒ Chap.
30-2.
– Removing the right flange shaft.
– Unscrew the cover -arrow- for the gearbox housing.

S00.5316.03.20
– 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.
– Removing the gear pinions and 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 fixing screws for the clutch housing on
the gearbox housing.
– Carefully release the clutch housing from the project-
ing housing lands and make sure the sealing surfaces
are not damaged in the process.
– Remove the differential gear from the gearbox hous-
ing.
– 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-.

34-9 page 6 S00.5316.03.20
– Unscrew the screw -A- for the shaft for reverse gear.
– Remove the bearing pins -B- at the bottom of the gear-
box.
Note
Do not remove the cover -arrow- to disassemble the
gearbox.
– Remove 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
-MP 3-406- and -MP 3-407- in such a way that the
dowel sleeves in the gearbox housing are not dam-
aged.
♦ During the pressing off procedure request the assist-
ance of second mechanic to prevent components
from falling.
♦ Always replace the bearing support for grooved ball
bearings after disassembly.
– Pressing off the drive and output shaft from the bear-
ing support for grooved ball bearings ⇒ Chap. 35-1.
Installing
1 2
– Pressing the bearing support for grooved ball bear-
ings onto the drive and output shaft ⇒ Chap. 35-1.
– Pressing the sleeve of the 5th gear sliding gear needle 3 4
bearing onto the drive shaft ⇒ Chap. 35-1.
– Place the drive shaft -2-, output shaft -1- with bearing
support for grooved ball bearing in special tool
-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 special tool -T10079- to the fitting of the re-
verse gear -arrow-.
T10085 T10079 S34-0432

S00.5316.03.20
– 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.
T10079
S34-0433
– Carefully press on the bearing support with the drive

and output shaft up to the arrester.
MP 3-408
T10083
MP 3-407
MP 3-406
S34-0434
– Tighten screw -A- for reverse wheel shaft.

– Install the bearing pins -B- at the bottom of the gear-
box.

34-9 page 8 S00.5316.03.20
– 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.
– Apply sealant -AMV 188 200- uniformly on the sealing
surfaces of the cover.
– Install the gearshift shaft with cover -A-. Subsequently
tighten the screws -arrows-.
– Use new screws -A- to secure the bearing support to

the drive shaft and output shaft.
Note
Tighten the screws gradually crosswise to the corre-
sponding tightening torque.
– Tighten hexagon nut -B- for the gearshift mechanism

(shift forks).
– Insert the differential gear.
– Apply sealant -AMV 188 200- uniformly on the sealing
surfaces.
– Screw down the clutch housing onto the gearbox
housing.
– Fit the 5th gear pinion -1-.
Fitting position of the 5th gear pinion:
The highest collar -arrow- points to the gearbox hous-
ing cover.

S00.5316.03.20
– Mount the 5th gear sliding gear with needle bearing.

– Position the 5th gear synchronizer ring on the sliding
gear.
– Mount the synchronizer body for the 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 dimension of the new circlip -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) Spare part No.

2,00 085 311 187
2,10 085 311 187 A
2,20 085 311 187 B
– Mount cover for gearbox housing

– Install both flange shafts with pressure springs, stop
discs and conical rings.
– Install the clutch release lever together with the re-
lease bearing and guide bushing.

34-9 page 10 S00.5316.03.20
34-10 Repairing the gearbox housing and clutch housing

♦ Assembly device -MP 3-434-
♦ Distance sleeve -MP 3-458/2-
♦ Centering mandrel -MP 3-463-
♦ Gearbox mount -T30012-
♦ Socket wrench insert -T30023-
♦ Separating device12 - 75 mm, for example - Kukko 17/1-
♦ Extractor, e.g. -Kukko 18/1 -
1 - Clutch housing
T if replaced: Setting the differ-
ential gear ⇒ Chap. 39-3.
2 - Gasket ring for drive shaft
T release with a screwdriver
page 3
3 - Ball stud, 20 Nm
T Grease with MoS2-grease
4 - Gasket ring
T for right flange shaft
T replacing ⇒ Chapter 39-1
5 - Bushing
T for gasket ring
T removing ⇒ Fig. 2 in 34-10
page 3
T inserting ⇒ Fig. 3 in 34-10
page 3
6 - Screw
T on housing of:
Magnesium - 24 Nm
Aluminium - 32 Nm
T screw and unscrew with
socket wrench insert
-T30023-
7 - O-ring
T always replace
8 - Sender for speedometer
T only on vehicles without ABS
T only on vehicles without ABS
T always replace
10 - Adjusting washer S2
T for differential
T Determine thickness ⇒ Chapter 39-3
Edition 01.03 Repairing the gearbox housing and clutch housing 34-10 page 1
S00.5316.05.20
11 - Outer ring/tapered-roller bearing

