Skoda Fabia II 2007 Workshop Manual Download

Page: 14 / 165

Manual gearbox

5 speed 02T

Identification characters

HZL

JHP

LVD

Manufac‐

tured

from

08.06

11.06

06.09

11.06

05.09

03.10

Assign‐

ment:

Engine

1.4 ltr./51 kW TDI-PD

Ratio:

Final drive

65 : 18 = 3.611

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

Speedometer

electronic

Filling capacity

2.0 ltr.

Specification

⇒ Electronic Catalogue of Original Parts

Gear oil change interval

Filled for life

Clutch control

hydraulic

Clutch disc ∅

⇒ Electronic Catalogue of Original Parts

Drive shaft flange ∅

90 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 .

1.3

Identification characters, aggregate assignment, ratios, filling capacities

(Rapid)

Manual gearbox

5 speed 02T

Identification characters

MAB

NVS

Manufac‐

tured

from

09.11

04.12

03.12

Assign‐

ment:

Engine

1.6 ltr./77 kW

Ratio:

Final drive

68 : 15 = 4.533

64 : 14 = 4.571

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

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Rapid 2011 ➤ , R ...

Gearbox 02T - Edition 05.2014

Rep. gr.00 - Technical data

Summary of Contents for Fabia II 2007

Page 1: ...Workshop Manual Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 Rapid NH 2013 Rapid NH 2014 Roomster 2006 Gearbox 02T Edition 05 2014 Service Service Department Technical Information ...

Page 2: ...kshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups Repair Group 00 Technical data 30 Clutch 34 Controls housing 35 Gears shafts 39 Final drive differential Service ...

Page 3: ... 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 Remov...

Page 4: ... of components 114 4 3 Removing and installing gearbox housing cover and 5th gear 115 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 5 Repairing gearbox housing and clutch housing 126 6 Repairing shift mechanism 130 7 Disassembling and assembling the gearshif...

Page 5: ... year 2006 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 gearbox identification characters to deter mine whether it is an aluminium or a magnesium gearbox 1 1 Iden...

Page 6: ...roduction 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 Manual gearbox 5 speed 02T Identification characters LVC LNR Manufac tured from 09 10 03 10 to Assign ment Engine 1 2 ltr 55 kW 1 2 ltr ...

Page 7: ...9 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 Speedometer electronic Filling capacity 2 0 litre Specification Electronic Catalogue of Original Parts Gear oil change interval Filled for life Clutch control hydraulic Clutch disc Electronic Catalogue of Original Parts Drive shaft flange 100 mm Note Vehicles with ABS do not have the sende...

Page 8: ...duction 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 Manual gearbox 5 speed 02T Identification characters MAB LNJ Manufac tured from 06 10 09 10 to 01 12 01 11 Assign ment Engine 1 6 ltr 77 k...

Page 9: ... 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 Speedometer electronic Filling capacity 2 0 litre Specification Electronic Catalogue of Original Parts Gear oil change interval Filled for life Clutch control hydraulic Clutch disc Electronic Catalogue of Original Parts Drive shaft flange 100 mm Note Vehicles with ABS do not have the sender for speedomet...

Page 10: ...6 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 1 2 Identification characters aggregate assignment ratios filling capacities Roomster Manual gearbox 5 speed 02T Identification characters HZK JHM JHM L...

Page 11: ...SI Ratio Final drive 69 14 4 929 58 16 3 625 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 Speedometer electronic Filling capacity 2 0 ltr Specification Electronic Catalogue of Original Parts Gear oil change interval Filled for life Clutch con...

Page 12: ...oxes 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 Manual gearbox 5 speed 02T Identification characters HXL JHL LVA MAB Manufac tured from 05 06 11 06 06 09 06 10 to 11 06 05 ...

Page 13: ... kW Ratio Final drive 68 15 4 533 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 Speedometer electronic Filling capacity 2 0 ltr Specification Electronic Catalogue of Original Parts Gear oil change interval Filled for life Clutch control hydraulic Clutch disc Electronic Catalogue of Original Parts Driv...

Page 14: ...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 1 3 Identification characters aggregate assignment ratios filling cap...

Page 15: ...1 4 Identification characters aggregate assignment ratios filling capacities Rapid NH Manual gearbox 5 speed 02T Identification characters MKG MFX LGQ Manufac tured from 07 12 07 12 07 12 to Assign ment Engine 1 2 ltr 55 kW MPI 1 2 ltr 63 kW TSI Ratio Final drive 69 14 4 928 58 16 3 625 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 gea...

Page 16: ...1 281 4 gear 37 42 0 881 5 gear 35 52 0 673 Reverse gear 35 24 x 24 11 3 182 Speedometer electronic Filling capacity 2 0 litre Specification Electronic Catalogue of Original Parts Gear oil change interval Filled for life Clutch control hydraulic Clutch disc Electronic Catalogue of Original Parts Drive shaft flange 100 mm Note Vehicles with ABS do not have the sender for speedometer G22 On gearboxe...

