D4B802C6D75-Manual Gearbox 0AH

Service
Workshop Manual
Octavia III 2013
Octavia III 2014
Manual gearbox 0AH
Edition 10.2013
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright 2013 KODA AUTO a. s. D4B802C6D75

Octavia III 2013 , Octavia III 2014
Manual gearbox 0AH - Edition 10.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification characters, aggregate assignment, ratios, capacities . . . . . . . . . . . . . . . . . . 2
2 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Designation of components and transmission ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Safety measures for working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . 4
3.2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Assembly overview - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Removing and installing bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Checking the master and slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.8 Removing and installing the over-centre helper spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.9 Removing and installing tension spring and over-centre helper spring . . . . . . . . . . . . . . . . 17
1.10 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.11 Removing and installing bearing block for clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.12 Removing and installing the master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.13 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.14 Removing and installing cables for clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.15 Bleeding the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.16 Repairing the clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 Repairs on the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Fitting location of shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Summary of components - Gearshift knob with shift lever collar . . . . . . . . . . . . . . . . . . . . 37
1.4 Removing and installing gearshift knob with shift lever collar . . . . . . . . . . . . . . . . . . . . . . 37
1.5 Assembly overview - Selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.6 SummaryProtected
of components - Gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
43
1.7 Removing and installing selector
unless authorised by KODA AUTO A. mechanism
S. KODA AUTO A. . .S..does
. . .not. .guarantee
. . . . .or. accept
. . . .any
. .liability
.............. 45
1.8 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.9 Removing and installing shift cable and selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.10 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 Schematic overview - Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i
4.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.3 Summary of components- Gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . 71
4.4 Summary of components - Clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.5 Summary of components - Drive shaft, output shaft, differential gear, gearshift mechanism,
and gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.6 Summary of components - Gearshift unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.7 Assembly overview - shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.8 Repairing gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.9 Repairing gearshift unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.10 Replace the gasket ring of the gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.11 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5 Gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.1 Summary of components - Gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . 89
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1 Summary of components - Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.2 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.1 Summary of components - Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.2 Disassembling and assembling the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1 Gasket rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.1 Summary of components - Gasket rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.2 Replacing left sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.3 Replacing right sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.1 Summary of components - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.2 Disassembling and assembling Protected differential gearCopying
by copyright. . . . for
. .private
. . . or
. .commercial
. . . . . .purposes,
. . . . .in. part
. . or. .in .whole,
. . . is. not
. 113
permitted
2.3 Adjusting the differential gear .unless . with
. . authorised
.respect
. . . .to.the
. .KODA
by . . . . . .
AUTO . .
A..S.. KODA
. . . . . . .
AUTO . .
A. .S.. does
. . . .
not. . . .
guarantee . . .
correctness of information in this document. Copyright by KODA AUTO A. S.
or.accept
. . . 115
any liability
ii Contents
00 Technical data
1 Identification of the gearbox
(SRL000644; Edition 10.2013)
Edition 10.2013; version 2.0
Location on the gearbox page 1 .
Identification characters, aggregate assignment, ratios, capaci
ties page 2 .
1.1 Location on the gearbox

Identification characters and production date -arrow 1-.
Identification of the gearbox 0AH -arrow 2-.
Gearbox 0AH -arrow 2-
Codes and production date of gearbox

Example: PKH 22 08 2
I I I I
Engine Day Month Manufac
code turing year
(2012)
Additional data provides information about the production facility.
Note
The gearbox identification characters also appear on the vehicle

data sticker.
1. Identification of the gearbox 1

1.2 Identification characters, aggregate assignment, ratios, capacities

Manual gearbox 5 speed 0AH
front-wheel-drive
Engine code PKG NHW
Manufac from 12.2012 12.2012
tured to
Allocation Engine 1.2 ltr./63 kW TSI 1.2 ltr./77 kW TSI
Ratio Final drive 73 : 18 = 4,055
1st gear 49 : 13 = 3,769
2nd gear 43 : 22 = 1,954
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
New filling 2, 2 l
Top-up Filled for life, no top-up
Lubricant Gear oil
electronic catalogue of original parts
Clutch operation hydraulic
Clutch disc Electronic Catalogue of Original Parts
Drive shaft flange 100 mm
2 Rep. gr.00 - Technical data

2 Overview of Transmission System

Designation of components and transmission ratios
page 3 .
2.1 Designation of components and transmission ratios
Note
The -arrows- show the direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
A - Final drive
2. Overview of Transmission System 3

3 General repair instructions

Safety precautions when working on vehicles with start-stop sys
tem page 4 .
General repair information page 4 .
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur
ing repair work.
A number of generally valid notes for individual repair operations
- which are otherwise listed several times at numerous points in
the workshop manual - are summarized here. They apply to this
workshop manual.
3.1 Safety measures for working on vehi

cles with start/stop system
WARNING
On vehicles with start-stop system, there is the risk of injury

from automatic engine start.
Deactivate the start-stop system when working on the ve
hicle. Switch off ignition.
If required switch on the ignition for a short period of time.
3.2 General repair instructions with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
Gearbox
When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
When installing carriers as well as waxed components, the
contact surfaces must be cleaned. Contact surfaces must be
free of wax and grease.
Bolts and other attachments should have a classification in the
Electronic Catalogue of Original Parts .
After installing, check the gear oil level page 68 .
Filling capacity page 2 .
Gaskets and seals
Before installing radial shaft seals, lightly oil outer diameter
and half-fill space between sealing lips with sealing grease -
G 052 128 A1- -arrow-.
The open side of the sealing rings faces the side with fluid
filling.
After installing, check the gear oil level page 68 .
Before inserting, lightly oil the O-rings in order to prevent the
rings being damaged during installation.
Sealant
Thoroughly clean housing joint surfaces before applying seal
ant.
Apply sealant - AMV 188 200 03- evenly and not too thickly.
No sealant must get into the ventilation holes.

Locking devices
Replace circlips.
Do not overstretch retaining rings.
Circlips must be positioned in the base of the groove.
Replace tensioning sleeves, installation location: Slot in the
direction of the force.
Nuts and bolts
Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
Do not twist particularly sensitive parts - e.g. clutch pressure
plates - slacken and tighten diagonally across in stages.
Specified torques given are for unlubricated nuts, bolts and
screws.
Always replace screws to be screwed in with locking agent and
self-locking nuts.
It is important to ensure at all bolted connections that the con
tact surfaces as well as the nuts and bolts are waxed only after
being installed, should this be necessary.
Clean all threaded holes into which bolts are screwed in with
locking agent, using a thread tap to remove hardened locking
agent residues. Otherwise there is a risk that the bolts will
shear at the next disassembling.
Bearing
Lubricate all bearings with gear oil before installing.
New taper roller bearings are fitted as supplied and do not
require any additional lubrication.
Position needle bearing with the lettered side (thicker end) to
wards the drift pin.
Always jointly replace tapered-roller bearings on the same
shaft and use products of the same manufacturer.
Heat the inner rings with an induction heater unit , e.g. -VAS
6414- , to approx. 100C before pressing on.
Do not exchange the outer and inner
Protected rings ofCopying
by copyright. bearings of orthe
for private commercial purposes, in part or in whole, is not permitted
same size. The bearings areunless
matched inbypairs.
authorised KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
3. General repair instructions 5

Shims
Gauge shims at several points with a micrometer. The various
thicknesses make it possible to achieve the exact shim thick
ness required.
Check for burrs or damage.
Install only flawless shims.
Synchro-rings
Do not interchange. When reusing synchro-rings, always fit to

the same synchromeshed gear.
Check for wear and renew if necessary.
Check grooves -arrow 1- on synchronizer ring -A-, or check
the inside of the ring for flattened parts (grooves worn).
If synchro-rings are coated, coating must not be damaged.
Protected
If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- fororscor
unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee accept any liability
ing and to
with respect signs of abnormal
the correctness wear,
of information and blue
in this document. discolouration
Copyright by KODA AUTO A. S.
(caused by overheating).
Check the cone of the sliding gear for scoring and signs of
abnormal wear.
Install synchronisation with gearbox oil.
Pinions
Clean and heat with induction heater unit , e.g. -VAS 6414- ,
to max. 100C before pressing on.
Synchromeshed gears
After installing, check the gear wheels for small axial play/
clearance.
Clutch
Do not tilt the clutch pressure plate; release and tighten cross
wise in small stages.
If the clutch has burnt out, thoroughly clean the clutch housing
and the friction surface of flywheel with a cloth to reduce the
smell of burnt linings.

30 Clutch
1 Repairing clutch control
Overview page 7 .
Summary of components - Foot controls page 9 .
Assembly overview - clutch hydraulics page 11 .
Assembly overview - clutch release mechanism page 12 .
Removing and installing bearing bush page 13 .
Checking the master and slave cylinder page 14 .
Removing and installing clutch position sender -G476-
page 14 .
Removing and installing over-centre helper spring page 15 .
Removing and installing tension spring and over-centre helper
spring page 17 .
Removing and installing clutch pedal page 19 .
Removing and installing bearing block for clutch pedal
page 20 .
Removing and installing master cylinder page 24 .
Remove and install slave cylinder page 24 .
Removing and installing cables for clutch control page 25 .
Bleed clutch mechanism page 27 .
Repairing the clutch release mechanism page 28 .
1.1 Overview
1. Repairing clutch control 7

I - Summary of components -
Foot controls page 9
II - Assembly overview - clutch
hydraulics page 11
Left-hand drive
III - Assembly overview - clutch
hydraulics
Right-hand drive
8 Rep. gr.30 - Clutch

1.2 Assembly overview - pedal cluster
1 - Master cylinder
removing and installing
page 24
2 - Bearing bush
page 13
3 - Clip
to remove and install the
tube-hose line pull out
retaining clip up to the
stop
4 - Seal
Self-adhesive
after removing the mas
ter cylinder, replace
Electronic Catalogue of
Original Parts
stick onto the master
cylinder
5 - Clutch position sender -
G476-
check Vehicle diag
nostic tester in the oper
ating mode Targeted
fault finding
Assignment Electron
ic Catalogue of Original
Parts
copyright.
Protected by page 14 Copying for private or commercial purposes, in part or in whole, is not permitted
6with
- Carrier bolt
respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
after removing, replace

Electronic Catalogue
of Original Parts
7 - Spring stop
8 - Hexagon nut, 25 Nm
Pillar to front wall
Qty. 3
self-locking
after removing, replace Electronic Catalogue of Original Parts
9 - Bearing shell
Qty. 2
is installed on both sides
mounted only in combination with over-centre helper spring
10 - Bearing bracket
For clutch pedal
removing and installing page 20
11 - Over-centre helper spring
installed according to the type

12 - Carrier bolt
for master cylinder
13 - Over-centre helper spring
different versions, assignment Electronic Catalogue of Original Parts
14 - Bearing bush
15 - Carrier bolt
of the tappet for master cylinder
16 - Clutch pedal
17 - Pedal rubber
18 - Bearing bush
19 - Tension spring
For clutch pedal
20 - Damping element
is only mounted in combination with tension spring

1.3 Assembly overview - clutch hydraulics
1 - Hexagon bolt, 20 Nm
2 - Bleeder valve, 4,5 Nm
Bleeding the clutch con
trol page 27
3 - Dust cap
4 - Supply hose
5 - Brake fluid reservoir
6 - Seal
must be located on the
return hose
7 - Master cylinder
page 24
8 - Clip
to remove and install the
tube-hose line pull out
retaining clip up to the
stop
9 - Seal / O-ring
Renew if damaged.
fit onto the line connec
tion
Insert with brake fluid
Gasket rings/O-rings
are adapted to the ver
sion of the line connec
tion page 12
Assignment Electron
Parts
10 - Bracket
for tube-hose line
11 - Tube-hose line
Assignment Electronic Catalogue of Original Parts
12 - Seal / O-ring
Renew if damaged.
fit onto the line connection
Insert with brake fluid
Gasket rings/O-rings are adapted to the version of the line connection page 12
Assignment Electronic Catalogue of Original Parts
13 - Clip
to remove and install the tube-hose line pull out retaining clip up to the stop
14 - Slave cylinder

Disconnect the cables for the clutch control and connect

Separate
Unlock the clip -3- with a screwdriver and disconnect the tube-
hose line -1- from the connection -4-.
Connect
Note
An O-ring can also be installed instead of the gasket ring -2-

page 12 .
Replace damaged gasket ring -2-.
Push in the tube-hose line -1- at the connection -4- until the
clip -3- locks audibly into place.
For testing pull on the tube-hose line.
Seals and O-rings for pipe and hose lines

Pos. Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir
cumferential groove -arrow 3-
In case of a line connection with round slot -arrow 1- and
-arrow 3-, a gasket ring/O-ring must be inserted.
1.4 Assembly overview - clutch release mechanism

1 - Clutch release lever

Remove and install to
gether with the clutch re
lease lever and guide
bushing page 28
Remove original grease
from the contact surface
of the ball pin
Grease the contact sur
face of the ball pin with -
G 000 100-
2 - Release bearing
Remove and install to
lease lever and guide
bushing page 28
Do not wash out bear
ing; wipe only
Renew noisy bearings
3 - Bolt, turn 5 Nm + 90 further
Renew.
4 - Slave cylinder
page 24
5 - Gearbox
6 - Input shaft seal
Renew. page 99 .
7 - Guide sleeve
remove and install to
lease lever and clutch
release bearing
page 28
8 - ball pin, 20 Nm
Remove original grease from the contact surface of the ball pin
Grease the contact surface of the ball pin with -G 000 100-
9 - Retaining spring
secured to clutch release lever
1.5 Removing and installing bearing bush

Removing
Disconnect battery earth strap Electrical System; Rep. gr.
27 .