T for differential
T removing and installing ⇒ Chapter 39-2
T if replaced: setting the differential gear ⇒ Chap. 39-3.
T always replace
T for differential
T for differential
T always 1 mm thick
15 - Dowel sleeve
T (2 pieces)
16 - Gearbox housing
17 - Oil drain plug
T on housing of:
Magnesium - 24 Nm
Aluminium - 32 Nm
T screw and unscrew with socket wrench insert -T30023-
18 - Gasket ring
T for left flange shaft
T replacing ⇒ Chapter 39-1
19 - Bushing
T for gearshift shaft
T extracting ⇒ Fig. 4 in 34-10 page 4
T inserting ⇒ Fig. 5 in 34-10 page 4
20 - Magnet
T is held in position by the separator surface of the housing
21 - Cap
T Before screwing down apply -AMV 188 200- to the sealing surface
22 - Circlip
T insert in the slot of the cylindrical-roller bearing ⇒ item 25 in 34-10 page 2
23 - Circlip
T insert in the slot of the cylindrical-roller bearing ⇒ item 24 in 34-10 page 2
24 - Cylindrical-roller bearing
T for drive shaft
T for output shaft
26 - Plug
T inserted in the hole in the clutch housing
Repairing the gearbox housing and clutch housing Edition 01.03

34-10 page 2 S00.5316.05.20
Fig. 1: Insert the gasket ring for the drive shaft until
flush
Fig. 2: Remove bushing for gasket ring
– Position the distance sleeve -MP 3-458/2- and pres- A

sure plate -MP 3-484- on the differential.
A - Extractor, e.g. -Kukko 18/1-
B - Separating device 12 through 75 mm, e.g.
B
-Kukko 17/1-
MP 3-484
MP 3-458/2
S34-0426
Fig. 3: Insert bushing for gasket ring

A - Screw threaded rod from assembly device
-MP 3-434- into the threaded part of the differential
B - Nut with washer
– By turning the nut -B- insert the bushing over the pres-
sure plate -MP 3-420- up to the stop.
Note
If the gearbox is disassembled press the bushing with
pressure plate -MP 3-420- up to the stop.
Edition 01.03 Repairing the gearbox housing and clutch housing 34-10 page 3
S00.5316.05.20
Fig. 4: Remove the bushing -A- for the shiftgear

shaft
Fig. 5: Insert the bushing -A- for the shiftgear shaft
Repairing the gearbox housing and clutch housing Edition 01.03

34-10 page 4 S00.5316.05.20
34-11 Disassembling and assembling the gearshift mechanism on

the gearbox side
♦ Pipe -MP 3-479-
1 - Bushing
T for gearshift shaft
T removing and inserting
⇒ Chap. 34-10
2 - Gearshift shaft with cover
T replace jointly
3 - Reversing lever
4 - Bushing
5 - Gasket ring
T release with a screwdriver
T inserting ⇒ Fig. 1 in 34-11
page 1
6 - Cap
T for gearbox bleeder
7 - Gearshift lever
T insert in such a way that the
interrupted tooth-pitch is op-
posite the gearshift shaft
T may be replaced with the
gearshift mechanism mount-
ed
8 - Hexagon nut, 25 Nm
T self-locking
T always replace
9 - Lock washer
Fig. 1: Insert gasket ring up to the stop
MP 3-479
S34-0441
Edition 12.99 Disassembling and assembling the gearshift mechanism on the 34-11 page 1
S00.5316.01.20 gearbox side
Disassembling and assembling the gearshift mechanism on the Edition 12.99

34-11 page 2 gearbox side S00.5316.01.20
34-12 Disassembling and assembling the gearshift forks

♦ Driver -MP 1-304-
♦ Pressure washer -MP 3-455-
♦ Distance sleeve -MP 3-458-
♦ Pressure lever -MP 8-506-
1 - 3rd/4th gear shift fork

2 - Angular ball bearing
page 2
page 2
3 - Circlip
page 2
T installing⇒ Fig. 4 in 34-12
page 3
4 - Lock washer
5 - Washer
6 - Shift segment
T Identification ⇒ Fig. 5 in
34-12 page 3
T It must still be possible to ro-
tate the segment freely once
the circlip has been fitted
7 - Shift segment
T Identification ⇒ Fig. 5 in
34-12 page 3
T It must still be possible to ro-
tate the segment freely once
the circlip has been fitted
8 - 5th gear shift rail
9 - 3rd/4th gear shift rail
10 - 1st/2nd gear shift rail
11 - Reverse gear shift rail
12 - Bolt
13 - Gearshift fork reverse gear
14 - Fixation of the reverse gear
15 - Lock washer
16 - 1st/2nd gear shift fork
17 - Shift segment
T Identification ⇒ Fig. 5 in 34-12 page 3
T It must still be possible to rotate the segment freely once the circlip has been fitted
18 - 5th gear shift fork
19 - Shift segment
T Identification ⇒ Fig. 5 in 34-12 page 3
T It must still be possible to rotate the segment freely once the circlip has been fitted
Edition 12.99 Disassembling and assembling the gearshift forks 34-12 page 1
S00.5316.01.20
20 - Bearing bolt
T for 5th gear shift fork
Fig. 1: Removing the angular ball bearing
Note
MP 1-304
Do not bend the shift forks when removing and installing
the angular ball bearings.
MP 3-453
MP 3-407
S34-0460
MP 3-458
Fig. 2: Insert the angular ball bearing up to the
stop.
Fig. 3: Removing the circlip
– Secure the shift fork in a vice fitted with protective jaws