Page 17: ...ction 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 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 2 Overview of Transmission System 13 ...

Page 18: ...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 Bolts and other attachments should have a classification in the Electronic Catalogue of Original Parts When installing ensure the dowel sleeves ar...

Page 19: ... 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 Do not over tension the circlips Circlips must be positioned in the base of the groove Replace roll pins Fitting position Slot longitudinal to power flow arrow Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 3 General ...

Page 20: ...l 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 rings of the bearing on a heat ing plate or with the hot air blower e g V A G 1416 to approx 100 C when installing press in axial and play free up to the stop The temperat...

Page 21: ...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 page 65 further measures page 57 In order to reduce unpleasant odours if the clutch is burnt thorou...

Page 22: ...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 ov...

Page 23: ...tronic Catalogue of Original Parts 3 Bearing bracket 4 Screw 5 Gas brake foot controls 6 28 Nm always replace Elec tronic Catalogue of Original Parts 7 Clutch pedal switch F36 Difference between clutch pedal switch page 20 assign according to the Electronic catalogue of original parts Removing and installing page 20 angular clutch pedal switch Removing and installing page 21 cylindrical clutch ped...

Page 24: ... Pedal stop on bracket Pos 3 19 Pedal stop screw with screw Pos 18 onto bracket Pos 3 20 25 Nm always replace Electronic Catalogue of Original Parts Difference between clutch pedal switch F36 A Switch with angular housing Removing and installing page 20 B Switch with cylindrical housing Removing and installing page 21 1 2 Removing and installing setting angular clutch pedal switch F36 Fabia II 200...

Page 25: ...installed once to en sure that it has an adequately tight fit in the bracket Remove the storage area on the driver s side Body Work 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 The clutch pedal remains in the off position in this case do not depress Installing and setting Before instal...

Page 26: ... 2007 Roomster 2006 Removing Remove the storage area on the driver s side Body Work Rep gr 70 Release screws arrows Install Installation is carried out in the reverse order Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 22 Rep gr 30 Clutch ...

Page 27: ...Tightening torque Crash strut to steering column 9 Nm Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 23 ...

Page 28: ...e actuating rod master cylinder from the clutch pedal as follows Insert pliers T10005 in the clutch pedal recesses 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 h...

Page 29: ...ch 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 Install the storage area on the driver s side Body Work Rep gr 70 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 25 ...

Page 30: ...Tightening torque Crash strut to steering column page 22 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 26 ...

Page 31: ...ng wheel in the lower position Unscrew nut A Slowly turn steering wheel in a suitable position Pull screw out of the bracket Remove clutch pedal Install Installation is performed in the reverse order pay attention to the following points The support A must be located on the actuating rod B of the master cylinder To click in the support push the clutch pedal towards the front wall direction of the ...

Page 32: ... strut to steering column page 22 Clutch pedal to bracket 1 page 19 1 Always replace self locking nut Electronic Catalogue of Original Parts Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 28 ...

Page 33: ...n the bracket are located in the master cylinder 3 Bearing bracket removing and installing with master cylinder page 38 removing and installing without master cylinder page 43 4 25 Nm for bracket on front wall self locking 3 pieces always replace Elec tronic Catalogue of Original Parts 5 Clutch pedal switch F36 removing and installing page 31 6 Crash strut is attached to the steer ing column diffe...

Page 34: ...nal parts is inserted on the bracket Pos 3 and on the clutch pedal removing and installing page 31 14 Cap 15 Support only replace if the master cylinder has been removed removing and installing page 51 16 Master cylinder removing and installing page 61 17 Clamp to remove and install the tube hose line pull out retaining clip up to the stop is pulled out from the side on certain master cylinders 18...

Page 35: ...nstalled from the front wall Unplug connector from the clutch pedal switch F36 Turn the clutch pedal switch at the bracket 45 in direction of arrow and remove it from the support 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...

Page 36: ...ir Conditioning Rep 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 Remove the storage area on the driver s side Body Work Rep gr 70 Release screws arrows Install Installation is carried out in the reverse order Fabia II 2007 Fabia II 2009 Fabia II 2011 ...

Page 37: ...Tightening torque Crash strut to steering column 2 screws 9 Nm Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 33 ...

Page 38: ...e area on the driver s side Body Work Rep gr 70 Release screw arrow Unclip the crash strut from the steering column Install Installation is carried out in the reverse order Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 34 ...

Page 39: ...Tightening torque Crash strut to steering column 1 screw 20 Nm Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 35 ...

Page 40: ...der 3 Bearing bracket removing and installing with master cylinder page 41 removing and installing without master cylinder page 44 4 25 Nm for bracket on front wall self locking 3 pieces always replace Elec tronic Catalogue of Original Parts 5 Clutch pedal switch F36 removing and installing page 37 6 Stop for the clutch pedal 7 Bearing bolt always replace Elec tronic Catalogue of Original Parts 8 ...