Press the catches -arrows- and detach the studs -1- to the
right.
Turn the master cylinder tappet so that the recesses -1- and
bolt -2- are visible.
The recesses -1- and bolt -2- are facing the same direction.
Remove bearing bush -A- from recesses -1-.
Install
Turn the master cylinder tappet so that the recesses -1- and
bolt -2- are visible.
The recesses -1- and bolt -2- are facing the same direction.
Fit the bearing bush -A- into the recesses -1- and turn it in the
tappet lug until flush. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Connect the master cylinder tappet
with respect with
to the the clutch
correctness pedal,
of information todocument. Copyright by KODA AUTO A. S.
in this
do so use the new carrier bolt Electronic catalogue of orig
inal parts .
Connect battery Electrical System; Rep. gr. 27 .
1.6 Checking the master and slave cylinder

Before the master cylinder must be replaced due to a fault, first
of all carry out the test in the Targeted fault finding Ve
hicle diagnostic tester.
1.7 Removing and installing clutch position

sender - G476-
Removing
Push the driver seat as far as possible towards the rear.
Disconnect the plug connection -arrow- at the clutch position
sender - G476- .

Unlock catch -arrow- of clutch position sender - G476- -2- at

master cylinder -1- and remove.
Install
Installation is performed in the reverse order, while paying atten
tion to the following:
The catch -arrow- at the clutch position sender - G476- must
not be damaged.
The clutch position sender - G476- must click audibly into
place.
1.8 Removing and installing the over-centre

helper spring
Removing
27 .
If present, remove the knee airbag -1- on the driver's side
Body Work; Rep. gr. 69 .
Remove the footwell vent -1- on the driver's side Heating,

Air Conditioning; Rep. gr. 87 .

Remove data bus diagnostic interface - J533- -1- from bracket

Electrical System; Rep. gr. 97 and push it to the side.
Unscrew screw -2-, unhook crash strut -1- aushngen and

push it to the side.
Press the catches -arrows- and detach the carrier bolt -1- of
the tappet for master cylinder to the right.
Swivel the clutch pedal in -direction of arrow-, unhook and re

move over-centre helper spring -1-.

Install
Connect the master cylinder tappet with the clutch pedal, to
do so use the new carrier bolt Electronic catalogue of orig
inal parts .
Insert crash strut -1- and tighten screw -2- Body Work; Rep.
gr. 70 .
Install data bus diagnostic interface - J533- Electrical Sys
tem; Rep. gr. 97 .
Install footwell vent driver's side Heating, Air Conditioning;
Rep. gr. 87 .
Install knee airbag driver's side, in case it was removed
1.9 Removing and installing tension spring

and over-centre helper spring
Removing
27 .




Press the catches -arrows- and detach the carrier bolt -1- of
the tappet for master cylinder to the right.
If present, unhook the tension spring -1- and remove, while

doing so pull the clutch pedal in -direction of arrow A-.
Pull the clutch pedal in -direction of arrow A-, unhook the over-
centre helper spring -2- and remove.
Install
tion to the following: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
The bearing shells -arrows-
withof the bolts
respect -1- areofinstalled.
to the correctness information in this document. Copyright by KODA AUTO A. S.
Pull the clutch pedal in -direction of arrow A- ( previous fig

ure) into the passenger compartment.

Inser the bolt -1- into the mount -2- of the carrier.
Insert the bearing -3- into the mount -4- for the clutch pedal.
Press the clutch pedal in -direction of arrow B- ( previous
figure), until the over-centre helper spring engages in direction
of carrier.
Connect the tappet for master cylinder with the clutch pedal,
to do so use the new carrier bolt Electronic catalogue of
original parts .
gr. 70 .
tem; Rep. gr. 97 .
Rep. gr. 87 .
1.10 Removing and installing clutch pedal

Removing
27 .
Remove the mount -arrow- with the parking aid control unit -
J446- Electrical System; Rep. gr. 94 (if installed in the area
of the carrier) and push it to the side.
Right-hand drive with Climatronic system
Removing right temperature flap control motor - V159-
Heating, Air conditioning; Rep. gr. 87 .
Continued for all versions
Removing over-centre helper spring from carrier page 15 ,
or removing over-centre helper spring from carrier
page 17 .
Remove bearing block for clutch pedal

-1- - Socket wrench (SW 14)
To remove, turn the bearing bolt for the coupling pedal towards
the left in the -direction of the arrow- until the bolts -B- are
horizontal.
Note
As a result, the catches -A- are destroyed and the bearing bolt
must be replaced Electronic Catalogue of Original Parts .
Slightly move the clutch pedal in order to pull out the bearing
bolt.

Install bearing block for clutch pedal

-1- - Socket wrench (SW 14)
Slightly press on the clutch pedal and insert a new bearing bolt
Electronic catalogue of original parts .
It is important that the bolts -A- are positioned horizontally.
Turn the bearing bolt to the right in -direction of arrow-.
The catches -B- must click audibly into place.
Then the bolts -A- are positioned vertically.
Installing over-centre helper spring at carrier page 15 or in
stalling over-centre helper spring at carrier page 17 .
Right-hand drive with Climatronic system
Installing right temperature flap control motor - V159- Heat
ing, Air conditioning; Rep. gr. 87 .
If present, install the mount -arrow- with the parking aid control
unit - J446- Electrical System; Rep. gr. 94 .
1.11 Removing and installing bearing block

for clutch pedal
Special tools and workshop equipment required
Hose clamp - MP7-602 (3094)-
Sealing tool - T10249-
Removing
Remove the complete air filter housing if the cables for the
clutch control are not accessible Engine; Rep. gr. 24 .
27 .
Left-hand drive
Remove battery Electrical System; Rep. gr. 27 .

Right-hand drive
A heat-protection matting is installed in combination with certain
engines. The appearance may differ from the figure.
Remove heat-protection matting. Pay attention to the positions
-1...4-.
Caution
There is a danger that the brake fluid may drip out.

During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this is the case,
clean the affected area thoroughly.
Lay a lint-free cloth under master cylinder.
Disconnect return hose -2- to master cylinder with hose clamp

- MP7-602 (3094)-
Note
If the return hose with hose clamp - MP7-602 (3094)- is dis

connected, it will forever be deformed.
However the return hose is not defective.
After removing the hose clamp - MP7-602 (3094)- , it may be
necessary to bring the return hose back into its initial position.
Pull out the clip -3- at the tube-hose line up to the stop and
detach the tube-hose line.
Close the openings.
Detach the return hose -2- from the master cylinder and close
with the sealing tool - T10249/1- .
Push the driver seat as far as possible towards the rear.
Push steering wheel as far as possible towards the top, while
doing so use the entire adjustment range of the steering col
umn.






Note
When working in the footwell, protect the underbody cover with

cloths from escaping brake fluid.
Disconnect the plug connection -2- at the clutch position send

er - G476- .
Unscrew nuts -arrows- and remove carrier -1-.
Install
Note
Replace self-locking nuts each time they are removed.
gr. 70 .
tem; Rep. gr. 97 .
Rep.to the
with respect gr.correctness
87 . of information in this document. Copyright by KODA AUTO A. S.
Connect tube-hose line -1- with connector page 12 .

Fit return hose -2- on master cylinder.
Right-hand drive
If present, coil the heat-protection matting in the sequence
-1, 2 and 3- around the cable.
Secure the heat-protection matting with the circlip -4-.
Install battery Electrical System; Rep. gr. 27 .
Tightening torques
Bearing bracket for clutch pedal on front wall page 9 .

1.12 Removing and installing the master cyl

inder
Removing
Note

of all carry out the test in the Targeted fault finding Ve
When working in the footwell, protect the underbody cover with
cloths from escaping brake fluid.
Remove bearing bracket for clutch pedal page 20 .

Remove clutch position sender - G476- page 14 .
Unlock catches -arrows- and push out carrier bolt -2-.
Remove master cylinder -1-.
Install
After removing, replace carrier bolt Electronic Catalogue of
Original Parts .
Install bearing bracket for clutch pedal page 20 .
Install clutch position sender - G476- page 14 .
1.13 Removing and installing clutch slave

cylinder
Hose clamp - MP7-602 (3094)-
Grease - G 000 100-
Removing
Note

of all carry out the test in the Targeted fault finding
with respect Ve of information in this document. Copyright by KODA AUTO A. S.
to the correctness
If the slave cylinder with the tube-hose line is removed from
the gearbox, do no longer depress the clutch pedal. Other
wise, the piston can be pressed out of the slave cylinder and
thus be destroyed.

27 .

Lay a lint-free cloth under slave cylinder.

Unlock the clip -A- with a screwdriver and disconnect the tube-
hose line -B- from the connection.
Pull pipe/hose line -B- out from slave cylinder and seal hose.
Unscrew screws -arrows- and remove slave cylinder.
Caution
There is a risk of contamination through escaping brake fluid.

If the tube-hose line is disconnected from the connection,
do no longer depress the clutch pedal.
Install
Note
Grease all bearing points and contact surfaces with grease.

Assignment grease Electronic Catalogue of Original Parts .
Fit slave cylinder -A- and tighten screws -arrows-.

Connect tube-hose line -B- page 12 .
Tightening torque
Slave cylinder to gearbox page 11 .
1.14 Removing and installing cables for

clutch control
Hose clamp - MP7-602 (3094)-
Removing
Remove the complete air filter housingProtected
if the cables forCopying
by copyright. the for private or commercial purposes, in part or in whole, is not permitted
clutch control are not accessible Engine; Rep. gr.
unless authorised 24 . AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
by KODA
Remove battery and battery tray Electrical System; Rep.
gr. 27 .

Right-hand drive
A heat-protection matting is installed in combination with certain
engines. The appearance may differ from the figure.
Remove heat-protection matting. Pay attention to the positions
-1...4-.
Caution
There is a danger that the brake fluid may drip out.

During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this is the case,
clean the affected area thoroughly.
Lay a lint-free cloth under master cylinder.
Disconnect return hose -2- to master cylinder with hose clamp

- MP7-602 (3094)-
Note
If the return hose with hose clamp - MP7-602 (3094)- is dis
connected, it will forever be deformed.
However the return hose is not defective.
Pull the clip at the tube-hose line out of the master cylinder up
to the stop and detach the tube-hose line.
Close the openings.
Pull out the clip -A- up to the stop and detach the tube-hose
line -B- to the master cylinder.
Close the openings.
Note
Ignore -arrows-.
Close the open lines and connections, if necessary with a

clean plug from the plug set for engine - VAS 6122- .
Loosen tube-hose line and remove.

Install
Connect the tube-hose line -1- with connectors at the master
cylinder and at the slave cylinder.
Test line by tugging on it.
necessary to bring the return hose -2- back into its initial po
sition.
Right-hand drive
If present, coil the heat-protection matting in the sequence
-1, 2 and 3- around the cable.
Secure the heat-protection matting with the circlip -4-.
Install the battery tray and battery Electrical System; Rep.
gr. 27 .
1.15 Bleeding the clutch control

Brake filling and bleeding device , e.g. -VAS 5234- or -ROM
ESS-
Note
The system must be bled after performing work on the hy
draulic clutch control.
When performing the following work, make sure no brake fluid
comes into contact with the gearbox.
Prefilling system is not necessary!
Before bleeding, fill brake fluid reservoir up to Max marking
with brake fluid.
Clutch pedal in home position, not operated.
Specification of brake fluid Electronic catalogue of original
parts .
If the vent valve is not accessible, remove the complete air

filter housing (-arrow- in the illustration below) Engine; Rep.
gr. 24 .

Put the clutch pedal in home position.

Remove cap from vent valve -arrow-.
Connect the brake filling and bleeding device - VAS 5234- or
-V.A.G 1869- .
Fit on bleeder hose and connect to pressure hose of drip bot
tle.
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if
necessary.
Switch on brake filling and bleeding device .
Working pressure: 2.0 bar
Open bleeder valve.
Allow about 100 cm3 of brake fluid to flow out.
Close bleeder valve.
Rapidly operate clutch pedal from stop to stop 10 to 15 times.
Open bleeder valve.
Allow another 50 cm3 of brake fluid to flow out.
Close bleeder valve.
Switch off brake filling and bleeding device and release all of
the pressure from the device.
Depress clutch pedal several times after completion of bleed
ing process.
At the same time check the operation of the clutch control.
Tightening torque
Vent valve page 11 .
1.16 Repairing the clutch release mechanism

Grease - G 000 100-
Removing and installing clutch release lever -A- with release
bearing and guide sleeve
Gearbox is removed.
Removing unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
Unscrew screws -arrows-.
Separate the clutch release lever together with the release
bearing and guide sleeve from the drive shaft and ball stud.
Install
Installation is carried out in the reverse order.
Assembling gearbox page 69 .
Tightening torque
Guide bushing to gearbox page 12 .