-B-.
– Lift off the circlip -A-in the direction of the arrow.
Disassembling and assembling the gearshift forks Edition 12.99

34-12 page 2 S00.5316.01.20
Fig. 4: 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
Fig. 5: Shift segment identification dimension -a-
1- Shift segment 1st and 2nd gear as = 10,2

well as short 3rd and 4th Gear
2- long shift segment 3rd and 4th = 10,2
gear
3- 5th gear shift segment = 6,0
Edition 12.99 Disassembling and assembling the gearshift forks 34-12 page 3
S00.5316.01.20
Disassembling and assembling the gearshift forks Edition 12.99

34-12 page 4 S00.5316.01.20
35 – Wheels, shafts
35-1 Disassembling and as-

sembling the drive shaft
♦ Bushing -MP 1-316-
♦ Pipe section -MP 3-414-
♦ Inserting device -MP 9-400-
♦ Press-in base -T10083-
♦ Pressure plate -T10084A-
♦ Separating device, e.g. -Kukko 17/1-
♦ Extractor, e.g. -Kukko 18/1-
♦ Interior extractor, e.g. -Kukko 21/5-
♦ Countersupport, e.g. -Kukko 22/1-
Edition 04.03 Disassembling and assembling the drive shaft 35-1 page 1
S00.5316.06.20
Note
♦ When installing new pinions observe the technical data ⇒ Chap. 00-1.
♦ Insert all bearings, gears and synchronizer rings in the gearbox with gear oil.
♦ Do not interchange the synchronizer rings, if re-used always assign to the original sliding gear.
1 - Circlip
T always replace
⇒ Chapter 34-9
2 - Sliding sleeve with 5th gear
synchronizer body
⇒ Chapter 34-9
T disassembling ⇒ Fig. 15 in
35-1 page 8
T Assembling sliding sleeve
with 5th gear synchronizer
body ⇒ Fig. 15 in 35-1
page 8 and ⇒ Fig. 7 in 35-1
page 6
3 - 5th gear synchronizer ring
T check for wear ⇒ Fig. 9 in
35-1 page 6
5 - Needle bearing
T for 5th gear
T 27x32x24.8 mm
6 - Bushing
T for 5th gear needle bearing
T press off with bearing sup-
port for grooved ball bearing
⇒ Fig. 3 in 35-1 page 4
T pressing on ⇒ Fig. 13 in
35-1 page 8
T 21.8x27x25.8
7 - Gearbox housing
8 - Bearing support for grooved ball bearing
T Always replace grooved ball bearing together with the bearing support
T pressing off ⇒ Fig. 3 in 35-1 page 4
T pressing on ⇒ Fig. 12 in 35-1 page 7
9 - Drive shaft
10 - Needle bearing
T for 3rd gear
T 27x32x24.8 mm
11 - 3rd gear sliding gear
12 - 3rd gear synchronizer ring
T check for wear ⇒ Fig. 9 in 35-1 page 6
13 - Circlip
T when pressing out observe safety measures
T use pliers to insert in the slot
14 - Sliding sleeve with 3rd and 4th gear synchronizer body
T press off with 3rd gear sliding gear ⇒ Fig. 5 in 35-1 page 5
Disassembling and assembling the drive shaft Edition 04.03

35-1 page 2 S00.5316.06.20
T disassembling ⇒ Fig. 6 in 35-1 page 5
T Fitting position sliding sleeve/synchronizer body ⇒ Fig. 8 in 35-1 page 6
T Assembling sliding sleeve/synchronizer body ⇒ Fig. 6 in 35-1 page 5 and ⇒ Fig. 7 in 35-1 page 6
15 - Circlip
T insert with pliers
16 - 4th gear synchronizer ring
18 - Needle bearing
T for 4th gear
T Magnesium gearbox - 27x32x24.8 mm
T Aluminium gearbox - 30.5x35.5x26.5 mm
19 - Thrust washer
20 - Inner ring
T for cylindrical-roller bearing
T pull off with 4th gear sliding gear ⇒ Fig. 4 in 35-1 page 5
21 - Circlip
T replace
T with circlip
T removing ⇒ Fig. 1 in 35-1 page 4
T Fitting position: the circlip in the bearing points towards the drive shaft
23 - Clutch housing
24 - Spring
25 - Sliding sleeve 3rd and 4th gear
26 - Synchronizer body for 3rd and 4th gear
27 - Arresters for synchronizer body
T (3 pieces)
28 - Spring
T (3 pieces)
30 - 5th gear synchronizer body
31 - 5th gear sliding sleeve
32 - Stop ring
T prevents the arresters from wandering
T installing ⇒ Fig. 16 in 35-1 page 9
S00.5316.06.20
Fig. 1: Pull out the cylindrical-roller bearing from