Page 41: ...astic page 37 Plastic return hose 1 The gaskets 2 must be located in the return hose 1 8 1 Removing and installing 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 Removing the footwell vent Heating and Air Conditioning Rep gr 80 Note The clutch pedal switch is installed from ...

Page 42: ...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 9 Removing and installing the bracket with the master cylinder Fabia II 2011 Roomster 2011 Rapid NH 2013 Special tools and workshop equipment required Closing tool T10249 1 9 1 Removing Note After th...

Page 43: ...ll 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 fitted electrical plug connectors from the master cylinder Continued for all vehicles Note When performing work in the footwell put cloths on the carpet to protect it from possible brake fluid s...

Page 44: ... connectors 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 Continued for all vehicles 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 the clutch con...

Page 45: ...aged During the following work ensure that no brake fluid lands on longitudinal member or gearbox If this is the case these points must be cleaned thoroughly 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 performing work in the footwell put cloths on the carpet to protect it from possible brake fluid spills...

Page 46: ... to the clutch pedal switch F36 Install the footwell vent Heating and Air Conditioning Rep 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 For checking pull on the line Bleed the clutch control page 65 Tightening torques Bracket clutch pedal to front wall 1 page 36 Position ...

Page 47: ...ion on the nut in the opening between the dash panel 2 and the bottom steering column trim panel 3 Unlock the actuating rod master cylinder from the clutch pedal as follows Pull clutch pedal slightly into the passenger compartment Press together both sides of the support using the pliers T10005 arrows Unscrew the two lower fixing nuts arrows Remove the bracket A from the front wall B The master cy...

Page 48: ... Heating and Air Conditioning Rep gr 87 1 12 Removing and installing the bracket without the master cylinder Rapid 2011 Special tools and workshop equipment required Pliers T10005 Removing Removing the footwell vent Heating and Air Conditioning Rep gr 87 Put steering wheel in the highest position Unplug connector from the clutch pedal switch F36 Unscrew the top fixing nut arrow for the bracket To ...

Page 49: ...held by a 2nd mechanic Install Installation is performed in the reverse order pay attention to the following points Note Position self locking nuts 1 and 2 for bracket 3 on front wall and tighten The support A must be located on the actuating rod B of the master cylinder To click in the support A press the clutch pedal towards the front wall in direction of arrow While doing so make sure it catche...

Page 50: ...ctuating rod master cylinder from the clutch pedal as follows Pull clutch pedal slightly into the passenger compartment Press together both sides of the support using the pliers T10005 arrows Remove the bearing bolt for the clutch pedal Turn the bearing bolt for the clutch pedal to the left in direction of arrow for this purpose use the hexagon socket wrench 1 wrench size 8 mm While doing so the c...

Page 51: ...position the over centre helper spring on the centering pin of the clutch pedal arrow 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 The catches B must click audibly into place Then the bolts A are positioned vertically Insta...

Page 52: ...catches A are destroyed Then the bolts B are positioned horizontally to the fitting position 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 bolt Insert the over centre helper spring laterally from the bottom into the support A in the bracket next to t...

Page 53: ...re positioned vertically Install bracket without master cylinder page 44 1 15 Removing and installing the clutch pedal with the tension spring Fabia II 2011 Roomster 2011 Rapid NH 2013 Note Install the clutch pedal with a new bearing bolt If only the tension spring is removed pay attention page 51 Special tools and workshop equipment required Hook 3438 Pliers T10005 Allan key wrench size 8 mm comm...

Page 54: ... clutch pedal to the left 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 Subsequently move the clutch pedal so that the bearing bolt can be pulled out Remove clutch pedal from bracket Install Install the clutch pedal with a new bearing bolt The support 2 must be located ...

Page 55: ...th the support on the actuating rod of the master cylinder Hook in the tension spring Insert the vibration damper with the recess arrows as of the 2nd spring coil arrows Install the clutch pedal switch F36 page 31 If present install the crash strut page 32 Install the footwell vent Heating and Air Conditioning Rep gr 87 1 16 Summary of components Hydraulic Fabia II Roomster Rapid NH Fabia II 2007 ...

Page 56: ...he master cylinder Pos 3 up to the stop 5 Support only replace if the master cylinder Pos 3 has been removed removing page 53 installing page 53 6 Clutch pedal removing and installing page 27 7 28 Nm always replace Electronic Catalogue of Original Parts 8 O ring always replace Difference between the O rings page 53 assign according to the Electronic catalogue of original parts moisten with brake f...

Page 57: ...age 65 17 Gearbox Lift off the support A in the direction of the arrow Push the actuator rod master cylinder in the support A in direction of the arrow Difference between the O rings 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 ro...

Page 58: ... the mas ter cylinder Pos 4 has been removed removing page 55 installing page 56 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 always replace Elec tronic Catalogue of Original Parts 9 Brake lines 10 Support attached to the vehicle body for tube hose line Pos 14 11 Support attached to the vehicle body for tube hose ...