Remove and install guide bushing from the release bearing

Removing
Remove the clutch release lever together with the clutch re
lease bearing and the guide bushing page 28 .
Push guide bushing -3- toward top out of the release bearing
-2-.
Rotate the guide bushing -3- opposite the release bearing
-2- by approx. 90 in the -direction of the arrow- until the catch
pegs of the guide bushing are aligned with the slots -4- of the
release bearing.
In this position remove the guide sleeve from the release bear
ing.
Install
Installation is carried out in the reverse order.
Install the clutch release lever together with the release bear
ing and guide bushing page 28 .
Removing and installing release bearing

Removing
Press together locking lugs -arrows- on back of clutch release
lever and remove release bearing -A- from clutch release lev
er.
Install
Press the release bearingunless
-A- into the clutch release lever until
authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
the catch pegs -arrows- lockwithinto position.
Grease contact surface on the clutch release lever with grease

- G 000 100- .

2 Repairs on the clutch

Assembly overview - clutch page 30
Removing and installing clutch page 30 .
2.1 Assembly overview - clutch
1 - Flywheel
Removing and Installing
Engine; Rep. gr. 13
Ensure that centring
pins fit tightly
Keep contact surface for
clutch lining free of
grooves, oil and grease
2 - Clutch plate
Assignment Electron
Parts
center page 30
3 - Pressure plate
page 30
Check ends of dia
phragm spring
page 32
Check springs and rive
ted joints page 32
4 - Bolt
Assignment Electron
Parts
release or tighten in
small stages crosswise
Specified torque:
M6: 13 Nm
M7: 20 Nm unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
2.2 Removing and installing clutch

Counterholder - MP1-223 (3067)-
Centering mandrel - MP3-475A (3190A)-
Grease - G 000 100-
Removing
Gearbox is removed.

Insert counterholder - MP1-223 (3067)- when slackening the

bolts.
Note
In order to avoid a deformation of the pressure plate when re

moving it (this leads to jerking during start-up), the bolts on the
pressure plate must be loosened in small stages crosswise.
Loosen and remove all bolts.

Remove pressure plate and clutch disc.
Install
Note
Assign the clutch disc and pressure plate in accordance with

engine identification characters Electronic Catalogue of
Original Parts .
Clean input shaft splines and, on used clutch plates, the hub
splines too. Remove corrosion and grease the splines with an
ultra-thin layer of grease - G 000 100- . Then move clutch plate
to and fro on input shaft until hub moves freely on shaft. Re
move excessive grease.
Pressure plates are protected against corrosion and greased.
Except for the friction surface for the clutch disc, the pressure
plates may not be cleaned, doing so would reduce the lifetime
of the clutch considerably.
The friction surfaces for the clutch pressure plate and for the
flywheel must be cleaned thoroughly (remove grease).
If the clutch has burnt out, thoroughly clean the clutch housing,
the flywheel and the engine in the area of the clutch to reduce
the smell of burnt linings.
The clutch disc must be centred with the centring pin -
MP3-475A (3190A)- and the lining must lie completely on the
fly wheel and the friction surface for the clutch pressure plate.
Do not fit the securing bolts until you have done so.
Tighten the securing bolts evenly crosswise in small stages to
prevent damage to the centring holes for the pressure plate
and the centring pins of the flywheel.
Check whether the dowel sleeves for centring the engine/
gearbox are present in the cylinder block; insert if necessary.
If the dowel sleeves are not installed, there are problems with
the gearshift and the clutch or the gearbox is loud (sound of
loose wheels).
2. Repairs on the clutch 31

Installation location of the clutch disc: The lettering gearbox

side or the shorter end of the lock hub with the spring cage
faces the pressure plate.
Check ends of diaphragm spring

Wear is allowed up to half the thickness of the membrane
springs -arrows-.
Check tension springs and riveted joints
Check tension springs -Arrows A- between the pressure plate

and its covers for cracks.
Check all riveted joints -arrows B- for firm seating.
Replace a pressure plate with damaged springs/free riveted
joints.

Condition of the springs and riveted joints

I - Tension springs are OK
Slight bends in the external area -arrow A- are part of the
standard condition.
II - Tension springs are damaged
Clutch plates with strongly bent or broken feather joints
-arrow B- must be replaced.
Check metal plate ring

Check metal plate ring -arrow- in the clutch plate for damage.
Replace the clutch plates with the broken metal plate ring.
Centre clutch disc with centering pin - MP3-475A (3190A)- .

Insert counterholder - MP1-223 (3067)- when tightening the
bolts.
Bring all bolts to the end stop position crosswise in small
stages.
Installing the gearbox page 61 .
Tightening torque
Pressure plate to flywheel page 30 .
2. Repairs on the clutch 33

34 Controls, housing
1 Selector mechanism
Fitting location of shift mechanism page 34 .
Summary of components page 36 .
Summary of components - Gearshift knob with shift lever collar
page 37 .
Removing and installing gearshift knob with shift lever collar
page 37 .
Summary of components - Control cables page 38 .
Summary of components - Gearshift mechanism page 43 .
Removing and installing shift mechanism page 45 .
Dismantling and assembling selector mechanism page 48 .
Remove and install shift cable and selector cable page 51 .
Adjust selector mechanism page 52
1.1 Fitting location of shift mechanism

Noteauthorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
unless
Disconnect earth strap at battery before carrying out work on

the shift mechanism in the engine compartment Electrical
System; Rep. gr. 27 .
After the battery earth strap is disconnected and re-connected,
carry out additional operations Electrical System; Rep. gr.
27 .
Removing and installing shift mechanism page 45 .
-Arrow A- Shift movement

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

A - Gear selector cable

B - Gate selector cable
C - Heat shield
Remove before remov
ing selector mecha
nism.
1 - Gearshift lever
2 - Relay lever
1. Selector mechanism 35
1.2 Summary of components
Note
Disconnect earth strap at battery before carrying out work on the shift mechanism in the engine compartment
Electrical System; Rep. gr. 27 .
After the battery earth strap is disconnected and re-connected, carry out additional operations Electrical
Remove selector mechanism to renew selector cables page 45 .
Do not kink selector cables.
I - Summary of components -
Gearshift knob with shift lever
collar page 37
II - Assembly overview - shift
mechanism page 43
III - Summary of components -
Control cables page 38

1.3 Summary of components - Gearshift knob with shift lever collar
1 - Gear knob
With gaiter
The gearshift knob and
collar cannot be separa
ted
page 37
Plaque of gearshift lever
can only be separated
from the gearshift knob
e.g. with a screwdriver.
Assignment Electron
Parts
always replace together
Electronic Catalogue
of Original Parts
2 - Collar
with frame
3 - Open warm-type clamp
For securing gear knob
to gear lever
always replace Elec Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
tronic Catalogue of with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
Original Parts
1.4 Removing and installing gearshift knob

with shift lever collar
Release tool - T30098-
Hose strap pliers , e.g. -V.A.G 1275-
Removing
Push the unlocking tool - T30098- into the gap in the rear cen
tre between decorative frame and control lever sleeve
-arrow 1-.
Use the unlocking tool - T30098- to lever the control lever the
control lever sleeve carefully out of the centre console
-arrow 2-.
Pull gaiter upwards, inside out over gear knob.
Open clamp -arrow- and pull off gear knob together with gaiter.
Install
Press the gearshift knob together with the collar as far as the
stop onto the shift lever.
Note
When inserting the gearshift knob on the shift lever the gearshift
knob must lock into the round slot of the gearshift lever.
Attach gearshift knob with new clamp -arrow- onto gearshift

lever using hose binding claw .
1.5 Assembly overview - Selector cables
Note
Coat bearings and friction surfaces with grease.

Assign the grease via the Electronic Catalogue of Original Parts .

1 - Gearshift shaft with cover

2 - Sealing ring
Renew. page 80 .
3 - Shoe
4 - Relay lever
Assignment Electron
Parts
Fitting position
page 41
After installing, adjust
selector mechanism
page 52
Remove relay lever to
gether with cable lock
for selector cable
page 42 .
5 - Cable end-piece
For gate selector cable
to relay lever
After installing, adjust
selector mechanism
page 52
do not interchange, ca
ble locks for selector ca
ble at relay lever and for
shift cable at gearshift
lever are different, as
signment page 40
Remove from relay lev
er page 43
Press onto relay lever
page 43
6 - Gearshift lever unless
insert in such a way that tothe
with respect the interrupted spacing
correctness of information ofdocument.
in this the teeth matches
Copyright by KODA theAUTOgearshift
A. S. shaft page 42
Fitting position page 41
After installing, adjust selector mechanism page 52
7 - Hexagon nut
Tightening torque page 74
8 - Cable end-piece
For gear selector cable to gearbox selector lever
After installing, adjust selector mechanism page 52
do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are
different, assignment page 40
9 - Safety mechanism
Renew.
10 - Gate selector cable
connected with cable end-piece for selector cable
11 - Gear selector cable
connected with cable end-piece for gear selector cable
12 - Seal
Between selector housing and underbody
replace after removing the shift housing
Self-adhesive
stuck onto the shift housing
13 - Selector housing
disassembling and assembling page 48
14 - Safety mechanism
Renew.
do not damage cables when removing
15 - Hexagon bolt, 20 Nm
Qty. 2
for attaching cable support
16 - Cable support
for attaching cable support
18 - Grommet
Qty. 3
for mounting of cable support to gearbox
19 - Spacer
Qty. 3
20 - Clip unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
Allocation of cable end-pieces

The holes in the cable end-pieces have different diameters.
Cable end-piece Dimension a
-1- Shift cable at gearbox shift lever 8.5 mm
-2- Selector cable at relay lever 10 mm

Installation position of gearbox selector lever and relay lever

1 - Gearshift lever
2 - Relay lever is inserted over the sliding shoe -arrow- into the
sliding rail of the gearbox shift lever
During installation, the following areas in particular must be

greased thoroughly:
Shaft -A- of the relay lever -arrows-.
Apply grease to guide
unlessrail -B- ofbygearbox
authorised KODA AUTO selector lever
A. S. KODA in which
AUTO A. S. does not guarantee or accept any liability
the shoe of the relaywith
lever engages.
Pins for securing the cable locks.
Note
Assign the grease via the Electronic Catalogue of Original

Parts .
The picture of the gearbox selector lever and relay lever may
differ from the original part.
Install gearbox selector lever

When fitting the gearbox selector lever, ensure that the gap
-arrow A- is aligned with the master spline -arrow B-.
Removing and installing relay lever

Press the safety mechanism on the cable lock for the selector
cable forwards in the -direction of the arrow 1- until the stop,
afterwards lock it by turning to the left in the
-direction of the arrow 2- so that the gate selector cable re
mains loose.
Turn the relay lever towards the front in the
-direction of the arrow 3- and separate the cable end-piece
from the gate selector cable.
Pull off clip -arrow 1- and remove relay lever together with ca
ble end-piece for the gate selector cable.
Note
Cable end-piece for gate selector cable must be located be

hind catch -arrow 2-.
It is only permissible to remove cable end-piece for gate se
lector cable after the disassembled relay lever has been re
moved page 43 .
Install
Press cable end-piece for gate selector cable onto relay lever
page 43 .
Insert the relay lever with attached cable end-piece for gate
selector cable as far as the stop.
Secure the relay lever with a clip -arrow 1- ( previous figure).
Note with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
Ensure proper engagement of clip.

Cable end-piece for gate selector cable must be located be
hind catch -arrow 2- ( previous figure).