the clutch housing
– When removing compress circlip -arrow- of the cylin-

drical-roller bearing with pliers -C-.
A - -Gegenstütze-, e. g. -Kukko 22/1-
B - Interior extractor 30 up to 37 mm, e.g. -Kukko 21/5-
Fig. 2: Press the cylindrical-roller bearing into the

clutch housing
– Support the clutch housing by positioning pipe section

-MP 3-450- (not visible in figure) directly under the
bearing support.
– When inserting compress circlip -arrow- of the cylin-
drical-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.
Fig. 3: Press out the bearing support for grooved

ball bearing
– Slide the pressure plate -T10084A- sideways up to

stop onto the drive shaft.
– Insert the pressure plate -T10081- centering pins in
the holes of the drive shaft and output shaft.
Note
Always replace the bearing support together with the
grooved ball bearing.

35-1 page 4 S00.5316.06.20
Fig. 4: Remove the inner ring of the cylindrical-roll-
er bearing with the 4th gear sliding gear
– Remove circlip.
– Insert separating device -A- behind the running gear-
ing (not the engaging gearing) of the 4th gear and
press off.
A - Separating device 12 to 75 mm, e.g. -Kukko 17/1-
Fig. 5: 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.
Fig. 6: Disassembling and assembling the sliding

sleeve and 3rd and 4th gear synchronizer
body
1- Spring
2- Sliding sleeve
3- Synchronizer body
4- Arresters for synchronizer body
– Slide the sliding sleeve over the synchronizer body.

The deeper recesses -arrow A- of the arresters in the
synchronizer body and the recesses -arrow B- in the slid-
ing sleeve must be positioned above one another.
S00.5316.06.20
Fig. 7: Assembling the sliding sleeve and 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 with 120° offset.
The angled end of the springs must grip into the hol-
low arrester of the synchronizer body.
Fig. 8: Fitting position of the sliding sleeve and 3rd

and 4th gear synchronizer body
The groove on the front side -arrow- points towards the
4th gear.
Fig. 9: Check 3rd, 4th and 5th gear synchronizer

ring for wear
– Press the synchronizer ring on the cone of the sliding

gear and measure clearance -a- with a feeler gauge.
Fitting dimen- Wear limit

sion
Clearance -a- 1.1 to 1.7 mm 0.5 mm

35-1 page 6 S00.5316.06.20
Fig. 10: Press on the synchronizer body with the 3rd
and 4th gear sliding sleeve
Fig. 11: Press on the inner ring -A- for the cylindri-
cal-roller bearing
– Insert the circlip.
Fig. 12: Press on the bearing support for grooved

ball bearing
– Before pressing on the bearing support heat it to ap-

proximately 100 °C.
S00.5316.06.20
Fig. 13: Press on the bushing -A- for the 5th gear
needle bearing
Fig. 14: Removing the stop ring
– Unclip the hook -A- of the stop ring from the synchro-
nizer body with a screwdriver.

sleeve and 5th gear synchronizer body
1 - Spring
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 - Stop ring

The deeper recesses -arrow C- of the arresters in the
synchronizer body and the recesses -arrow D- in the
sliding sleeve must be positioned above one another.

35-1 page 8 S00.5316.06.20
Fig. 16: Installing the stop ring
– Press the stop ring onto special tool -MP 9-400-.

– Insert the stop ring together with the special tool in the
synchronizer body with 5th gear sliding sleeve (Ob-
serve fitting position ⇒ Fig. 15 in 35-1 page 8). The
hooks -arrow 1- are engaged in the recesses -arrow 2-
of the synchronizer body.
– Push the stop ring down until the hooks click into po-
sition.
S00.5316.06.20

35-1 page 10 S00.5316.06.20
35-2 Disassembling and as-

sembling the drive shaft
♦ Drive bushing -MP 3-427-
♦ Countersupport, e.g. -Kukko 22/1 -
Note
♦ When installing new pinions or a new output shaft observe the technical data ⇒ Chap. 00-1.
♦ Insert all bearings, gears and synchronizer rings in the gearbox with gear oil.
♦ Do not interchange the synchronizer rings, if re-used always assign to the original gear.
1 - Clutch housing
T with circlip
page 3
T pressing on ⇒ Fig. 2 in 35-2
page 3
T Fitting position: the circlip in
the bearing points towards
the output shaft
3 - Output shaft
T is paired with the gear pinion
of the final drive, replace to-
gether
4 - Gear pinion of 4th gear
T Fitting position: Collar points
to the 3rd gear ⇒ Fig. 4 in
35-2 page 4
5 - Circlip
6 - Circlip
7 - Gear pinion of 3rd gear
T Fitting position: Collar points
to the 4th gear ⇒ Fig. 4 in
35-2 page 4
8 - Circlip
9 - 2nd gear sliding gear
10 - Needle bearing
T for 2nd gear
T 30.5x35.5x26.3 mm
11 - Inner ring for 2nd gear
T check for wear ⇒ Fig. 5 in
35-2 page 4
S00.5316.02.20
12 - Outer ring for 2nd gear