Page 59: ...ox not fitted to all vehicles Assignment Electronic Catalogue of Original Parts 17 Screw 20 Nm not fitted to all vehicles Assignment Electronic Catalogue of Original Parts 18 Dust cap 19 Vent valve Bleeding the clutch control page 65 20 Screw 20 Nm 21 Slave cylinder removing and installing page 61 after installing bleed the clutch control page 65 22 Clamp to remove the tube hose line Pos 14 pull i...

Page 60: ...ection 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 O rings must be inserted into the slots Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 56 ...

Page 61: ...pedal return must not be obstructed by moved or additional covers floor coverings 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...

Page 62: ...7 602 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 Release and cut the tube hose line C out of the master cyl inder Remove the storage area on the driver s side Body Work Rep gr 70 Re...

Page 63: ...inder Unscrew pedal stop page 19 Pos 19 Remove the master cylinder 1 19 2 Install Installation is performed in the reverse order pay attention to the following points The support A must be located on the actuating rod B of the master cylinder To click in the support push the clutch pedal towards the front wall in the direction of the arrow while doing so make sure it catches correctly After instal...

Page 64: ... strut to steering column page 22 Clutch pedal to bracket 1 page 19 1 Always replace self locking nut Electronic Catalogue of Original Parts Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 60 ...

Page 65: ...05 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 Press the support 2 into the recess on the clutch pedal 3 until it clicks audibly into place Install bracket with master cylinder Fabia II 2011 Roomster 2011 Rapid NH 2013 page 38 Rapid 2011 page 41 1 21 Removing and installing the slave cylin der S...

Page 66: ...nition off Elec trical System Rep gr 27 If present remove engine cover Engine Rep gr 10 Remove air filter Engine Rep gr 23 or Engine Rep gr 24 Remove battery and battery tray Electrical System Rep 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 Remove circlip arrow 2 for selector cable from rela...

Page 67: ...dal 1 21 2 Install Installation is performed in the reverse order pay attention to the 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 in...

Page 68: ...cylinder to gearbox Fabia II Roomster Rapid NH page 51 Rapid page 54 Cable support to gearbox page 84 Gearbox shift lever to gearbox page 84 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 64 ...

Page 69: ...e Rep gr 24 Remove battery and battery tray Electrical System Rep 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 Allow approx 100 cm3 of brake fluid to flow out until no more air bubbles are visible Close vent valve Rapidly operate pedal from stop to s...

Page 70: ...ch re 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 4 Retaining spring attach to clutch release lever 5 Guide bushing for clutch release bearing removing and installing page 67 remove and install together with the clutch release lever Pos 3 and clu...

Page 71: ...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 Installation is carried out in the reverse order Removing and installing the release bearing Press the catch pegs arrows together and remove clutch re lease bearing ...

Page 72: ...onic Catalogue of Original Parts 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 The pressure plates are protected against corrosion and are grease...

Page 73: ... 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 ...

Page 74: ... removing inverse the position of the pressure pad MP1 223 3067 Note The thrust surface of the pressure plate and the clutch disc 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 Check the extremities of the membrane spring Wear is allowed up to half the...

Page 75: ...e plate with wrong spring identification Assign pressure plate via the Electronic catalogue of original parts Mechanical fault at the pressure plate or the clutch disc Replace defective components Clutch disc on the serration sluggish jams Check the hub for damage burrs if necessary replace clutch disc Clean the hub and the drive shaft serration from corrosion and residues of lubricant and grease ...

Page 76: ...ls clutch is not fully depressed Inform customer The pressure plate is bent due to incorrect installation the clutch disc is deformed due im proper handling Check components if necessa ry replace make sure the cen tering pins are correctly fitted If scratching still occurs check the serration of the clutch disc on the drive shaft for ease of movement if necessary repair the gearbox Tips of membran...

Page 77: ...een fitted Check clutch disc and pressure plate for damage if necessary replace The lining is spalled off because of too high revs shift back into lower gears during high speeds When starting linings are spal led off through slipping for too long a time Replace clutch disc Inform cus tomer Complaint Fault description Measure Load change jolts when throttle is depressed and sudden reduction of the ...

Page 78: ... necessary Slave cylinder leaking Replace slave cylinder Complaint Fault description Measure Clutch grabbing unit shaking Air in the system Bleed system check brake fluid level check system for tight ness Replace defective part Engine does not run clean Check engine power correct Driving error starting speed is too low Inform customer Wrong clutch disc installed Assign clutch disc via the Electron...

Page 79: ...ove excess grease Complaint Fault description Measure Acoustic knock klack when cou pling Carrier earth drive shaft is ac celerated with sudden coupling The drive shaft serration of the pinions in mesh knocks this noise is increased for clutch discs with noise insulation as the damping reaches the stop Inform customer Complaint Fault description Measure Noises in idle Torsional damper spring kinke...

Page 80: ...ft 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 pos...

Page 81: ...B Selector cable C Heat shield take off before removing the shift mechanism 1 Gearshift lever 2 Reversing lever Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 1 Shift mechanism 77 ...