Lever out cable end-piece for gate selector cable from the relay
lever while the gate selector cable is disconnected.
Relay lever has been removed.
Insert cross-head screwdriver -A- between bushing -B- and
relay lever.
Press cable end-piece for gate selector cable onto relay lever
Relay lever has been removed.
The bolt for the cable end-piece for gate selector cable must
be greased Electronic Catalogue of by
Protected Original
copyright. Parts . private or commercial purposes, in part or in whole, is not permitted
Copying for
The cable lock must only be pressed ontotothe
with respect bushingof information in this document. Copyright by KODA AUTO A. S.
the correctness
-arrow-.
Cable end-piece must move freely on relay lever.
Cable end-piece must be located behind catch -arrow 2-.
page 42
1.6 Summary of components - Gearshift

mechanism
Note
Grease all bearing and contact surfaces with grease -G 000 450
02- .
1 - Base plate
Bend open tabs to re
move
always replace Elec
tronic Catalogue of
Original Parts
2 - Seal
always replace Elec
tronic Catalogue of
Original Parts
3 - Selector lever
4 - O-ring
insert onto gearshift lev
er -arrow- up to the stop
in case of damage re
place Electronic
Catalogue of Original
Parts
5 - Locking clip
do not damage cables
when removing
always replace Elec
tronic Catalogue of
Original Parts
6 - Gate selector cable
page 51
Fitting position
page 38
adjust page 52
7 - Bush for selector cable
8 - Gear selector cable
adjust page 52
9 - Damping
10 - Bearing shell
when removing, the catches are usually damaged
always replace Electronic Catalogue of Original Parts
11 - Bushwith respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
12 - Lock washer
13 - Compression spring
14 - Bush
15 - Shift lever guide
16 - Nut
M8: 25 Nm

M6: 8 Nm
17 - Seal
between shift housing and body
Self-adhesive
18 - Selector housing
with pressure spring and selector angle
Pressure spring as well as selector angle cannot be removed
Removing and installing lock washer

Hold the gearshift lever -2-.
Press spacer sleeve -3- in direction of arrow.
Remove lock washer -1-.
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 -arrow-.
1.7 Removing and installing selector mech

anism
1.7.1 Removing
Note
After 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 System; Rep. gr. 27 .
Remove air filter Engine; Rep. gr. 24 , if it is installed above
the gearbox.
-arrow 1-.
-arrow 2-.
Open clamp -arrow- and pull off gear knob together with gaiter.
Remove the centre console Body Work; Rep. gr. 68 .
Unscrew nuts -arrows- attaching the shift housing.
Remove safety mechanism -1- for cable end-piece for gear

selector cable -2- and remove cable end-piece for gear selec
tor cable with attached gear selector cable from the pin of
gearbox selector lever -3-.
Remove the cable end-piece for gate selector cable together
with the relay lever -4- page 42 .

Disconnect the Bowden cable support from gearbox

-arrows-.
Remove the sound dampening system Body Work; Rep.
gr. 50 .
Remove underbody cover on right and left -arrows-.

Detach tunnel bridges below the exhaust system Engine;
Rep. gr. 26 .
Caution
There is a risk of damaging the decoupling element in the pre-

exhaust pipe should not be bent by more than 10.
Detach exhaust system below the exhaust system Engine;

Rep. gr. 26 .
Remove the heat shield below the gearshift mechanism
Swivel shift housing down and remove with selector cables.
1.7.2 Install
Installation is carried out in the reverse order. When installing,
note the following:
Align selector housing parallel to body and screw tightly.
The distance to the vehicle body is the same on both sides.
Lay the shift cable and selector cable from the selector hous
ing to the gearbox.
The control cables must run parallel to one another and not
cross each other.
The holes in the cable locks have different diameters page 40
Apply a small quantity of grease onto the studs of the gearbox
shift lever -3- and of the relay lever -4- page 41 .
Install cable end-piece for gear selector cable -2- and lock with
a new securing mechanism -1-.
Install relay lever -4- together with cable end-piece for relay
lever page 42 .
Insert the gate selector cable for the cable end-piece for gate
selector cable Protected
to the relay lever.
Install the centrewith
console
respect to Body Work;
the correctness Rep.ingr.
of information 68 . Copyright by KODA AUTO A. S.
this document.

Install gearshift knob with collar page 37 .
Attach the heat shield below the gearshift mechanism Body
Work; Rep. gr. 66 .
Assemble the exhaust system free of stress ; Rep. gr. 26
and tunnel bridges.
Install the noise insulation Body Work; Rep. gr. 50 .
Install battery tray, if it has been removed Electrical System;
Rep. gr. 27 .
Note
After the battery earth strap is disconnected and connected, carry

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

Install air filter Engine; Rep. gr. 24 , if it has been removed.
Tightening torques
Selector housing to body page 43 .
Selector cable support bracket to gearbox page 38 .
Remove the underbody cover Body Work; Rep. gr. 50 .
1.8 Dismantling and assembling selector

mechanism
Special tools and by workshop equipment required
unless authorised KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
Insert base - T10083-
Grease - G 000 450 02-
1.8.1 Dismantling
Remove selector mechanism page 45 .
Bend up tabs -arrows- of base plate for the shift mechanism
using a screwdriver and remove base plate.
Remove gasket ring.

Remove lock washers -2 and 3- (lock washers -1 and 4- are

no longer available), selector cable and shift cable must be
levered off from the shift lever or selector lever e.g. with a
screwdriver.
Remove shift lever.
Note
Hold the gearshift lever -2-.

Press spacer sleeve -3- -in direction of arrow-.
Remove lock washer -1-. unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
Offset the top pressure spring arm -A- via the peg of the se
lector angle.
Press the catches of the bearing shell -arrows- e.g. with a
screwdriver in -direction of arrow- (the catch can break off).
Slacken bearing shell -A- and shift lever guide -B- from shift
housing.
Remove bearing shell -A- from shift lever guide -B-.
Press bottom pressure spring arm -arrow 1- onto shoulder of

selector angle.
Note
When removing the shift lever guide, the guides -A- must not
be damaged.
Bottom pressure spring arm -arrow 1- can slide uncontrolled
out of the shoulder of the selector angle during further han
dling.
Remove shift lever guide from shift housing upwards

-arrow 2-.
1.8.2 Assembling
Place shift lever guide into the shift housing and while doing
so insert the bottom pressure spring arm -B- and the top pres
sure spring arm -A- into the guides (see fig. N34-10865).
Note
For purposes of clear presentation, only the selector angle plate

is partially illustrated.
Adjust selector angle up to the stop in -direction of arrow 1-

and press the ball pin for shift lever guide into the selector
angle -arrow 2-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Note
When installing, ensure that the guides -A- and the tabs -B- are
not damaged.
Lay shift housing or shift lever guide underneath with insert

base - T10083- in such a way that this guide is shifted as far
as possible from the shift housing.
Offset the top pressure spring arm -A- via the peg of the se
lector angle.
Press new bearing shell -B- (coat with grease -G 000 450 02- )
up to the stop onto the ball of shift lever guide.
Remove shift housing from the insert base - T10083- .
Insert top pressure arm -A- into the guide.
Press bearing shell -B- in -direction of arrow- up to the stop
into the shift housing (all catches of the bearing shell must click
into place audibly).
Install shift lever.

Attach shift cable and selector cable to shift housing with cir
clips -2 and 3-.
Press shift cable and selector cable onto shift lever and se
lector lever into shift housing (lock washers -1 and 4- are no
longer available).
Install gasket and attach base plate for shift mechanism by

bending up the tabs -arrows-.
Install selector mechanism page 45 .
1.9 Removing and installing shift cable and

selector cable
1.9.1 Removing
Bend up tabs -arrows- of base plate for the shift mechanism
using a screwdriver and remove base plate.
Remove gasket ring.
Remove lock washers -2 and 3- (lock washers -1 and 4- are

no longer available), selector cable and shift cable must be
levered off from the shift lever or selector lever e.g. with a
screwdriver.
Remove shift cable and selector cable from shift housing.
Unlock catches -A- for shift cable and selector cable as follows:
Slide sliding sleeve forwards up to the stop -arrow 1-.
Turn sliding sleeve to the right up to the stop -arrow 2- until it
locks in place.
Remove the catches from the cables.
Remove circlips -1- and -2-.

Remove the cable support from the cables.
1.9.2 Install
Installation is carried out in the reverse order. When installing,
note the following:
Attach shift cable and selector cable to shift housing with cir
clips -2 and 3-.
Press shift cable and selector cable onto shift lever and se
lector lever into shift housing (lock washers -1 and 4- are no
longer available).
Install gasket and attach base plate for shift mechanism by

bending up the tabs -arrows-.
1.10 Adjusting selector mechanism

Release tool - T30098-

Rig pin - T10027A-
Note
The following points are essential to ensure correct adjustment of

selector mechanism:
Gearbox, clutch and clutch control in perfect condition.

Shift mechanism operates freely.
Control elements and transmission elements of the shift mech
anism are in perfect condition.
Gearbox must be in neutral.
-arrow 1-.
-arrow 2-.
Guide shift lever in Neutral position to the left into the 1st/2nd
gear gate via the leg.
Lock shift lever with rig pin -T10027A- .

Remove air filter Engine; Rep. gr. 24 , if it is installed above
the gearbox.
Unlock cable locks for shift cable and selector cable as follows:
Push sliding sleeve

AUTO at shift cable
AUTOand at selector cable for
unless authorised by KODA A. S. KODA A. S. does not guarantee or accept any liability
wards
with uptheto
respect to the stop
correctness -arrow in1-.
of information this document. Copyright by KODA AUTO A. S.
Turn the sliding sleeves in direction of the -arrows 2- as far as

the stop until they lock in place.
Note
The cables can be moved in the catches.
Gearbox must be in neutral.
Lock the gearshift shaft as follows:

Push down the gearbox shift lever in the
-direction of the arrow 1- into the gear gate of the 1st/2nd gear.
Turn the angle lever -A- in -direction of arrow 2-, until it locks.
This locks the gearshift shaft and can no longer be moved.
Make sure that the shift cable and selector cable sit stress-free
in the catches.
Turn sliding sleeves at shift cable and selector cable in

-direction of the arrow- up to the stop.
The springs push the sliding sleeves back into the initial position.
Note
The shift cables are now adjusted.
Turn angle lever -A- back to the initial position (in

-direction of arrow-).
Pull rig pin -T10027A- out of the gearshift mechanism.
Install shift lever collar. unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability

Inspect gearshift mechanism page 54 .
1.10.1 Checking function

The shift lever must be positioned in neutral position in the
selector gear gate of the 3rd/4th gear.
Actuate clutch pedal.
Select all gears several times. Pay particular attention to prop
er operation of the reverse gear lock.
If a problem arises when shifting the gear again:
Re-adjust selector mechanism page 52

2 Removing and installing the gearbox

Removing the gearbox page 55 .
Installing the gearbox page 61 .
Specified torques for gearbox page 67
2.1 Removing the gearbox

Supporting device - T30099-
Adapter - T40091/3-
Adapter - MP9-200/18-
Support - 10-222A/31-
Surface - T30119-
Hook - MP9-200/10 (10-222A/10)-
Gearbox mount - 3282-
Adjusting plate - 3282/46-
Engine/gearbox jack , e.g. -V.A.G 1383 A-
Gearbox attachment device - MP3-478 (3336)-
Grease - G 000 100-
Remove battery and battery tray Electrical System; Rep.
gr. 27 .
Completely remove the air filter Engine; Rep. gr. 24 , if it is
installed above the gearbox.
Remove securing mechanism -1- for gear selector cable from
the pin of gearbox selector lever -B-.
Remove relay lever -A- together with cable end-piece for gate
selector cable bypage
Protected 42Copying
copyright. . for private or commercial purposes, in part or in whole, is not permitted
Remove nut -arrow 2- and remove the gearbox selector lever
-B-.
Unscrew the bolts -arrows- and lay the cable support with
control cables to the side.
2. Removing and installing the gearbox 55

Unscrew the bolts -arrows- and lay the slave cylinder to the
side; do not open the hydraulic system.
Caution
Do not operate clutch pedal any more!
Screw out bottom fixing screw for top starter and screw out the
upper engine/gearbox connecting bolts.
Note
If hose and cable connections are located in the area of the lifting
eye of the engine for the hook - MP9-200/10- , these must now
be removed.
Fit supporting device -T30099- .

Slightly take up weight of engine/gearbox assembly on spin
dles of the hook - MP9-200/10- .
gr. 66 .
Remove the bottom part of the front left wheelhouse liner
Unscrew the nut -arrow- and remove the bracket for the elec
trical cables.
Removing starter Electrical System; Rep. gr. 27 .
Unscrew the front left vehicle level sensor - G78- , where

available, from the transverse arm Chassis; Rep. gr. 43 .

Disconnect existing electrical plug connections:

1- Gearbox neutral position sender - G701-
2- Reversing light switch - F4-
Caution
There is risk of damaging the decoupling element of the ex

haust system.
Unscrew bolts -arrows- for holders for exhaust systems on the

assembly carrier.
Separate exhaust system at the clamping sleeve -arrow-.
Remove pendulum support.

Unscrew nut -1- from both sides of anti-roll bar bracket -3-.
Pull anti-roll bar bracket -3- on both sides out of the anti-roll
bar -2-.
If present, remove heat shield for drive shaft -arrows- Chas

sis; Rep. gr. 40 .
Remove drive shafts from flange shafts and tie up as far as
possible, do not damage the surface protection Chassis;
Rep. gr. 40 .
Unscrew nut -arrow- and remove earth strap from gearbox

mount.
Unscrew the bolts -arrows 1- from the gearbox mount.