T position on the synchronizer ring ⇒ item 11 in 35-2 page 1
T replace if there are grooves or traces of friction
13 - 2nd gear synchronizer ring
14 - Sliding sleeve with 1st and 2nd gear synchronizer body
T press off together with 2nd gear sliding gear ⇒ Fig. 3 in 35-2 page 3
T disassembling ⇒ Fig. 8 in 35-2 page 5
T Assembling the sliding sleeve with synchronizer body ⇒ Fig. 8 in 35-2 page 5 and ⇒ Fig. 9 in 35-2 page 6
T Fitting position ⇒ Fig. 8 in 35-2 page 5 and ⇒ Fig. 10 in 35-2 page 6
15 - Circlip
T use pliers to insert in the slot
16 - 1st gear synchronizer ring
T insert in such a way that the recesses lock into the arresters on the sliding sleeve ⇒ item 14 in 35-2 page 2
17 - Outer ring for 1st gear
T insert into the synchronizer ring ⇒ item 16 in 35-2 page 2, fitting position ⇒ Fig. 11 in 35-2 page 6
T replace if there are grooves or traces of friction
18 - Inner ring for 1st gear
T check pegs for wear
19 - Needle bearing
T for 1st gear
T 27x32x24.8 mm
20 - 1st gear sliding gear
21 - Bearing support for grooved ball bearing
T Always replace grooved ball bearing together with the bearing support
T replace after each removal
T pressing off and on ⇒ Chap. 35-1
23 - Gearpinion of 5th gear
T Fitting position: Collar points towards the cover of the gearbox housing ⇒ Chap. 34-9
24 - Circlip
T always replace
T Determining thickness ⇒ Chap. 34-9
25 - Spring
26 - Sliding sleeve
27 - Synchronizer body
T (3)

35-2 page 2 S00.5316.02.20
Fig. 1: Pull out the cylindrical-roller bearing from
the clutch housing
– When pulling out the cylindrical-roller bearing com-

press the circlip -arrow- with pliers -C-.
A - Countersupport, e.g. -Kukko 22/1-
B - Interior extractor 30 up to 37 mm, e.g. -Kukko 21/5-
Fig. 2: Press the cylindrical-roller bearing into the

clutch housing
– Support the clutch housing by positioning pipe

-MP 3-450 - (not visible in figure) directly under the
bearing support.
– When pressing in the cylindrical-roller bearing com-
press the circlip -arrow- with pliers -C-.
– Remove pliers before the cylindrical-roller bearing is
in fitting position. The circlip must lock into the clutch
housing slot.
Fig. 3: Sliding sleeve and synchronizer body for

the 1st and 2nd gear
– After removing the circlip jointly press off the 2nd gear
sliding gear and the synchronizer body.
S00.5316.02.20
Fig. 4: Fitting position of gear pinion of 3rd and 4th

gear
– 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 -A- on the output shaft.
Fitting position:
The collar -arrow 2- points towards the 4th gear pinion
-A-.
– Insert circlip -3-.

Fig. 5: Check 1st and 2nd gear inner ring for wear
– Press the inner ring on the cone of the sliding gear and
measure clearance -a- with a feeler gauge.

sion
Clearance -a- 0.75 through 0.3 mm
1.25 mm
Fig. 6: Check 1st and 2nd gear synchronizer ring

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
Clearance -a- 1.2 through 1.8 0.5 mm
mm

35-2 page 4 S00.5316.02.20
Fig. 7: Fitting position of the outer ring, inner ring
and 2nd gear synchronizer ring
– Position the inner ring -A- on the 2nd gear sliding gear.
The angled lands -arrow 1- point towards the outer
ring -B-.
– Position the outer ring -B-.

Lock the lands -arrow 2- in the recesses -arrow 3- of
the sliding gear.
– Position the synchronizer ring -C-.

Lock the recesses -arrow 4- in the lands -arrow 1- of
the inner ring -A-.

sleeve and 1st and 2nd gear synchronizer
body
1- Spring
2- Sliding sleeve
3- Synchronizer body
4- Arresters for synchronizer body

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
synchronizer body and the recesses -arrow E- in the slid-
ing sleeve must be positioned above one another.
S00.5316.02.20
Fig. 9: Assembling the sliding sleeve and 1st and

2nd gear synchronizer body
• The sliding sleeve is drawn over the synchronizer

body.
– Insert the arresters in the deeper recesses -arrows-

and mount the springs with 120° offset.
The angled end of the spring must grip into the syn-
chronizer body bore.
Fig. 10: Press on the sliding sleeve and 1st and 2nd
gear synchronizer body
Fitting position:
The slot for the shift fork in the sliding sleeve points to-
wards the 1st gear, the serration of the reversing gear
points towards the 2nd gear.
– 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.
Fig. 11: Fitting position of the 1st gear outer ring

The pegs -arrows- point towards the reversing gear ser-
ration -A-.