Page 82: ...l cables Remove shift mechanism for replacing the control cables Fabia II Roomster Rapid NH page 89 Rapid page 94 I Summary of components Gearshift knob with shift lever collar page 79 II Assembly overview shift mechanism page 82 III Summary of components Control cables page 84 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 78 Rep gr 34 Controls housing ...

Page 83: ...l Parts removing and installing Fabia II Roomster page 79 Rapid page 80 Rapid NH page 81 Plaque of gearshift lever 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 Special tools and workshop equipment required Disassembly wedge 3409 2 pieces Fabia II 2007 Fabia II 2009 Fabia II...

Page 84: ...t 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 1 5 Remove and install gearshift knob and shift lever collar Rapid Special tools and workshop equipment required Release tool T30098 2 pieces Fabia...

Page 85: ...the gearshift knob must lock into the round slot of the gearshift lever 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 1 6 Remove and install gearshift knob and shift lever collar Rapid NH Special tools and workshop equipment required Release tool T30098 Hose strap pliers e g V A G 1275 A Lever the co...

Page 86: ...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 1 7 Summary of components Shift lever and shift housing Note Grease bearing and friction surfaces with grease G 000 450 02 Fabia II 2007 Fabia II 2009 Fa...

Page 87: ...riginal Parts 10 Bush 11 Selector cable pressed onto selector angle plate slacken from selector angle plate within the shift mechanism press onto selector angle plate within the shift mechanism Fitting position page 76 after installing set shift mechanism page 96 12 Shift cable pressed onto the shift lever guide slacken from the shift lever guide within the shift mechanism press onto the selector ...

Page 88: ... carefully Removing and installing damping arrow Press the pressure spring arm A as far as possible to the left until it is located outside the damping arrow Press the shift lever to the lift and pull off the damping After installing the damping the pressure spring arms A and B must rest on the damping Pfeil 1 8 Summary of components Control cables Note Grease bearing and friction surfaces with gr...

Page 89: ...fter installing set shift mechanism page 96 3 Bush 4 Lock washer do not damage cables when removing always replace Elec tronic Catalogue of Original Parts 5 Shift housing 6 Cable support can be made out of plastic or metal 7 Bush for mounting of cable support to gearbox 8 Spacer bush 9 20 Nm 3 pieces for cable support 10 Cable lock for selector cable page 86 after installing set shift mechanism pa...

Page 90: ...ver with balancing weight Fitting position page 87 after installing set shift mechanism page 96 17 20 Nm always replace Electronic Catalogue of Original Parts 18 Lock washer always replace Electronic Catalogue of Original Parts 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 ...

Page 91: ...t 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 Gearbox shift lever is located in the neutral position 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 Fabia...

Page 92: ...relay lever towards the front in the direction of arrow 3 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 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 88 Rep gr 34 Controls housing ...

Page 93: ...ted behind the catch arrow 2 The pin detent or the clip arrow 1 secures the relay lever Lever off cable lock for selector cable from plastic relay lever Relay lever removed Position a cross head screwdriver A between bushing B and relay lever Press on cable lock Relay lever removed The cable lock must only be pressed onto the bushing arrow Cable lock must move freely on relay lever The cable lock ...

Page 94: ...from relay lever 2 Remove selector cable and shift cable from the studs Plastic relay lever Pull off shift cable from the stud Remove relay lever together with cable lock page 87 Continued for all vehicles Disconnect the Bowden cable support from gearbox arrows Remove gearshift knob and shift lever collar Fabia II and Roomster page 79 Rapid NH page 81 Remove the centre console cover Body Work Rep ...

Page 95: ...all vehicles Unhook rear silencer in such a way that it does not come in contact with the rear axle Remove heat shield arrows 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 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 1 Shift mechanism 91 ...

Page 96: ...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 Install the noise insulation Body Work Rep gr 50 Setting the shift mechanism page 96 Install air filter Engine Rep gr 23 or Engine Rep gr 24 Connect earth strap of battery while pa...

Page 97: ... Underbody cover 2 Nm Shift housing to body page 82 Cable support to gearbox page 84 Tunnel bridge Engine Rep gr 26 Bracket for the exhaust system Engine Rep gr 26 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 93 ...

Page 98: ...Engine Rep gr 24 Remove circlip 3 for shift cable from gearbox shift lever 1 Pull off shift cable from the stud arrow Remove circlip 4 for the selector cable from relay lever 2 Pull off the selector cable from the stud arrow Remove Bowden cable support arrows Remove gearshift knob and shift lever collar page 80 Remove the centre console Body Work Rep gr 68 If present remove noise insulation from s...

Page 99: ...tact with the rear axle Remove heat shield arrows Swivel shift housing down and remove with control cables 1 11 2 Install Installation is performed in the reverse order pay attention to the following points The holes in the cable locks have different diameters page 84 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 95 ...