Lower the gearbox by adjusting the spindles of the hook -

MP9-200/10 (10-222A/10)- by the dimension -a-.
Dimension -a- = 60 mm
Screw out bolts -arrows 2- and remove gearbox console.
Connecting screws -2, 3- for engine/gearbox and bolts -4, 5- on

the starter are unscrewed.
Unscrew the connecting screws -7, 8- for engine/gearbox.
Note
Connecting screws -1, 6,9- are unscrewed for engine/gearbox

later. with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
The gearbox support - 3282- is to be adjusted before removing

the gearbox 0AH with the aim of the adjusting plate - 3282/46- .
Insert gearbox support - 3282- into engine/gearbox jack -
V.A.G 1383 A- .
Lay adjusting plate - 3282/46- onto gearbox support - 3282- .
The adjusting plate only fits in one position.
The arrow symbol on the adjusting plate points in the direction
of travel.
Align arms of the gearbox support with the holes in the ad
justing plate.
Insert mounting bolts as shown on the adjusting plate.
Align adjustment plate parallel to gearbox.

Secure bolts - 3282- on the gearbox with M8 nut -arrow-.

The bolt - 3282- should stand on a level with the guide on the
gearbox holder - 3282- .
Screw in the pins - 3282/29- into the rear hole for the fixing
screw of the pendulum support.
Remove engine/gearbox connecting screw -arrow-.
Remove engine/gearbox connecting screw -A-.

Remove remaining engine/gearbox connecting bolts.
Press the gearbox out of the dowel sleeves and carefully swing
towards the upper part of the vehicle.
Carefully pass with the flange shaft right -A- on the flywheel/
at the intermediate plate.

Turn the gearbox with the counterweight upwards and rotate

the cover for 5th gear downwards.
Lower the gearbox, while doing so pay attention to ensuring
sufficient distance of the flange shaft -A- towards the flywheel
and the flange shaft -B- towards the assembly carrier.
Note
Observe all lines when lowering the gearbox.

While the gearbox is reduced, a 2nd mechanic presses the
engine carefully forwards if required.
If necessary, adjust the position of the gearbox when lowering
over the spindles of the gearbox support - 3282- .
2.1.1 Transporting the gearbox

Gearbox attachment device - MP3-478 (3336)-
Workshop crane , e.g. -V.A.S 6100-
Screw down gearbox suspension device - MP3-478 (3336)-
onto clutch housing.
Adjust supporting arm at slide piece with locking pin -arrow-.

No. of holes visible = 5
Raise gearbox with workshop crane and gearbox suspension
device - MP3-478 (3336)- .
Set gearbox aside, for example in a transport container.
2.2 Installing the gearbox
Note
Refer to procedure Removing gearbox for required special tools

page 55 .
Clean all threaded holes into which bolts are screwed in with
locking agent, using a suitable thread tap to remove old locking
agent residues.

After the installation, replace screws to be screwed in with

locking agent and self-locking nuts.
Check whether the dowel sleeves for centring the engine/
gearbox are present in the cylinder block; insert if necessary.
If the dowel sleeves are not installed, there are problems with the
gearshift and the clutch or the gearbox is loud (sound of loose
wheels).
Check whether the intermediate plate is suspended from the
sealing flange -arrow top- and slid onto the dowel sleeves
-arrows below-.
Clean splines of drive shaft and apply a thin film of grease -
G 000 100- .
The clutch plate must slide easily to and fro on the input shaft.
The gearbox support - 3282- is to be adjusted before installing
the gearbox 0AH with the aim of the adjusting plate - 3282/46- .
Insert gearbox support - 3282- into engine/gearbox jack -
V.A.G 1383 A- .
Position adjusting plate - 3282/46- onto the gearbox support -
3282- (adjusting plate fits in only one position).
Align arms of the gearbox mount to match the holes in the
adjusting plate .
Insert mounting bolts as shown on the adjusting plate.
Place the gearbox on the gearbox mount - 3282- .
Align the adjusting plate parallel to the gearbox.
Screw in the pins - 3282/29- into the rear hole for the fixing
screw of the pendulum support.

Secure bolts - 3282- on the gearbox with M8 nut -arrow-.

The bolt - 3282- should stand on a level with the guide on the
gearbox holder - 3282- .
Turn the gearbox with the counterweight upwards and rotate
the cover for 5th gear downwards.
Position engine/gearbox jack - V.A.G 1383 A- below vehicle,
arrow symbol on adjusting plate points in the direction of travel.
Carefully raise the gearbox.
The gearbox faces with the cover for 5th gear towards the up
per part of the vehicle.
Note
Be careful of all lines when installing gearbox.

A 2nd mechanic carefully pushes the engine towards the front.
Pass the gearbox with the flange shaft left -B- at the assembly
carrier and with the flange shaft right -A- at the coupling pres
sure plate.
Carefully pass with the flange shaft right -A- on the flywheel
as displayed.
Align gearbox in the fitting position opposite the engine.
Insert gearbox, screw in the bolt above and below the

-arrow- of the flange shaft on the right, and tighten
pageProtected
67 . by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Screw inwith
therespect
remaining lower of
to the correctness engine/gearbox connecting
information in this document. Copyright bolts
by KODA AUTO A. S.
and tighten page 67 .

Remove the gearbox holder - 3282- after screwing on the en
gine/gearbox.

Install the gearbox console with the new bolts -arrow 2- and
tighten to 40 Nm and turn 90 further.
By tightening the spindles of the hook - MP9-200/10- align the
motor/gearbox aggregate in the fitting position until the gear
box console rests against the gearbox mount.
Caution
There is a risk of damaging the thread in the gearbox console

by tightening the bolts obliquely.
To avoid damages to the threads in the gearbox console,
gearbox bearings and gearbox console must run parallel
to one another.
Insert new bolts -arrows 1- and tighten to 60 Nm and turn 90

further.
Install earth cable -arrow-.
Caution
Risk of injury!
Do not remove support bracket - T30099- until all bolts
securing the assembly mounting have been tightened to
specified torque.
Insert new bolts and install pendulum support Engine; Rep.

gr. 10 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Check the setting of the assembly bracket Engine; Rep. gr.
10 .
Assemble exhaust system free of stress Engine; Rep. gr.
26 .
Install the drive shifts Chassis; Rep. gr. 40 .

If present, screw heat shield for drive shaft -arrows- Chas
sis; Rep. gr. 40 .

Screw the front left vehicle level sensor - G78- , where avail
able, on the transverse arm Chassis; Rep. gr. 43 .
On both sides, install the anti-roll bar bracket -3- to the anti-
roll bar -2- on both sides Chassis; Rep. gr. 40 .
Mount plug -1- at the oil level and oil temperature sender -
G266- .
Check that the vacuum hose of the brake system is installed

correctly, install a vacuum hose where necessary Brake
system; Rep. gr. 47 .
Installing starter and electrical cables -arrow- Electrical sys
tem; Rep. gr. 27 .
Screw in the upper engine/gearbox connecting bolts and tight
en page 67 .

Install clutch slave cylinder page 24 .

On gearboxes of vehicles with the start-stop system: Plug the
connector -arrow- to the transmission neutral sender - G701- .
Attack cable support to gearbox and tighten the bolts

-arrows- page 38 .
Install gearshift lever -B- page 38 .

Screw on hexagon nut -arrow 2- page 38 .
Install relay lever -A- together with cable end-piece for gate
selector cable page 42 .
Spread a small amount of grease on pin of gearbox selector
lever -B-.
Assignment grease for gearshift mechanism Electronic Cata
logue of Original Parts .
Connect gear selection cable with gearbox selector lever.
Note
Replace safety mechanism -arrow 1- after removal.

Install the battery tray, battery and battery cover Electrical
Check gear oil level page 68 .
Install the bottom part of the front left wheelhouse liner Body
Work; Rep. gr. 66 .
On vehicles with front left vehicle level sensor - G78- , check
headlight beam setting
unless byElectrical
authorised KODA AUTOSystem;
A. S. KODA Rep.
AUTOgr.
A. S. 94
does. not guarantee or accept any liability

2.3 Specified torques for gearbox

Vehicles with 1.2 l / 63; 77 kW TSI engines
Pos. Bolt Piece Nm
1 M12 60 2 80
2 M12 165 + M8 x 16 2 80
additional starter
to gearbox
3 M10 55 3 40
4 M12 70 2 80
Pos. -A-: Dowel sleeves for centering

3 Gear oil
Check gear oil level page 68 .
3.1 Checking gear oil level

Socket wrench insert - T30023 (3357)-
Gearbox oil specification and amount of oil in gearbox
page 2 .
Procedure
gr. 66 .
Unscrew locking screw for oil filler hole -arrow- for checking
the oil.
The oil is at the correct level if the gear is filled up to the lower
edge of the oil filler hole.
Where necessary, pour in gear oil up to lower edge of the filler
hole.
Screw in plug -arrow-.
Torque for different versions of oil filler plug and oil drain plug
I - Oil filler plug and oil drain plug with internal serration: 25 Nm
II - Oil filler plug Protected
and oilbydrain plug
copyright. withforAllan
Copying key:
private or 30 Nm
commercial purposes, in part or in whole, is not permitted
Install the noise insulation
with respect to the Body ofWork;
correctness Rep.
information gr.
in this 66 . Copyright by KODA AUTO A. S.
document.

4 Disassembling and assembling the

gearbox
Schematic overview - Gearbox page 69
Summary of components page 70 .
Removing gearbox housing cover and 5th gear page 71
Summary of components - Clutch housing page 72 .
Summary of components - Drive shaft, output shaft, differential
gear, gearshift mechanism, and gearshift forks page 73 .
Summary of components - Gearshift unit page 74 .
Assembly overview - shift forks page 76
Repairing gearshift unit page 78
Replacing the gasket ring for the gearshift shaft page 80 .
Repairing gearshift forks page 77 .
Disassembling and assembling the gearbox page 80 .
4.1 Schematic overview - Gearbox

1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Cover for gearbox housing
7 - Gearbox housing
8 - Reverse gear sliding gear
9 - Selector mechanism
(Gearshift forks)
10 - Clutch housing
11 - Input shaft
12 - Output shaft
13 - Differential
4. Disassembling and assembling the gearbox 69

4.2 Summary of components
I - Removing gearbox housing

cover and 5th gear
page 71
II - Summary of components -
Clutch housing page 72 .
Drive shaft, output shaft, differ
ential gear, gearshift mecha
nism, and gearshift forks
page 73 .
Gearshift unit page 74 .
III - Assembly overview - shift
forks page 76
III - Repairing gearshift forks
page 77 .
III - Repairing gearshift unit
page 78
III - Replacing the gasket ring
for the gearshift shaft
page 80 .

4.3 Summary of components- Gearbox housing cover and 5th gear
1 - Gearbox housing
2 - 5th gear pinion
Fitting position
page 88
3 - Lock washer
Renew.
Determine thickness
page 88
4 - Seal
5 - Cover for gearbox housing
Note
After installing the cover for the

gearbox housing of a gearbox in
stalled in a vehicle, check the gear
oil level and where necessary refill
with gearbox oil page 68 .

Renew.
7 - Lock washer
Renew.
Determine thickness
page 88
8 - Synchronizer body with slid
ing sleeve and stop ring for 5th
gear
disassembling and as
sembling page 91
9 - 5th gear synchronizer ring
10 - 5th gear sliding gear
11 - Needle bearing
5th gear
12 - Gearshift fork for 5th gear
Shift segments are connected inseparably with the gearshift fork
Identification page 77
13 - Carrier bolt
for 5th gear gearshift fork

4.4 Summary of components - Clutch housing
1 - Conical screw
page 112
2 - Flange shaft with pressure
spring
page 80
complete page 112
Renew.
4 - Clutch housing
repairing page 89
5 - Gearbox housing
repairing page 89
6 - Clutch release lever
with guide bushing and
clutch release bearing
page 28
7 - Bolt
page 12

4.5 Summary of components - Drive shaft, output shaft, differential gear, gear
shift mechanism, and gearshift forks
1 - Differential
disassembling and as
sembling page 112
2 - Gearbox housing
repairing page 89
3 - Oil drain plug
Tightening torque
page 68
4 - Flange shaft with pressure
spring
page 80
complete page 112
5 - Conical screw
page 112
to secure the bearing
support with grooved
ball bearings for the
drive and output shaft
replace Electronic
Catalogue of Original
Parts
7 - Hexagon collar nut, 23 Nm
Selector mechanism
self-locking
Renew.
8 - O-ring
Renew.
9 - Carrier bolt
Renew.
(Gearshift unit)
repairing page 78
Renew.
13 - Screw, 6 Nm
14 - Gearbox neutral position sender - G701-
on vehicles with start-stop system
15 - Reversing light switch - F4- , 20 Nm
new version with captive sealing ring
16 - Sealing ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
not present on all gearboxes with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.

17 - Selector mechanism
(Gearshift forks)
repairing page 77
18 - Drive shaft and output shaft with bearing support for grooved ball bearings
the bearing support must be replaced each time the gearbox housing is replaced
pressing off and on bearing support page 94
Disassembling and assembling the drive shaft page 91
Disassembling and assembling the output shaft page 101
19 - Axle for reverse gear sliding gear
20 - Reverse gear sliding gear
for securing the axle for reverse gear sliding gear
Renew.
22 - Oil drip pan
23 - Magnet
24 - Oil guide part Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
4.6 Summary of components - Gearshift

unit
Note
Coat bearings and friction surfaces with grease.