35-2 page 6 S00.5316.02.20
Fig. 12: Fitting position for 1st gear inner ring -A-
The pegs -arrow 1- lock into in the recesses -arrow 2- of
the synchronizer ring -B-.
Fig. 13: Fitting position 1st gear sliding gear

The higher collar -A- points towards the 2nd gear -B-. The
recesses in the collar -arrows- lock into the pegs of the
outer ring ⇒ Fig. 11 in 35-2 page 6.
S00.5316.02.20

35-2 page 8 S00.5316.02.20
39 – Final drive/Differential
39-1 Replacing the flange shaft

gasket rings (gearbox fit-
ted)
♦ Inertia extractor -MP 9-501-
♦ Gasket ring extractor -MP 3-419/37-
♦ Striker -T10082-
♦ Sealing grease G 052 128 A1
Removing
For left gasket ring
– Turn steering to full left lock.

– Remove wheel and raise vehicle.
– If applicable remove the noise insulation below the en-
gine/gearbox
– Remove the wheelhouse liner from the left wheel-
house.
– Unscrew the drive shaft from the flange shaft.
– Mark installation position of bolts -1- for steering joint,
otherwise the steering geometry must be checked.
– Release screws -1-.
– Unbolt coupling rod -2- from the anti-roll bar -arrow-.
For right gasket ring
– Turn steering to full right lock.

– If applicable remove the noise insulation below the en-
gine/gearbox
– Unscrew the drive shaft from the flange shaft.
Proceed as follows for both gasket rings
– Tie up the drive shaft as far as possible. Avoid dam-

aging the paintwork on the drive shaft during this op-
eration.
– Position the catch pan under the gearbox.
– Release fixing screw for flange shaft; while doing so
prevent flange shaft from turning along.
– Remove the flange shaft with pressure spring.
– Remove the gasket ring of the flange shaft.
Installing
For left gasket ring
Edition 11.00 Replacing the flange shaft gasket rings (gearbox fitted) 39-1 page 1
S00.5316.02.20
– Drive the new gasket ring in up to the stop, do not twist

the gasket ring.
For right gasket ring
– Drive the new gasket ring into the bushing up to the

stop, do not twist the gasket ring.
Proceed as follows for both gasket rings
– Fill the space between the sealing lip and dust lip with
sealing grease G 052 128 A1.
The further installation occurs in reverse order, while pay-
ing attention to the following:
– Check gear oil level, if necessary fill up to lower edge

of filler hole ⇒ Chap. 34-8.
Tightening torques
Drive shaft to flange shaft ⇒ Rep. Gr. 40; Running Gear.
Flange shaft to gearbox 25 Nm

Coupling rod to anti-roll bar 40 Nm
Wheel bolts to wheel hub 120 Nm
Steering joint to track control arm 1) 20 Nm + 90°
1) Always replace these bolts
Replacing the flange shaft gasket rings (gearbox fitted) Edition 11.00
39-1 page 2 S00.5316.02.20
39-2 Disassembling and assembling the differential

♦ Pressure pad -MP 1-223-
♦ Pipe -MP 3-409-
♦ Insertion bushing -MP 3-412-
♦ Pressure pipe -MP 6-408-
♦ Pipe -MP 6-419-
♦ Pipe -T30019-
♦ Extractor -V.A.G 1582-
♦ Gripper -V.A.G 1582/4-
♦ Countersupport, e.g. -Kukko 22/2-
Note
♦ Before installing heat the inner ring of the tapered-roller bearing to 100 °C.
♦ Replace both tapered-roller bearings together.
♦ When replacing the tapered-roller bearing of the differential housing, gearbox housing and clutch housing adjust
the differential ⇒ Chap. 39-3.
Edition 12.99 Disassembling and assembling the differential 39-2 page 1

S00.5316.01.20
T screw into threaded piece
⇒ item 8
2 - Right flange shaft
T do not interchange, the left
and right flange shafts are
different
3 - Pressure spring for flange
shaft
T fitted behind flange shaft
4 - Stop disc
T Fitting position: Collar to-
wards pressure spring
5 - Conical ring
T Fitting position: Cone to-
wards differential housing
6 - Circlip
T holds the conical ring, stop
disc and pressure spring in
position when the flange
shaft is removed
7 - Differential bevel gear large
page 5
8 - Threaded part
page 5
9 - Differential bevel gear shaft
T to remove
⇒ item 18cut⇒ Fig. 7 in
39-2 page 5 tensioning
sleeve
page 5
10 - Differential bevel gear small
T installing⇒ Fig. 8 in 39-2 page 5
11 - Stop disc compound
T Install with gearbox oil
12 - Flange shaft left
T with dust guard
T do not interchange, the left and right flange shafts are different
13 - Gasket ring
T for left flange shaft
T diameter of left and right differ
T replace with installed gearbox ⇒ Chap. 39-1
T for differential
T always 1 mm thick
16 - Inner ring/tapered-roller bearing
Disassembling and assembling the differential Edition 12.99