Page 100: ... the battery tray and battery Electrical System Rep gr 27 Note After the battery earth strap is disconnected and connected carry out additional operations Electrical System Rep gr 27 Tightening torques Components Tightening torque Underbody cover 2 Nm Shift housing to body page 82 Cable support to gearbox page 84 Tunnel bridge Engine Rep gr 26 Bracket for pre exhaust pipe Engine Rep gr 26 1 12 Set...

Page 101: ... 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 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 Pull the collar upwards over the gearshift knob Guide...

Page 102: ... test of the shift mechanism page 98 Fit collar into the surround for centre console Install air filter Engine Rep gr 23 or Engine Rep gr 24 Install the battery tray and battery Electrical System Rep 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 Shift through all gears several times Pay particular attentio...

Page 103: ... 200 10 10 222A 10 Grease G 000 100 If present remove engine cover Engine Rep gr 10 Note All cable straps which are detached or cut open when remov ing should be fitted on again in the same place when installing If the battery earth strap is disconnected and connected carry out additional operations Electrical System Rep gr 27 Disconnect the battery earth strap with the ignition off Elec trical Sy...

Page 104: ...Catalogue of Original Parts Plastic relay lever In order to avoid damage at the selector cable the catch must be seperated from the selector cable before removal 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 Remove relay lever together with cable lock page 87 Continued for all vehicles Remove the gearshift lev...

Page 105: ...re Do not open line system Note Do not depress the clutch pedal Vehicles with petrol engines Unplug connector arrow from speedometer sender G22 if available Vehicles with diesel engines Unplug connector arrow from speedometer sender G22 if available Continued for all vehicles Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 2 Removing and installing the gearbox 10...

Page 106: ... 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 I Original spindle Dimension a 442 mm Dimension x 100 mm II shortened spindle MP9 2...

Page 107: ...hen connect the shackle 10 222 A 12 with the shortened spindle page 102 Supporting device for vehicles Rapid NH Remove wiper arms Electrical System Rep gr 92 Remove the cooling water tank cover Body Work Rep gr 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 Support supporting device T300...

Page 108: ...ether with the lines Removing starter Electrical System Rep gr 27 Remove pre exhaust pipe Engine Rep gr 26 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 Remove small cover plate A if present for flywheel behind the right flange shaft arrows Note If only a one piece intermediate plate is...

Page 109: ...t 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 Separate plug connection 2 Note Unscrew bracket for AC pipe if present from the fan shroud Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 2 ...

Page 110: ...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 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 gearbo...

Page 111: ...e engine and swivel towards the assembly carrier For vehicles fitted with a 1 4 ltr 51 kW engine When lowering the gearbox if necessary remove the inserted intermediate piece arrow Continued for all vehicles Push the engine forwards 2nd mechanic Carefully lower the gearbox Change the gearbox position at the spindles of the gearbox mount 3282 when lowering Screw down gearbox suspension device MP3 4...

Page 112: ...ronic 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 tween the engine and gearbox is correctly installed Check whether the dowel sleeves for centering the gearbox are presen...

Page 113: ...eves for centering 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 1 Screw with threaded pin M8 A Dowel sleeves for centering 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...

Page 114: ... threaded pin M8 x 12 A Dowel sleeves for centering 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 1 Screw with threaded pin M8 A Dowel sleeves for centering Pendulum support Note Position the screws 1 in the elongated holes of the pendulum support in such a way that there is maximum distanc...

Page 115: ...ne Rep gr 15 Pre exhaust pipe with catalytic converter and clamping sleeve Engine Rep gr 26 Drive shaft to flange shaft Chassis Rep gr 40 Coupling rod to anti roll bar Chassis Rep gr 40 Screen cap for drive shaft on 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 screws Electronic Catalogue of Orig inal Parts Fabia...

Page 116: ...he following Unscrew oil filler plug arrow Pour in gear oil up to lower edge of the 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 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 Install the noise insulation Body Work ...

Page 117: ...f components 1 1 gear 2 2 gear 3 3 gear 4 4 gear 5 5 gear 6 Cover for gearbox housing removing and installing page 115 7 Gearbox housing repairing page 126 8 Reverse gear 9 Shift mechanism Gearshift forks removing and installing page 117 disassembling and as sembling page 132 10 Clutch housing repairing page 126 11 Drive shaft removing and installing page 117 12 Output shaft removing and installin...

Page 118: ...d 5th gear page 115 II Detaching and attaching clutch housing page 116 III Removing and installing the drive shaft output shaft differential gear shift mecha nism and gearshift forks page 117 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 114 ...

Page 119: ... if necessary top up with oil page 112 6 5 Nm 90 further always replace Elec tronic Catalogue of Original Parts 7 Lock washer always replace Elec tronic Catalogue of Original Parts Determine thickness page 125 8 5th gear synchronizer body with sliding sleeve and stop ring disassembling and assembling page 135 9 5th gear synchronizer ring 10 5th gear sliding gear 11 Needle bearing 5 gear replace to...