Assign the grease via the Electronic Catalogue of Original
Parts .

1 - Bushing
for gearshift shaft
extracting page 79
inserting page 79
replace jointly
3 - Locking angle
for setting the gearshift
mechanism
removing page 79
inserting page 79
4 - Relay lever
Fitting position
page 41
5 - Retaining clip
6 - Sealing ring
Renew. page 80 .
7 - Cap
for gearbox bleeder
8 - Gearshift lever
Display may vary from
original part
insert in such a way that
the interrupted spacing
of the teeth matches the
gearshift shaft
Can be renewed with
the selector mechanism
installed
Fitting position
page 41
self-locking
Renew.

4.7 Assembly overview - shift forks
Note
The gearshift fork group does not have to be disassembled for the disassembly and assembly of the shift
segments, clamping plates and angular ball bearings.
1 - Gearshift fork group with

shift guides
2 - 3rd/4th gear shift segment
Identification
page 77
It must still be possible
to rotate the shift seg
ment freely once as
sembled
3 - Angular ball bearings
Qty. 4
removing page 78
installing page 78
4 - Circlip
Renew.
removing page 77
installing page 78
5 - 1st/2nd gear shift segment
Identification
page 77
It must still be possible
to rotate the shift seg
ment freely once the Cir
clip is assembled
Gearshift fork with shift
segments page 77
6 - 5th gear shift fork with shift
segments
Shift segments are con
nected inseparably with
the gearshift fork
Identification
page 77
7 - Carrier bolt
for 5th gear gearshift fork

4.8 Repairing gearshift forks

Pressure plate - MP3-407 (VW 402)-
Pressure element - 3290/1- from assembly device - T30100
(3290)-
Assembly tool - MP5-402 (3301)-
Thrust piece - MP3-453 (VW 431)-
Distance sleeve - MP3-458 (VW 472)-
Driver - MP1-304 (10-206)-
Removal tool for inner lining of the door panel - MP8-602/1
(80-200)-
Identification of the shift segments and shift fork for 5th gear with
shift segments
Dimension -a-
1- Shift segments 1st/2nd gear = 10.0 mm
2- 3rd/4th gear shift segment = 78.6 mm
3- 5th gear shift fork with shift segments = 79.5 mm
1st/2nd gear shift fork with shift segments

Dimension -a- = 78unless
mmauthorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
Removing the circlip

Secure the shift fork in a vice fitted with protective jaws -B-.
Lift off the circlip -A- in -direction of the arrow-.

Fitting the circlip

Press the circlip with a handle wrench into the slot of the shift
segment.
Note
It must still be possible to rotate the shift segment freely once the
Circlip is assembled.
A - Handle wrench (SW 10)

B - Protective jaws
Removing the angular ball bearings
Note
Do not bend the shift forks when removing and installing the an
gular ball bearings.
Insert the angular ball bearings up to the stop into the gearshift
fork
The recess in the thrust piece - 3290/1- points towards the ball
bearing.
4.9 Repairing gearshift unit

Centering mandrel - MP3-463 (12-551)-
Pressure spindle
unless- authorised
MP3-448 (VW AUTO
by KODA 408 A.A)-
S. KODA AUTO A. S. does not guarantee or accept any liability
Thrust piece - T40008-
Sealant - AMV 188 200 03-


Remove locking angle -A- from gearshift cover
Remove the outer part of the locking angle.
Then lever out the locking angle carefully with a screwdriver.
Drive locking angle -A- into gearshift cover

Fitting position:
The marking -1- points towards the marking -2- on the gear
shift cover.
Remove the bushing -A- for the shiftgear shaft
Drive in the bushing -A- for the shift rod up to the stop

4.10 Replace the gasket ring of the gearshift

shaft
Tube - MP3-479 (VW 423)-
Sealing grease Electronic Catalogue of Original Parts
Remove the gearshift lever and relay lever page 38 .
Lever out gasket ring with a screwdriver.
Lightly oil new gasket ring at outer surface.
Fill space between sealing lip and dust lip -arrow- with sealing
grease .
Insert gasket ring -A- up to the stop

Install the gearshift lever and relay lever page 38 .
4.11 Disassembling and assembling the

gearbox
Removing and installing cover for gearbox housing, clutch hous
ing, gearshift shaft with gearshift cover, drive shaft, output shaft,
differential gear and gearshift mechanism
Assembly stand - MP9-101-
Bracket - MP1-202-
Adapter - T10235-
Pressure plate - with
MP3-406 (VW
respect to the 401)-of information in this document. Copyright by KODA AUTO A. S.
correctness

Pressure spindle - MP3-408 (VW 412)-
Pressure spindle - VW 407-
Adapter - T10235-
Guide bolt - T10079-
Catch pan , e.g. -VAS 6208-

Washer - T10083/1-
Pressure screw - 3074-
Cap - T10080-
Sealant - AMV 188 200 03-
Disassembling gearbox
Secure gearbox -arrows- to the assembly stand - MP9-101-
with bracket - MP1-202- and adapters - T10235- .
Place catch pan underneath.
Drain out gear oil.
Remove clutch release lever -A- together with release bearing

and guide sleeve page 28 .
Release fixing screw for right flange shaft.

To this end insert 2 screws in the flange and counterhold the
flange shaft using an assembly lever.
Pull out the right flange shaft together with pressure spring,
stop disc and conical ring.
Unscrew the cover -arrow- for the gearbox housing carefully
remove.

Pull out the support bolt -1- for the 5th gear shift fork -2- and
remove gearshift fork.
Remove circlip -3- for 5th gear synchronizer body.
Remove the sliding sleeve with synchronizer body, 5th gear
sliding gear with synchronizer ring and needle bearing from
the output shaft.
Remove circlip -4- for 5th gear pinion and remove the pinion.
Release the fixing screws -A- for the bearing support of the
drive shaft and output shaft.
Unscrew hexagon collar nut -B- for shift mechanism (fitting of
the reverse gear).
Unscrew the fixing screw for the flange shaft-C-; to do this,
insert two screws in the flange and hold the flange shaft using
an assembly lever.
Remove flange shaft -C- together with pressure spring.
Then turn the gearbox in the assembly stand with the clutch
housing upwards.
Remove bolts which are used to secure the gearbox housing
from the clutch housing.
Carefully release the clutch housing from the projecting hous
ing lands and make sure the sealing surfaces are not damaged
in the process.
Clutch housing must not tilt, so that the roller bearing and its
bearing assembly on the drive shaft and output shaft are not
damaged.
Remove the differential gear -A- from the gearbox housing.

Afterwards, remove the oil drip pan -A- and the oil guide part
-B- with the solenoid from the gearbox housing.
On gearboxes of vehicles with the start-stop system: Remove

transmission neutral sender - G701- -arrow-.
Remove the gearshift shaft with cover -A-. While doing so, put
the gearshift shaft into Neutral. Subsequently unscrew screws
-arrows- and remove the gearshift shaft from the gearbox
housing.
Remove the bearing bolts -B- at the top of the gearbox.
Unscrew the by
Protected reversing lightsforswitch
copyright. Copying private or -C-.
commercial purposes, in part or in whole, is not permitted
Unscrew the screw -A- for securing the shaft for reverse gear.
Remove the bearing bolts -B- at the bottom of the gearbox.
Note
The screw cap -arrow- is not to be dismantled when disassem

bling the gearbox.

Press off the drive shaft and output shaft together with the
bearing support, gearshift mechanism (shift forks) and reverse
gear.
Note
Position the gearbox housing in such a way that the dowel

sleeves in the gearbox housing are not damaged.
During the pressing off procedure request the assistance of
second mechanic to prevent components from falling.
Remove the bearing support with grooved ball bearings from

the drive shaft and output shaft page 95 .
Assembling gearbox
Note
Pressing the bearing support with grooved ball bearings onto

the drive and output shaft page 98 .
Pressing the sleeve of the 5th gear pinion needle bearing onto
the drive shaft page 98 .
Place the assembled components drive shaft -2-, output shaft

-1- with bearing support and grooved ball bearings in the thrust
piece - 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 guide bolts - T10079- into the threaded bolts (Fitting

reverse gear) -arrow-.
Insert the parts into the gearbox housing together. Guide the
guide pin - T10079- through the bore for securing the gearshift
mechanism in the gearbox housing.
Unscrew guide bolt - T10079- .
Before pressing on, pay attention to the following:
To click in the shift forks into the sliding sleeves correctly.

Check the dimension -a- on the input shaft serration.
Note
The drive shafts of the individual gearboxes have different

lengths due to the different heights of the serration, dimension
-a-.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
In order to press
with respect in the drive
to the correctness shaftinand
of information the output
this document. shaft
Copyright at theAUTO A. S.
by KODA
same time, a 3 mm thick washer - T10083/1- must be posi
tioned onto the drive shaft, if necessary.
Therefore, the dimension -a- of the output shaft serration must
be measured.
Dimension -a- = 30.6 mm

Put disc - T10083/1-
into position page 85 .
Fit the washer - T10083/1- onto the drive shaft and carefully press
in the bearing support together with the drive shaft and the output
shaft up to the stop.

Press on the bearing support with the drive and output shaft up
to the arrester
Tighten the screw -A- for the shaft for reverse gear.
Install the carrier bolt -B- at the bottom of the gearbox.
Screw on the reversing lights switch -C-.

Install the carrier bolt -B- at the top of the gearbox.
Put the gearshift guides into Neutral.
Apply sealant - AMV 188 200 03- uniformly on the sealing sur
face of the gearshift cover.
Install the gearshift shaft with cover -A-. Subsequently tighten
the bolts -arrows-.
On gearboxes of vehicles with the start-stop system: Installing

transmission neutral sender - G701- -arrow- and tighten fixing
screw to tightening torque Item 13 (page 73) .

Use new screws -A- to secure the bearing support to the drive
shaft and output shaft.
Note
Gradually tighten the screws according to the torque starting from

the middle and crosswise Item 6 (page 73) .
Screw in hexagon collar nut -B- for the gearshift mechanism

(shift forks).
Afterwards, insert the oil drip pan -A- into the recess -1- and
into the hole -2- of the gearbox housing.
Next, install the oil guide part -B- with
withinserted solenoid
respect to the correctness into
of information in this document. Copyright by KODA AUTO A. S.
the gearbox housing.
Insert differential gear -A-.

Apply sealant - AMV 188 200 03- uniformly on the sealing sur
face.
Screw down the clutch housing onto the gearbox housing.
Then turn the gearbox in the assembly stand with the gearbox
housing upwards.

Fit the 5th gear pinion -1-.

Fitting position of the 5th gear pinion
The highest collar -arrow- points to the gearbox housing cover.
Mount the 5th gear sliding gear with needle bearing.
Position the 5th gear synchronizer ring on the sliding gear.
Mount the synchronizer body 5th gear together with sliding
sleeve and stop ring.
Insert the 5th gear shift fork -2- and push the carrier bolts -1-
up to the stop in the -direction of arrow-.
Determine 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 Electronic Catalogue of
Original Parts
Thickness (mm)
2.00 2.10
2.20
Tighten cover for gearbox housing.
Install both flange shafts together with pressure springs, stop

discs and conical rings.
Tightening torques
Drive shaft, output shaft, differential gear, gearshift mecha
nism, and gearshift forks page 73 .
Gearbox housing and clutch housing page 72 .
Cover for gearbox housing page 71
Flange shafts on gearbox (conical screws) page 112

5 Gearbox housing and clutch housing

Summary of components - Gearbox housing and clutch housing
page 89 .
5.1 Summary of components - Gearbox housing and clutch housing
1 - Clutch housing
when replacing, set the
differential gear
page 115
2 - Sealing ring
for drive shaft
Renew. page 99 .
3 - Ball pin
page 12
4 - Sealing ring
for right flange shaft
replace, on installed
gearbox page 110
5 - Oil filler plug
Tightening torque
page 68
6 - Adjusting washer
for differential gear
Determine thickness
page 115
7 - Outer ring/tapered-roller
bearing
press out of the clutch
housing and press into
the coupling housing
page 112 unless with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
when replacing, set the
differential gear
page 115
Renew.
9 - Outer ring/tapered-roller bearing
remove from the gearbox housing and press into the gearbox housing page 112
when replacing, set the differential gear page 115
10 - Fitting sleeve
Qty. 2
11 - Gearbox housing
when replacing, set the differential gear page 115
12 - Oil drain plug
Tightening torque page 68
5. Gearbox housing and clutch housing 89

13 - Sealing ring
for left flange shaft
replace, on installed gearbox page 108
14 - Bushing
for gearshift shaft
extracting page 79
inserting page 79
15 - Screw cap
Before screwing down apply sealing agent - AMV 188 200 03-
16 - Circlip
insert in the cylinder roller bearing groove
17 - Circlip
insert in the cylinder roller bearing groove
18 - Cylindrical-roller bearing
for drive shaft
extracting and inserting page 91
for output shaft
extracting and inserting page 101
20 - Plug
present on certain gearboxes
inserted into the hole in the clutch housing