39-2 page 2 S00.5316.01.20
17 - Differential housing
T with riveted pinion for final drive
T is paired with the output shaft, replace together
18 - Tensioning sleeve
T to secure the differential bevel gear shaft
T is cut when removing ⇒ Fig. 7 in 39-2 page 5
T installing⇒ Fig. 8 in 39-2 page 5
19 - Inner ring/tapered-roller bearing
T pressing out ⇒ Fig. 5 in 39-2 page 4
T for differential
T Determine thickness ⇒ Chap. 39-3
22 - Gasket ring
T for right flange shaft
T diameter of left and right differ
T replace with installed gearbox ⇒ Chap. 39-1
24 - Clutch housing
Fig. 1: Remove outer ring/tapered-roller bearing

from gearbox housing
A - Countersupport, e.g. -Kukko 22/2-
B - Interior extractor 46..00,58 mm, e.g. -Kukko 21/7-
Fig. 2: Press outer ring/tapered-roller bearing into

the gearbox housing
– Position adjusting washer S1 always 1 mm thick, un-

der outer ring.

S00.5316.01.20
Fig. 3: Remove inner ring/tapered-roller bearing
– Before fitting the extractor position distance sleeve

-MP 3-458/2- and pressure plate -MP 3-431- on the
differential housing.
Note
Both inner rings/tapered-roller bearings of the differential
housing are removed in the same way.
Fig. 4: Press on inner ring/tapered-roller bearing
– Support the opposite side of the inner ring with an in-

sertion bushing -MP 3-412-.
Fig. 5: Press the outer ring/tapered-roller bearing

-A- out off the clutch housing
B - Interior extractor 46..00,58 mm, e.g. -Kukko 21/7-

39-2 page 4 S00.5316.01.20
Fig. 6: Press outer ring/tapered-roller bearing into
the clutch housing
– Support the clutch housing with a pipe -T30019- di-

rectly below the bearing support.
Fig. 7: Press out the differential bevel gear shaft

The tensioning sleeve is cut during pressing out.
– Drive the remaining part of the tensioning sleeve out

of the differential housing.
Fig. 8: Install the differential bevel gears
– Install stop disc compound with gearbox oil.

– Insert both large differential bevel gears and secure
(e.g. with flange shaft).
– Insert and swivel the small differential bevel gears into
position with a 180° offset.
– Push in the differential bevel gear shaft -arrow A- up
to the first small bevel gear.
– Insert the threaded parts -arrow B- in the large differ-
ential bevel gears.
Fitting position: Heel of the differential bevel gear
– Insert the differential bevel gear shaft up to end posi-

tion and secure with tensioning sleeve.

S00.5316.01.20

39-2 page 6 S00.5316.01.20
39-3 Adjusting the differential

gear
♦ Gauge block plate -MP 3-405/17-
♦ Universal dial indicating gauge -MP 3-447-
♦ Pressure pipe -MP 6-408-
♦ Pipe -MP 6-419-
♦ Pipe -T30019-
♦ Interior extractor, e.g. -Kukko 21/7 -
The differential gear must be re-set when:

♦ Gearbox housing
♦ Clutch housing
♦ Differential housing
or the
♦ differential gear tapered-roller bearing
have been replaced.
– Press the outer ring/tapered-roller bearing (pinion

side) with adjusting washer S1 (always 1 mm thick)
into the gearbox housing.
Note
The inner and outer ring of the tapered-roller bearing are
paired. Do not interchange!
– Press the outer ring/tapered-roller bearing (opposite

pinion side) without adjusting washer into the clutch
housing.
– Insert the differential gear in the gearbox housing.
– Position the clutch housing and tighten 5 screws to the
given tightening torque.
Edition 12.01 Adjusting the differential gear 39-3 page 1

S00.5316.03.20
– Install the measuring device and dial gauge (3 mm

measuring range, dial gauge extension -A- of approx.
30 mm)
– Set the dial gauge to 0 with 1 mm bias.
– Move the differential gear up and down, read off and
write down the clearance on the dial gauge. (Example:
1.50 mm)
Note
Do not turn when measuring the differential as otherwise
the bearing will settle and the measuring result will be in-
accurate.
Determining adjusting washer S2
The required bearing preload is reached by adding to the

value measured for S 2 (for example: 1.50 mm) a con-
stant value for pressure (0.25 mm or 0.35 mm).
Example:
For magnesium gearboxes:
measured value 1.50 mm

+ pressure (const. value) 0.35 mm
Thickness of adjusting washer S2 = 1.85 mm
For aluminium gearboxes:
measured value 1.50 mm