Page 120: ...ic Catalogue of Original Parts 4 Clutch housing is made out of alumini um or magnesium page 1 Assignment Electron ic Catalogue of Original Parts repairing page 126 5 Gearbox housing is made out of alumini um or magnesium page 1 Assignment Electron ic Catalogue of Original Parts repairing page 126 6 Clutch release lever with guide bushing and clutch release bearing removing and installing page 118 ...

Page 121: ... Nm Oil drain plug with hexa gon socket head 32 Nm 4 Flange shaft with pressure spring removing and installing page 118 complete page 154 5 Conical screw 25 Nm 6 5 Nm 90 further self locking always replace Electronic Catalogue of Original Parts 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 alw...

Page 122: ...rse shaft support Pos 17 M6 5 Nm 90 further M8 25 Nm 45 further always replace Electronic Catalogue of Original Parts 4 6 Mounting sequence Removing and installing cover for gearbox housing clutch hous 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 synch...

Page 123: ...lever together with the release bearing and guide bushing Release screws arrows Separate the clutch release lever together with the release 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...

Page 124: ...e 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 ...

Page 125: ...ring 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 Electron...

Page 126: ...gh 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 th...

Page 127: ...he 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 Apply sealant AMV 188 200 03 uniformly on the sealing sur faces of the cover Install the gearshift shaft with cover A Tighten screws arrows On gearboxes of vehicles with the start stop system Fabia II 2007 Fabia II 2009 F...

Page 128: ...ly sealant AMV 188 200 03 uniformly on the sealing sur 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 5th gear sliding gear with needle bearing Position the 5th gear synchronizer ring ...

Page 129: ...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 Install both flange shafts with pressure springs stop discs and conical rings Install the clutch release lever together with the release bear ing and guide bushing page 66 Pour in gear oil page 112 Fabia II 2007 Fabia II 2009 Fabia II 2011 Ra...

Page 130: ...AMV 188 200 03 Grease G 000 100 1 Clutch housing is made out of alumini um or magnesium page 1 when used Adjusting differential gear page 159 Assignment Electron ic Catalogue of Original Parts 2 Gasket ring for drive shaft release with a screw driver installing page 128 3 Ball stud 20 Nm grease with grease G 000 100 4 Sealing ring for right flange shaft replace page 151 5 Bushing for gasket ring r...

Page 131: ... 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 Assignment Electronic Catalogue of Original Parts 15 Fitting sleeve 2 pieces 16 Gearbox housing is made out of aluminium or magnesium page 1 when used Adjusting differential gear page 159 ...

Page 132: ...g groove Pos 24 24 Cylindrical roller bearing for drive shaft removing and installing page 135 25 Cylindrical roller bearing for output shaft removing and installing page 144 26 Plug inserted in the hole in the clutch housing 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 ...

Page 133: ...eaded rod from assembly device MP3 434 3066 into the threaded part of the differential gear 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 Fabia II 2007 Fabia II ...

Page 134: ...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 release with a screw driver installing page 131 7 Cap for gearbox bleeder 8 Gearshift lever insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft may be replaced with the gearshift mechanism mount...

Page 135: ...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 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 6 Repairing shift mechanism 131 ...

Page 136: ...roup with shift rails 2 3rd 4th gear shift segment Identification page 133 It must still be possible to rotate the shift seg ment freely once fitted 3 Angular ball bearing 4 pieces pressing off page 134 installing page 134 4 Circlip always replace Elec tronic Catalogue of Original Parts removing page 133 installing page 134 5 1st 2nd gear shift segment Identification page 133 It must still be poss...

Page 137: ...ent 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 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 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 7 Disassembling and assembling the gearshift forks 133 ...

Page 138: ...once the circlip has been fitted A Handle wrench wrench size 10 B Protective jaws Pressing off 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 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 134 ...

Page 139: ...1 3002 Pipe section MP3 450 VW 415 A Pipe section MP3 451 VW 422 Distance sleeve MP3 458 2 Flywheel type belt pulley fitting tool MP9 400 Cap T10080 Thrust piece T10081 Insert base T10083 Pressure plate T10084A Separating tool e g Kukko 17 1 Puller e g Kukko 18 1 Interior extractor e g Kukko 21 5 Countersupport e g Kukko 22 1 Hot air blower e g V A G 1416 Note When installing new pinions observe t...

Page 140: ...ge 115 2 Sliding sleeve with 5th gear synchronizer body removing and installing 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 3 5th gear synchronizer ring check for wear page 140 4 5th gear sliding gear 5 Needle bearing 5 gear replace together with Pos 6 Assignment...

Page 141: ...e synchronizer body page 140 and page 140 pressing on page 141 on gearboxes as of production date 06 09 the springs Pos 23 are changed 14 4th gear synchronizer ring on gearboxes as of production date 06 09 the synchronizer ring for 3rd and 4th gear is changed Electronic Catalogue of Original Parts check for wear page 140 15 4th gear sliding gear 16 Bushing for 4th gear needle bearing replace toget...