35 Gears, shafts
1 Input shaft
Summary of components - Drive shaft page 91 .
Disassembling and assembling the drive shaft page 94 .
Replace gasket ring for drive shaft page 99
1.1 Summary of components - Drive shaft
Note
When installing new pinions or a new drive shaft observe the technical data page 1 and instructions in
the Electronic Catalogue of Original Parts .
Insert all bearings, sliding gears and synchronizer rings onto the drive shaft with gear oil.
Do not interchange the synchronizer rings, if re-used always assign to the original sliding gear.
1 - Circlip
replace after disassem
bly Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Determine thickness with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
page 88
2 - Sliding sleeve with 5th gear
synchronizer body
page 80
disassembling
page 99
Assemble sliding sleeve
and 5th gear synchron
izer body page 99
Fitting position
page 99
check for wear
page 96
5 - Needle bearing
5th gear
replace together with
bushing
6 - Bushing
for 5th gear needle
bearing
replace together with
needle bushing
press off with bearing
support for grooved ball
bearing page 95
pressing on
page 98
1. Input shaft 91
7 - Gearbox housing
8 - Bearing support with grooved ball bearings
Always replace grooved ball bearing together with the bearing support
Replace bearing support after each time the gearbox housing is undone
Pulling off page 95
pressing on page 97
9 - Input shaft
10 - Needle bearing
3rd gear
11 - 3rd gear sliding gear
12 - 3rd gear synchronizer ring
check for wear page 96
13 - Sliding sleeve with 3rd and 4th gear synchronizer body
pull off with 3rd gear sliding gear page 95
disassembling page 95
Fitting position sliding sleeve and synchronizer body page 96
assembling page 95
pressing on page 96
16 - Bushing
for 4th gear needle bearing
replace together with needle bushing
pull off with 3rd gear sliding gear page 95
pressing on page 96
17 - Needle bearing
4th gear
replace together with bushing
18 - Thrust washer
19 - Inner ring/cylindrical-roller bearing
Pulling off page 95
pressing on page 97
20 - Circlip
Renew.
Determine thickness page 97
with circlip
removing page 94
installing page
with respect to the 94
correctness of information in this document. Copyright by KODA AUTO A. S.
Fitting position: The circlip in the bearing points towards the drive shaft
22 - Clutch housing
23 - Spring
92 Rep. gr.35 - Gears, shafts

24 - Sliding sleeve 3rd and 4th gear

25 - Synchronizer body for 3rd and 4th gear
26 - Arrester
Qty. 3
27 - Spring
28 - Arrester
Qty. 3
29 - 5th gear synchronizer body
30 - 5th gear sliding sleeve
31 - Stop ring
prevents the arresters from wandering
dismantling page 98
installing page 99
1. Input shaft 93
1.2 Disassembling and assembling the

drive shaft
Pressure spindle - MP3-423 (VW407)-
Tube - MP3-450 (VW 415 A)-
Tube - MP3-451 (VW 422)-
Distance sleeve - MP3-458 (VW 472/2)-
Tube - MP3-414 (VW 516)-
Cap - T30066 (30 - 23)-
Drive bushing - MP1-316 (30-100)-
Circlip pliers - VW 161A-
Tube - MP3-429 (2010)-
Washer - T10083/1-
Pressure plate - T10084A-
Interior extractor - Kukko 21/5-
Countersupport - Kukko 22/2-
Feeler gauges
Pull out the cylindrical-roller bearing from the clutch housing
When removing the compress circlip -arrow- of the cylindrical-
roller bearing with pliers -C-.
A - Countersupport , e.g. -Kukko 22/2-
B - Interior extractor 30...37 mm , e.g. -Kukko 21/5-
Drive the cylindrical-roller bearing into the clutch housing

Support the clutch housing by positioning pipe section -
VW 415 A- (not visible in figure) directly under the bearing
support.
When inserting compress circlip -arrow- of the cylindrical-roller
bearing with pliers -A-.
Let go of the pliers before the cylindrical-roller bearing is in
fitting position. The circlip must lock into the clutch housing
slot.

Detach bearing support with grooved ball bearings

Sliding sleeve for 1st and 2nd gear to 2nd gear.
Slide the pressure plate - T10084/A- sideways up to stop onto
the drive shaft.
Insert centring pins of thrust piece - T10081- into the holes of
the drive shaft and output shaft.
remove inner ring for cylindrical-roller bearing

First remove compress circlip with circlip pliers - VW 161 A- .
Remove inner ring for cylindrical-roller bearing together with
thrust washer, 4th gear sliding gear with needle bearing, slid
ing sleeve and synchronizer body for 3rd and 4th gear and
3rd gear sliding gear.
Disassembling and assembling the sliding sleeve and 3rd and 4th
gear synchronizer body
1- Spring
2- Sliding sleeve
3- Synchronizer body
4- Arrester
Slide the sliding sleeve over the synchronizer body.
The deeper recesses -arrow A- of the arresters in the synchron
izer body and the recesses -arrow B- in the sliding sleeve must
be positioned above one another.
Assembling the sliding sleeve and 3rd and 4th 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 hollow arrester.
1. Input shaft 95
Fitting position of the sliding sleeve and 3rd and 4th gear syn
chronizer body
The groove on the front side -arrow- points towards the 4th gear.
Check synchronizer ring for wear

Press the synchronizer ring on the cone of the sliding gear and
measure clearance -a- with a feeler gauge.
Clearance -a- Installation dimen Wear limit
sion
3rd, 4th and 5th gear 1.1...1.7 mm 0.5 mm
Press on the synchronizer body with the 3rd and 4th gear sliding
sleeve
Press on the bushing -A- for the 4th gear needle bearing
After pressing in the sleeve -A- needle bearing 4th gear, install
synchronizer ring with 4th gear sliding gear and thrust washer.

Press on the inner ring -A- for the cylindrical-roller bearing
Determining the circlip

Insert circlip -A- with a thickness of 2.0 mm in the slot of the
drive shaft and push upwards -arrow-.
Measure dimension between inner ring -B- and positioned cir
clip -A- using a feeler gauge -C-.
Remove the circlip used to take the measurement.
Determine the first circlip required according to the table.
Note
Assign the circlips via the Electronic catalogue of original parts .
The following circlips are available.

Measured value Circlip thickness Axial play (mm)
(mm) (mm)
0.050.14 2.0 0.050.15
0.150.24 2.1 0.050.15
0.250.34 2.2 0.050.15
0.350.44 2.3 0.050.15
0.450.51 2.4 0.050.10
Pressing the bearing support with grooved ball bearings onto the
drive and output shaft
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
The output shafts of the individual gearboxes have different
lengths due to the different heights of the serration, dimension

-a- (the installed shafts are shown here).
In order to press in the bearing support evenly onto the shafts,
it is necessary that the shafts are also positioned evenly on
the insert base - T10083- .
A 3 mm thick washer - T10083/1- must be inserted in the fas
tening opening of the drive shaft, if necessary page 98 .
Therefore, the dimension -a- of the output shaft serration must
be measured.
Dimension -a- = 30.6 mm

Insert washer - T10083/1- page 98 .
1. Input shaft 97
Insert washer - T10083/1-
Pressing on the bearing support

Before pressing on the bearing support heat it to approximate
ly 100 C.
WARNING
Wear protective gloves!
Press on the bushing -A- for the 5th gear needle bearing
Removing the stop ring

Bend back the hook -A- of the stop ring from the synchronizer
body with a screwdriver.
Disassembling and assembling the 5th gear sliding sleeve and

synchronizer body
1- Spring
2- Arrester
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 synchron
izer body and the recesses -arrow D- in the sliding sleeve must
Assemble sliding sleeve and 5th gear synchronizer body

Installing the stop ring

Press the stop ring onto the tube - 2010- .
Insert the stop ring together with the tube - 2010- in the syn
chronizer body with 5th gear sliding sleeve (Observe fitting
position page 99 ).
Lock the hooks -arrow 1- in the recesses -arrow 2- of the syn
chronizer body arresters.
Push the stop ring down until
with respect the
to the hooks ofclick
correctness into inposition.
information this document. Copyright by KODA AUTO A. S.
1.3 Renewing input shaft seal

Puller hooks - T20143/1-
Sealing grease - G 052 128 A1-
1. Input shaft 99
Procedure
Removing the gearbox.
Lever out gasket ring for drive shaft with ejection hook -
T20143/1- .
Note
Do not damage the running surface of the gasket ring for the on
the input shaft.
Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
Slightly moisten the outer circumference of the gasket ring with
gearbox oil.
Insert the gasket ring for the drive shaft until flush
Install clutch release lever together with release bearing and
guide sleeve page 12 .
Install gearbox.

2 Output shaft
Summary of components - Output shaft page 101 .
Disassemble and assemble output shaft page 103 .
2.1 Summary of components - Output shaft
Note
When installing new pinions or a new output shaft observe the technical data page 1 and Electronic
Catalogue of Original Parts .
Insert all bearings, sliding gears and synchronizer rings onto the output shaft with gear oil.
Do not interchange the synchronizer rings, if re-used always assign to the original sliding gear.
1 - Clutch housing
with circlip
removing page 103
installingunless
page 103
Fitting position: The cir
clip in the bearing points
towards the output shaft
3 - Output shaft
with inner ring/cylindri
cal-roller bearing
inner ring cannot be re
moved from output shaft
with scoring or damage
to the inner ring for the
cylindrical-roller bear
ing, replace the drive
shaft and cylindrical-
roller bearing together
4 - 4th gear pinion
Fitting position: Collar
points to the 3rd gear
page 104
5 - Circlip
6 - Circlip
7 - 3rd gear pinion
points to the 4th gear
page 104
8 - Circlip
9 - 2nd gear sliding gear
10 - Needle bearing
2nd gear
11 - Inner ring for 2nd gear
2. Output shaft 101

12 - Outer ring for 2nd gear

placed on the inner ring for 2nd gear
replace if there are any traces of scoring or friction
13 - 2nd gear synchronizer ring
14 - Sliding sleeve with 1st and 2nd gear synchronizer body
after removing the circlip, remove with the 2nd gear sliding gear page 104
disassembling page 105
Assemble sliding sleeve and synchronizer body page 105
pressing on page 106
15 - Circlip
pushing out page 103
inserting page 106
16 - 1st gear synchronizer ring
insert in such a way that the recesses lock into the arresters of the sliding sleeve for 1st and 2nd gear
17 - Outer ring for 1st gear
inserted into synchronizer ring for 1st gear, fitting location page 106
replace if there are any traces of scoring or friction
18 - Inner ring for 1st gear
Check pegs for damage
Fitting position
unless authorised page
by KODA AUTO106A. S. KODA AUTO A. S. does not guarantee or accept any liability
19 - Needle bearing
1st gear
20 - 1st gear sliding gear
21 - Bearing support with grooved ball bearings
Always replace grooved ball bearing together with the bearing support
the bearing support must be replaced each time the gearbox housing is replaced
Pulling off page 95
pressing on page 97
23 - 5th gear pinion
Fitting position: collar points towards the cover of the gearbox housing page 88
24 - Circlip
replace after disassembly
25 - Spring

26 - Sliding sleeve
27 - Synchronizer body
28 - Arrester
Qty. 3
2.2 Disassembling and assembling the out

put shaft
Pressure spindle - MP3-423 (VW407)-
Tube - MP3-450 (VW 415 A)-
Thrust piece - MP3-4014 (VW 432)-
Drive bushing - MP1-316 (30-100)-
Thrust piece - MP3-427 (40-21)-
Interior extractor - 1- Kukko 21/5-
Countersupport - 4- Kukko 22/2-
Pull out the cylindrical-roller bearing from the clutch housing
When removing the compress circlip -arrow- of the cylindrical-
roller bearing with pliers -C-.
Drive the cylindrical-roller bearing into the clutch housing

Support the clutch housing by positioning pipe section -
VW 415 A- (not visible in figure) directly under the bearing
support.
When inserting compress circlip -arrow- of the cylindrical-roller
bearing with pliers -A-.
Let go of the 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.
2. Output shaft 103

Removing the sliding sleeve and synchronizer body 1st and 2nd
gear
After removing the circlip jointly remove the 2nd gear sliding
gear and the sliding sleeve/synchronizer body.
Fitting position of gear pinion of 3rd and gear pinion of 4th

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 -2- and -3-.
Place the 3rd gear pinion -B- on the output shaft.
Fitting position:
The collar -arrow 2- points towards the 4th gear pinion -A-.
Insert circlip -1-.
Check 1st and 2nd gear inner ring for wear

Press the inner ring on the cone of the sliding gear and meas
ure clearance -a- with a feeler gauge.
sion
1st and 2nd gear 0.75...1.25 mm 0.3 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.
sion
1st and 2nd gear 1.2...1.8 mm 0.5 mm