+ pressure (const. value) 0.25 mm
Thickness of adjusting washer S2 = 1.75 mm
– Remove the clutch housing and press out the outer

ring/tapered-roller bearing -A-.
-B- Interior extractor 46 ... 58 mm, e.g. -Kukko 21/7-
– Insert adjusting washer S2 with the required thickness

(in this example 1.75 or 1.85 mm) and press the outer
ring/tapered-roller bearing back into the clutch hous-
ing.
– Position the clutch housing and tighten the screws to
the given tightening torque.
The following adjusting washers are available:
For magnesium gearboxes:
Adjusting the differential gear Edition 12.01

39-3 page 2 S00.5316.03.20
Thickness Spare part No.

(mm)
0,70 02K 409 210 A
0,75 02K 409 210 B
0,80 02K 409 210 C
0,85 02K 409 210 D
0,90 02K 409 210 E
0,95 02K 409 210 F
1,00 02K 409 210 G
1,05 02K 409 210 H
1,10 02K 409 210 J
1,15 02K 409 210 K
1,20 02K 409 210 L
1,25 02K 409 210 M
1,30 02K 409 210 A
1,35 02K 409 210 P
For aluminium gearboxes:
Tlouštka C. náhradního dílu

(mm)
0,65 02K 409 210
0,70 02K 409 210 A
0,75 02K 409 210 B
0,80 02K 409 210 C
0,85 02K 409 210 D
0,90 02K 409 210 E
0,95 02K 409 210 F
1,00 02K 409 210 G
1,05 02K 409 210 H
1,10 02K 409 210 J
1,15 02K 409 210 K
1,20 02K 409 210 L
1,25 02K 409 210 M
Different tolerances allow to measure the required thick-

ness for each washer very precisely.
If the measured washer thickness is greater than the one
listed in the table, 2 washers corresponding to the meas-
ured value may be fitted.
Edition 12.01 Adjusting the differential gear 39-3 page 3

S00.5316.03.20
Adjusting the differential gear Edition 12.01

39-3 page 4 S00.5316.03.20

Skoda Fabia 2000 Workshop Manual Gearbox

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Skoda Fabia 2000 Workshop Manual Gearbox

Uploaded by

Copyright:

Available Formats

Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 04.03 List of Supplements

List of Supplements Edition 04.03

Edition 04.03 Table of Contents I

Table of Contents Edition 04.03

00-1 Identification of the gear-

Identification characters and manufacturing date of

Additional data depend on the manufacturing.

Edition 04.03 Identification of the gearbox 00-1 page 1

Identification characters, aggregate assignment, ratios, capacities

Manual gearbox 5 speed 02T

Manual gearbox 5 speed 02T

Identification of the gearbox Edition 04.03

Manual gearbox 5 speed 02T

Manual gearbox 5 speed 02T

Manual gearbox 5 speed 02T

Edition 04.03 Identification of the gearbox 00-1 page 3

Manual gearbox 5 speed 02T

Manual gearbox 5 speed 02T

Manual gearbox 5 speed 02T

Identification of the gearbox Edition 04.03

Manual gearbox 5 speed 02T

Manual gearbox 5 speed 02T

Manual gearbox 5 speed 02T

Edition 04.03 Identification of the gearbox 00-1 page 5

Manual gearbox 5 speed 02T

Manual gearbox 5 speed 02T

1) Only on vehicles without ABS.

Identification of the gearbox Edition 04.03

00-2 Overview of Transmission System

Edition 08.99 Overview of Transmission System 00-2 page 1

Overview of Transmission System Edition 08.99

00-3 General Repair Informa-

Edition 12.01 General Repair Information 00-3 page 1

General Repair Information Edition 12.01

30-1 Clutch control

Summary of components - Foot controls

Edition 01.03 Clutch control 30-1 page 1

Summary of components - Hydraulics

Clutch control Edition 01.03

Edition 01.03 Clutch control 30-1 page 3

Clutch control Edition 01.03

30-2 Repair of the clutch control

1 - Clutch release bearing

Edition 12.99 Repair of the clutch control 30-2 page 1

Fig. 1: remove and install the clutch release lever

– Release screws -arrows-.

Fig. 2: Removing and installing the guide bushing

– Rotate the guide bushing -3- opposite the clutch re-

Fig. 3: Removing and installing the clutch release

– Press the catch pegs -arrows- together and remove

Repair of the clutch control Edition 12.99

30-3 Repairing the clutch

Edition 11.00 Repairing the clutch 30-3 page 1

Fig. 1: Centering clutch disc and removing and in-

– Release and tighten screws gradually and crosswise.

Fig. 2: Centering the clutch disc and removing and

– Release and tighten screws gradually and crosswise.

Fig. 3: Check the extremities of the membrane

• Wear is allowed up to half the membrane spring thick-

Repairing the clutch Edition 11.00

34-1 Shift mechanism