Page 142: ...eces 29 5th gear synchronizer body 30 5th gear sliding sleeve 31 Supporting ring prevents the arresters from wandering removing page 143 installing page 143 Pull out the cylindrical roller bearing from the clutch housing When removing compress circlip arrow of the cylindrical roll er bearing with pliers C A Countersupport e g Kukko 22 1 B Interior extractor 30 up to 37 mm e g Kukko 21 5 Press the ...

Page 143: ...nd 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...

Page 144: ... 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 Fitting position of the sliding sleeve 3rd and 4th gear synchronizer body The groove on the front side arrow points towards the 4th gear Check 3rd 4th and 5th ge...

Page 145: ...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 mm Circlip thickness mm Axial play 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 P...

Page 146: ...r 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 Fabia II ...

Page 147: ...n 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 The angled end of the springs must grip into the hollow arrester of the synchronizer body Install supporting ring Place the supporting ring onto the flywheel type belt pulley fit ting tool MP9 400 Insert t...

Page 148: ...2 Drive bushing MP3 427 40 21 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 Fabia II page 1 Roomster page 6 Rapid page 10 Rapid NH page 11 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 ori...

Page 149: ...pinion Fitting position Collar points to the 3rd gear page 148 5 Circlip always replace Elec tronic Catalogue of Original Parts 6 Circlip always replace Electronic Catalogue of Original Parts 7 3rd gear pinion Fitting position Collar points to the 4th gear page 148 8 Circlip always replace Electronic Catalogue of Original Parts 9 2nd gear sliding gear 10 Needle bearing 2 gear 11 Inner ring for 2nd...

Page 150: ... gear check for wear page 148 Check pegs for traces of wear Fitting position page 150 19 Needle bearing 1 gear 20 1st gear sliding gear Fitting position page 150 21 Bearing support for grooved ball bearing Always replace grooved ball bearing together with the bearing support replace after each removal removing and installing page 135 22 Gearbox housing repairing page 126 23 5th gear pinion Fitting...

Page 151: ...lindrical roller bearing compress the circlip arrow with pliers A Remove pliers before the cylindrical roller bearing is in fitting position The circlip must lock into the clutch housing slot 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...

Page 152: ...3 mm 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 1 1 and 2nd gear Installation dimen sion Wear limit Clearance a 1 2 to 1 8 mm 0 5 mm Fitting position of the inner ring outer ring and 2nd gear syn chronizer ring Position the inner ring A on the 2nd gear sliding ge...

Page 153: ...in the sliding sleeve must be positioned above one another 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 by turning them 120 The angled ends of the springs must grip into the recesses of the arresters for the synchronizer body Press on the sliding s...

Page 154: ...oint towards the reversing gear serration A Fitting position for 1st gear inner ring A The pegs arrow 1 lock into the recesses arrow 2 of the syn 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 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbo...

Page 155: ...cle 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 Release screws 1 Unbolt coupling rod 2 arrow For right gasket ring Turn steer...

Page 156: ...l For left gasket ring Drive the new seal ring in up to the stop do not twist the seal 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 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 tention...

Page 157: ...ck control arm Chassis Rep gr 40 Wheel bolts to wheel hub Chassis Rep gr 44 Fabia II 2007 Fabia II 2009 Fabia II 2011 Rapid 2011 R Gearbox 02T Edition 05 2014 1 Replacing the flange shaft gasket rings gearbox assembled 153 ...

Page 158: ... Counterholder MP1 223 3067 Pipe MP6 419 3259 Tube for wheel bearing T30019 3345 Tapered roller bearing extractor V A G 1582 Gripper V A G 1582 4 Interior extractor Kukko 21 7 Countersupport Kukko 22 2 Drive bushing MP3 427 40 21 Gripper V A G 1582 3 Hot air blower e g 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 Replace b...

Page 159: ...cut out page 159 installing page 159 10 Small differential bevel gear installing page 159 11 Stop disc compound insert with gear oil 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 for left flange shaft diameter of left and right differ replace with ...

Page 160: ...ting washer S2 for differential gear Determine thickness page 161 22 Sealing ring for right flange shaft diameter of left and right differ replace with installed gearbox page 151 23 Gearbox housing is made out of aluminium or magnesium page 1 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 Be...

Page 161: ...ngs 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 ...

Page 162: ...rtion bushing MP3 412 VW 455 Press the outer ring tapered roller bearing A out of the clutch housing B Interior extractor 46 up to 58 mm e g Kukko 21 7 While doing so tighten the interior extractor behind the outer ring tapered roller bearing Press outer ring tapered roller bearing into the clutch housing Support the clutch housing with a pipe for wheel bearing T30019 3345 directly below the beari...

Page 163: ...ith flange shafts Insert both small differential bevel gears with a 180 offset 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 Insert the differential bevel gear shaft up to stop and secure with new Spannhülse 2 2 Adjusting th...

Page 164: ...yes Continued for all vehicles 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...

Page 165: ...using made out of aluminium measured value 1 50 mm pressure const value 0 25 mm Thickness of the adjusting washer S2 1 75 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 th...

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