Fitting position of the outer ring, inner ring and 2nd gear syn
chronizer ring
Place 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 pegs -arrows 2- in the recesses -arrows 3- of the sliding
gear.
Position the synchronizer ring -C-.
Lock the recesses -arrows 4- in the pegs -arrows 1- of the inner
ring -A-.
Disassembling and assembling the sliding sleeve and 1st and 2nd
gear synchronizer body
1- Spring
2- Sliding sleeve
3- Synchronizer body
4- Arrester
Fitting position:
After assembly the groove on the front side -arrow A- and the
higher collar -arrow B- of the synchronizer body point towards the
outer serration of the sliding sleeve -arrow C-.
The deeper recesses -arrow D- of the arresters in the synchron
izer body and the recesses -arrow E- in the sliding sleeve must
Assembling the sliding sleeve and 1st and 2nd gear synchronizer
body
2. Output shaft 105

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 towards 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 circlip

Insert the 1st gear synchronizer ring in the sliding sleeve with
synchronizer body.
Fitting position of the 1st gear outer ring

The pegs -arrows- point towards the reversing gear serration.
Fitting position for 1st gear inner ring to
with respect -A-
the correctness of information in this document. Copyright by KODA AUTO A. S.
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 into the pegs of the outer
ring (-arrow- page 106 ).
2. Output shaft 107

39 Final drive - differential

1 Gasket rings
Summary of components - Gasket rings page 108 .
Replace left gasket ring page 108
Replace right gasket ring page 110
1.1 Summary of components - Gasket rings
1 - Sealing ring
for drive shaft
Renew. page 99 .
2 - Sealing ring
Renew. page 110 .
3 - Sealing ring
Renew. page 108 .
4 - Sealing ring
for gearshift shaft
Renew. page 80 .
1.2 Replacing left sealing ring

Replacing the left flange shaft gasket ring page 108 .
1.2.1 Replacing the left flange shaft gasket

ring
Multi-purpose tool - MP3-419 (VW 771)-
Puller hooks - MP3-419/37 (VW 771/37)-
108 Rep. gr.39 - Final drive - differential


Removing
Remove left wheel.
gr. 66 .
Turn steering to full left lock.
Unscrew drive shaft from flange shaft Chassis; Rep. gr.
40 .
Strap up output shaft as far as possible, being careful not to
damage the surface protection.
Position the catch pan under the gearbox.
Unscrew the fixing screw for the flange shaft; to do this, insert
two bolts in the flange and hold the flange shaft using an as
sembly lever.
Remove flange shaft together with pressure spring.
Pull out gasket ring for flange shaft with multi-purpose tool -
MP3-419 (VW 771)- and puller hooks - MP3-419/37 (VW
771/37)- .
Install
Drive in new seal to stop, being careful not to cant seal.

Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .
Insert the flange shaft.
Secure the flange shaft with the conical screw and tighten with
tightening torque.
Bolt drive shaft to flange shaft Chassis; Rep. gr. 40 .
Check gear oil level, if necessary fill up to lower edge of filler
hole page 68 .
Install wheel Chassis; Rep. gr. 44 .
Tightening torques
Flange shaft to gearbox page 112
1. Gasket rings 109

1.3 Replacing right sealing ring

Replacing the right flange shaft gasket ring page 110 .
1.3.1 Replacing the right flange shaft seal ring

Multi-purpose tool - MP3-419 (VW 771)-
Puller hooks - MP3-419/37 (VW 771/37)-
Removing
gr. 66 .
If present, remove heat shield for drive shaft -arrows- Chas
sis; Rep. gr. 40 .
Unscrew drive shaft from flange shaft Chassis; Rep. gr.
40 .
Strap up output shaft as far as possible, being careful not to
damage the surface protection.
Position the catch pan under the gearbox.
Unscrew the fixing screw for the flange shaft; to do this, insert
two bolts in the flange and hold the flange shaft using an as
sembly lever.
Remove flange shaft together with pressure spring.
Pull out gasket ring for flange shaft with multi-purpose tool -
MP3-419 (VW 771)- and puller hooks - MP3-419/37 (VW
771/37)- or with the assembly lever.
Install

Drive in new seal to stop, being careful not to cant seal.

Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .
Insert the flange shaft.
Secure the flange shaft with the conical screw and tighten with
tightening torque.
Bolt drive shaft to flange shaft Chassis; Rep. gr. 40 .
If present, install heat shield for drive shaft -arrows- Chas

sis; Rep. gr. 40 .
Check gear oil level, if necessary fill up to lower edge of filler
hole page 68 .
Tightening torques
Flange shaft to gearbox page 112
1. Gasket rings 111

2 Differential
Summary of components - Differential page 112 .
Disassembling and assembling differential gear page 113 .
Setting the differential gear page 115 .
2.1 Summary of components - Differential
1 - Conical screw, 25 Nm
screwed with threaded
part
Item 8 (page 112)
2 - Right flange shaft
3 - Compression spring
for flange shaft
fitted behind flange
shaft
4 - Thrust washer
for compression spring
5 - Conical ring
Fitting position: Cone for
differential gear housing
6 - Circlip
holds the conical ring,
stop disc and pressure
spring in position when
the flange shaft is re
moved
7 - Large differential bevel gear
installing page 115
8 - Threaded part
installing page 115
9 - Differential bevel gear shaft
The tensioning sleeve is
cut during removal
page 115
installing page 115
10 - Small differential bevel
gear
installing page 115
11 - Stop disc compound
insert with gear oil
12 - Flange shaft left
13 - Sealing ring
removing page 114
installing page 114

15 - Inner ring/tapered-roller bearing

Pulling off page 114
16 - Differential gear housing
with gear pinion for final drive
17 - Tensioning sleeve
to secure the differential bevel gear shaft
is cut when removing page 115
18 - Inner ring/tapered-roller bearing
Pulling off page 114
removing page 115
installing page 115
20 - Adjusting washer
21 - Sealing ring
22 - Clutch housing
repairing page 89
repairing page 89
2.2 Disassembling and assembling differen

tial gear
Special tools and workshopProtected
equipment required
Pressure plate - MP3-407 (VW
with 402)-

Pressure spindle - MP3-448 (VW 408 A)-
Tube - MP3-409 (VW 418 A)-
Thrust plate - MP3-464 (30-205)-
Press-on sleeve - MP3-412 (VW 455)-
Distance sleeve - MP3-458 (VW 472/2)-
Thrust piece - MP3-427 (40-21)-
Pressure pipe - MP6-408 (30-14)-
Pipe - T30041 (2040)-
Thrust piece - MP3-431 (3002)-
Counterholder - MP1-223 (3067)-
Tube - MP6-419 (3259)-
Tapered-roller bearing extractor - V.A.G 1582-
2. Differential 113
Gripper - V.A.G 1582/3-

Countersupport - Kukko 22/2-
Note
Before installing heat the inner ring of the tapered-roller bear

ing to 100C.
Replace both tapered-roller bearings together.
When replacing the tapered-roller bearings, the differential
housing, the gearbox housing or the clutch housing, set the
differential gear page 115 .
Remove outer ring/tapered-roller bearing from gearbox housing

Press in outer ring/tapered-roller bearing in the gearbox housing

Support the gearbox housing with a pipe - 3259- directly below
the bearing support.
Removing inner ring/tapered-roller bearing
Note
Both inner rings/tapered-roller bearings of the differential gear

housing are removed in the same way.
Press on inner ring/tapered-roller bearing

Support the opposite side of the inner ring with an insertion
bushing - VW 455- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
The shoulder of the insertion unless
bushing - VW 455- points to theindif
with respect to the correctness of information this document. Copyright by KODA AUTO A. S.
ferential gear housing.
Note
Both inner rings/tapered-roller bearings of the differential gear

housing are pressed on in the same way.

Remove the outer ring/tapered-roller bearing -A- from the clutch

housing
tension the interior extractor behind the outer ring/tapered-
roller bearing.
Press in outer ring/tapered-roller bearing in the clutch housing
Press out differential bevel gear shaft

The tensioning sleeve is cut during pressing out.
Drive the remaining part of the tensioning sleeve out of the
differential gear housing.
Install differential bevel gears

Protected
Installby stop disc
copyright. compound
Copying for private orwith gearbox
commercial oil.in part or in whole, is not permitted
purposes,
with
Insert both
respect to thelarge differential
correctness bevel
of information gears and
in this document. secure
Copyright (e.g.AUTO
by KODA with
A. S.
flange shaft).
Insert the small differential bevel gears offset at 180 and turn
into the fitting position.
Slide 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.
Drive in the differential bevel gear shaft up to end position and
secure with tensioning sleeve.
2.3 Adjusting the differential gear

End dimension plate - 50 mm - MP3-405/17 (VW 385/17)-
Universal dial gauge bracket - MP3-447 (VW 387)-
2. Differential 115

Pressure spindle - MP3-448 (VW 408 A)-
Thrust plate - MP3-464 (30-205)-
Pressure pipe - MP6-408 (30-14)-
Pipe - T30041 (2040)-
Pipe key - MP3-433 (3059)-
Dial gauge
The differential gear must be re-set when the following compo
nents are replaced:
Gearbox housing,
clutch housing,
Differential gear housing
or
tapered-roller bearings of the differential gear.
Press in outer ring/tapered-roller bearing (pinion side) in 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.

Assemble the dial gauge.

A - Dial gauge extension 30 mm
Set the dial gauge to 0 with 1 mm bias.
Move the differential shaft up and down, read off and write
down the clearance on the dial gauge (in this example: 1.50
mm).
Determine the adjusting washer
The prescribed bearing preload is reached by adding to the es
tablished measured value a constant compression value (0.35
mm).
Example
measured value 1.50 mm
+ pressing (constant value) 0.35 mm
Thickness of the adjusting washer = 1.85 mm
Remove the clutch housing and remove the outer ring/ta

pered-roller bearing -A-.
Assign the adjusting washers via the Electronic Catalogue
of Original Parts .
The various thicknesses make it possible to achieve the exact
shim thickness required.
If the measured washer thickness is greater than the one listed in
the Electronic catalogue of original parts , 2 washers corre
sponding to the measured value may be fitted.
Insert adjusting washer with the required thickness (in this ex
ample 1.85 mm) and press the outer ring/tapered-roller bear
ing back into the clutch housing.
Put the clutch housing into place and tighten the bolts.
Tightening torques
Gearbox housing and clutch housing page 72 .
2. Differential 117

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Service

Service Department. Technical Information

All rights reserved.

Copyright 2013 KODA AUTO a. s. D4B802C6D75

4.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1.1 Location on the gearbox

Gearbox 0AH -arrow 2-

Codes and production date of gearbox

The gearbox identification characters also appear on the vehicle

1. Identification of the gearbox 1

1.2 Identification characters, aggregate assignment, ratios, capacities

2 Rep. gr.00 - Technical data

2 Overview of Transmission System

2.1 Designation of components and transmission ratios

The -arrows- show the direction of travel.

2. Overview of Transmission System 3

3 General repair instructions

3.1 Safety measures for working on vehi

On vehicles with start-stop system, there is the risk of injury

4 Rep. gr.00 - Technical data

3. General repair instructions 5

Do not interchange. When reusing synchro-rings, always fit to

6 Rep. gr.00 - Technical data

1. Repairing clutch control 7

8 Rep. gr.30 - Clutch

1.2 Assembly overview - pedal cluster

after removing, replace

1. Repairing clutch control 9

10 Rep. gr.30 - Clutch

1.3 Assembly overview - clutch hydraulics

1. Repairing clutch control 11

Disconnect the cables for the clutch control and connect

An O-ring can also be installed instead of the gasket ring -2-

Seals and O-rings for pipe and hose lines

1.4 Assembly overview - clutch release mechanism

12 Rep. gr.30 - Clutch

1 - Clutch release lever

1.5 Removing and installing bearing bush

1. Repairing clutch control 13

1.6 Checking the master and slave cylinder

1.7 Removing and installing clutch position

14 Rep. gr.30 - Clutch

Unlock catch -arrow- of clutch position sender - G476- -2- at

1.8 Removing and installing the over-centre

Remove the footwell vent -1- on the driver's side Heating,

1. Repairing clutch control 15

Remove data bus diagnostic interface - J533- -1- from bracket

Unscrew screw -2-, unhook crash strut -1- aushngen and

Swivel the clutch pedal in -direction of arrow-, unhook and re

16 Rep. gr.30 - Clutch

1.9 Removing and installing tension spring

Remove the footwell vent -1- on the driver's side Heating,

1. Repairing clutch control 17

Remove data bus diagnostic interface - J533- -1- from bracket

Unscrew screw -2-, unhook crash strut -1- aushngen and

If present, unhook the tension spring -1- and remove, while

Pull the clutch pedal in -direction of arrow A- ( previous fig

18 Rep. gr.30 - Clutch

1.10 Removing and installing clutch pedal

Remove bearing block for clutch pedal

1. Repairing clutch control 19

Install bearing block for clutch pedal

1.11 Removing and installing bearing block